Eaton Roadranger Fuller UltraShift F-406-ASW... Installation Manual Download Page 2

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Summary of Contents for Roadranger Fuller UltraShift F-406-ASW...

Page 1: ...Fuller AutomatedTransmissions Installation Guide Fuller Automated Transmissions TRIG0082 October 2007 More time on the road...

Page 2: ...This page intentionally left blank...

Page 3: ...ear Display Module 35 Ignition Circuit Detail 37 J 1587 Diagnostic Detail 38 Dimmer Control Input Connection 40 Typical Start Enable Circuit 41 J 1939 Data Link Detail 43 Vehicle Harness Connector for...

Page 4: ...cation Engineering Contact Eaton Application Engineering or your OEM Application Engineering department for proper Application form All applications must be submitted for approval OEM facilities must...

Page 5: ...y available VOM Eaton Corporation OEM Engineering Support Group TBD Pull to Neutral Box O E Tool Equipment Group Kent Moore SPX Corporation 1 800 328 6657 Kent Moore Part no Description J 43318 Eaton...

Page 6: ...shall be a minimum of 16 gauge 1 0 mm The cable inside the cab shall be a min imum of 18 gauge 0 8 mm When the Eaton Push Button Shift Control is used the EPL the communications link between the Shift...

Page 7: ...ystems installed at OEM plants the engine ECU must contain the proper configuration settings For the proper engine configuration settings required for Eaton Transmission operation contact Eaton OEM En...

Page 8: ...ler lines must be flushed or cleaned A minimum of 12 3 4 inch I D cooler hose or comparable tubing must be used Dipstick and Dipstick Tube Requirements 1 Dipstick New dipstick and tube designs are req...

Page 9: ...8 93 248 1 248 1 11 18 11 18 213 2 213 2 8 40 8 40 83 30 83 30 7 217 7 217 240 2 240 2 9 46 9 46 240 2 240 2 9 46 9 46 OIL FILL TUBE OEM SUPPLIED OIL FILL TUBE OEM SUPPLIED FOR WET CLUTCH SECTION FOR...

Page 10: ...7 Installation Requirements Fuller UltraShift ASW FO x406x ASW 98 43 3 875 20 6 0 81...

Page 11: ...OEM specifications for concentricity Refer to engine specifications for runout lim its 3 Install the flywheel onto the engine crankshaft using the hardware and mounting specifications of the engine m...

Page 12: ...ing any capscrews Do not use the capscrews to seat the housing 6 Tighten four mounting capscrews at 90 intervals around the clutch housing then tighten the remaining trans mission mounting capscrews u...

Page 13: ...n Requirements Transmission Mounting Typical Lift Points TRANSMISSION LIFTING EYES 3 POINT LIFT CHAIN WITH MINIMUM 1 TON CAPACITY TO CLU TCH LIF TIN G EYE T O C L U T C H L I F T I N G E Y E 5 POINT L...

Page 14: ...ion of the dipstick tube must be vertical from the oil pan connector a minimum of 2 5 above the clutch housing oil pan mounting surface to insure accurate level readings 5 Horizontal or near horizonta...

Page 15: ...t remain vertical for a minimum of 2 5 inches from the end of the fill tube Note A ball end or some equivalent is recommended on the dipstick to prevent interference with tube mounting Note All fluid...

Page 16: ...il flow at 6 gallons per minute 6 A minimum heat extraction rate of 700 BTU minute is required for most applications A minimum heat extrac tion rate of 1 000 BTU minute is required for severe applicat...

Page 17: ...TO WATER PUMP WATER TO COOLER OIL FROM COOLER TO TRANSMISSION OIL COOLER MINIMUM 12 RECOMMENDED WC OUT TO OIL COOLER 1 1 16 12 UN 2B FOR SAE 12 O RING FITTING 37 DEGREE FLARED FITTING OEM SUPPLIED WC...

Page 18: ...conditions which may require the use of a thermostat bypass 1 Under certain conditions such as extreme cold temperature operation or extended periods of low speed oper ation the engine alone may not...

Page 19: ...R PUMP WATER TO COOLER OIL FROM COOLER TO TRANSMISSION OIL COOLER MINIMUM 12 RECOMMENDED WC OUT TO OIL COOLER 1 1 16 12 UN 2B FOR SAE 12 O RING FITTING 37 DEGREE FLARED FITTING OEM SUPPLIED WC IN FROM...

Page 20: ...ys be within the operating marks on the dipstick The exact amount of oil depends on the transmission inclination and cooling system capacity 6 Insufficient oil damages the pump and other components an...

Page 21: ...bricant circulated by the motion of gears and shafts Thus all parts will be amply lubricated if these procedures are closely followed 1 Use Roadranger CD 50 or equivalent synthetic per Eaton publicati...

Page 22: ...X Y Shifter at any time Lubrication Change and Inspection HIGHWAY USE First 1 000 to 1 500 miles Inspect oil levels Check for leaks Every 2 500 miles Inspect oil levels Check for oil leaks Every 150...

Page 23: ...way 2 Body 12048455 3 Terminal 12103881 10 16 0 400 32 21 1 268 57 28 2 255 101 98 4 015 165 10 6 500 172 72 6 800 22 86 0 900 39 75 1 565 38 10 1 500 76 20 3 000 83 82 3 300 22 23 0 875 27 00 1 063...

Page 24: ...pplied mounting bezel If no bezel is used the OEM must ensure the Shift Control is accessible to the driver at all times 3 A cab floor transmission access plate is necessary to service components on t...

Page 25: ...reach of the driver s normal position Note The driver must be able to see and use the Shift Control at all times 4 The Shift Control assembly should not interfere with other vehicle related controls o...

Page 26: ...ling positive lock or bolt together style Packard Delphi 280 Series or equivalent should be used when possible Connectors shall have the capability of being probed by a commercially available volt ohm...

Page 27: ...om Mesh Coverage A minimum of 10 maximum of 12 picks per inch The braid shall be woven so as to produce a tight non slip covering over the cables The braid shall be heat sealed to prevent unraveling B...

Page 28: ...ve weld is also an approved method for splicing Splices shall be insulated with 2 inch long heat shrinkable tubing Circuit Identification Circuit identification shall be by either numbers letters or c...

Page 29: ...ition power switched power run to main power lead that feeds the ignition bus 10 AMP 12 volt only automatic resetting circuit breaker 10 or 15 AMP fuse Or A B C D E F J 1587 data link E1 E2 E3 C1 B2 C...

Page 30: ...0 70 80 90 100 MPH KPH C A B E A B C D E F Dimmer Control Input Start Enable Relay Firewall Floor Board ATA Connector J1587 Link Transmission Interface Harness Vehicle Interface Harness Terminating Re...

Page 31: ...RPM 0 10 20 30 40 50 60 70 80 90 100 MPH KPH C A B E A B C D E F Dimmer Control Input Start Enable Relay Firewall Floor Board ATA Connector J1587 Link Transmission Interface Harness Vehicle Interface...

Page 32: ...Harness is four foot long made of 12 AWG 3 0mm which equals 0016 ohms per foot 12 vdc and ground wires combined equals 8 feet 203mm The Main Power connector is connected to the starter which equals si...

Page 33: ...ed reliable battery sources FROM TO WIRE DESCRIPTION J3 A T2 Ground J3 B J2 B 12 Volts J2 A T1 Battery J2 PACKARD BODY 12020341 CONNECTOR SEAL 12077383 TERMINAL 12033997 10 12 AWG CAP 12033731 CABLE S...

Page 34: ...n Shift Control Push Button Control 30 way connector J1939 Data Link A1 A2 A3 B1 B3 C1 C3 D1 D2 D3 E1 E2 E3 F1 F2 F3 G1 G2 G3 H1 H2 H3 B2 C2 J3 K3 A2 C1 C3 D1 D2 D3 E3 B2 C2 F1 F2 F3 A3 B3 E1 E2 A1 B1...

Page 35: ...1939 Green J1 J3 J2 A3 GND 1 J1 G3 J3 C J 1939 Shield To Dash Components Push Button Control 30 Way Connector Bulkhead Connector Located at Firewall J1 J1939 Data Link EPL Data Link EPL EPL_Shield EPL...

Page 36: ...o start signal from igntion switch Run to starter solenoid Ignition power switched power run to main power lead that feeds the ignition bus 10 AMP 12 volt only automatic resetting circuit breaker 10 o...

Page 37: ...J1587 6 pin J1 C2 J4 B J1587 6 pin J1 B3 J5 DIMMER CONTROL J1 C3 J6 85 START ENABLE RELAY J1 A3 J6 86 START ENABLE RELAY J1 A2 J6 87 START ENABLE RELAY LATCH J6 87 SPLICE STARTER SOLENOID J1 Push But...

Page 38: ...Y POWER J1 E3 J2 4 DISPLAY POWER Truck Components 1 2 3 4 EATON P N 4302640 Top View Pin 4 Pin 1 A1 A2 A3 B1 B2 B3 C2 C3 D1 D2 D3 F1 F2 F3 G1 G2 G3 H1 H2 H3 J1 J2 J3 K1 K2 K3 FRONT VIEW Shift Control...

Page 39: ...Display Module Panel Cut Out Dimensions 43 1 1 70 X 56 1 2 20 X 0 254 010 Mating Connector information AMP 4 way Body 1 480702 0 Terminal 350551 2 Truck Components 33 93 1 336 2 190 2 350 1 850 46 99...

Page 40: ...lt only automatic resetting circuit breaker 10 AMP fuse Or C1 Push Button Shift Control Push Button Control 30 way connector J1 Ignition Power Switched Power Run to Main Power lead that feeds the Igni...

Page 41: ...rical Requirements J 1587 Diagnostic Link C A B E 12 volts battery For transmission diagnostics A B C D E F J 1587 data link B2 C2 B F G A 6 way 9 way Push Button Shift Control Push Button Control 30...

Page 42: ...PTION J1 B2 A F ATA J1 C2 B G ATA __ C B BATTERY __ E A GROUND J1 G1 __ C J 1939 J1 G2 __ D J 1939 J1 G3 __ E J 1939 shield ATA ATA A B C D E F A1 A2 A3 B1 B3 C1 C3 D1 D2 D3 E1 E2 E3 F1 F2 F3 C2 H1 H2...

Page 43: ...n When VDASH input is off the lights on the Shift Control will be on full FROM TO J1 B3 VDASH Back side of gauges Dash lights B3 Push Button Shift Control Push Button Control 30 way connector Dimmer C...

Page 44: ...3 1 3 The engine starter shall be inoperative when the transmission shift lever is in a forward or reverse direction position Start enable relay Run to start signal from igntion switch Run to starter...

Page 45: ...Run to Starter Solenoid 85 30 86 87a 87 Start Enable Battery C3 Run to Starter Solenoid Run to Start Post of Ignition Switch BATT KEY SWITCH ACC OFF IGNITION KEY START If Used Relay Coil Relay N O Sta...

Page 46: ...Data Link Terminating resistor J 1939 11 data link OEM supplied GND _ Shield termination Engine ECM Terminating resistor Bulkhead connector located at firewall G1 G2 G3 Push Button Shift Control Push...

Page 47: ...ts J 1939 Data Link Detail FROM TO DESCRIPTION J1 G1 A J 1939 High J1 G2 B J 1939 Low J1 G3 C J 1939 Shield A1 A2 A3 B1 B3 C1 C3 D1 D2 D3 E1 E2 E3 F1 F2 F3 H1 H2 H3 FRONT VIEW Shift Control 30 Way Con...

Page 48: ...P006 N A N A N A If an additional wire is added to the drain for insertion into the connector no shield terminal is used and the signal terminal quantity is 3 If the drain wire is to be directly inser...

Page 49: ...e on the solder sleeve to a length of 25 mm and strip the insulation back 7 mm Crimp the appropriate terminal on each data wire and solder sleeve wire or the extended socket per the manufacturer s rec...

Page 50: ...exposed wires to within 2 mm from cable jacket Strip insulation from data wires 7 mm 0 8 mm Crimp stub branch lines and drain wire to main backbone data lines and drain wire Cover each splice with in...

Page 51: ...to within 2 mm from cable jacket Strip insulation from data wires 7 mm 0 8 mm Attach X link wire to drain wire with crimp splice per manufacturer s recommendation Slide adhesive filled shrink tube ove...

Page 52: ...per inch 120 Ohm terminating resistors must be used Connector at ECU is not defined The third pin for shield is not used in in line and T connectors Recommended Cable Manufacturer Cable Part Number R...

Page 53: ...in this manual for connector information FROM DESCRIPTION P1 50 J 1939 High P1 34 J 1939 Low P 42 J 1939 Shield PEI 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31...

Page 54: ...9 Control Data Link on Detroit Diesel DDECIII and IV Engines FROM TO DESCRIPTION K1 F K4 A J 1939 High K1 E K4 B J 1939 Low K1 D K4 C J 1939 Shield J 1939 SHIELD J 1939 J 1939 F E D C B A K4 K1 Electr...

Page 55: ...Interface Harness J 1939 3 pin Deutch connector will already be present No additional con nections are needed to connect the engine ECM to the J 1939 backbone Note It may be necessary to extract the c...

Page 56: ...ing wiring into wheel splash areas should be avoided When such routing cannot be avoided adequate clipping or protective shielding is required to protect wiring from stone and ice damage 8 Routing wir...

Page 57: ...rect gauge Failure to adopt this precaution will lead to switch contacts burning The following wire table suggest wire gauges for various maximum current draws and will aid in the selection of the cor...

Page 58: ...FROM TO Description J1 A1 J2 A Auto Neutral Input J1 B1 J2 C Auto Neutral Return J1 H1 J2 E Quick to Neutral Return J1 H3 J2 F Quick to Neutral Input A1 B1 H1 H3 A C E F J1 J2 PACKARD Body 12064752 T...

Page 59: ...ection Table FROM TO Description J3 D3 J4 A Aux 1 Input J3 E3 J4 B Aux 1 Input Return J3 F3 J4 C Aux 1 Output Lo side J3 F1 J4 D PTO Input J3 F2 J4 E PTO Input Return D3 E3 F3 F1 F2 PACKARD Body 12129...

Page 60: ...tationary PTO operation and a transmission gear engagement cannot be selected When disengaged switch opened normal transmission gear engagement can be selected The Fuller UltraShift ASW transmission m...

Page 61: ...sion main box countershaft Incorrect or no PTO interface signal to the transmission will result in no clutch activation and therefore no PTO operation The active signal will illuminate the Mode indica...

Page 62: ...gaged for split shaft PTO operation The transmission default mode for the pin F1 input is for countershaft PTO operation if split shaft PTO operation is desired the PC based service tool ServiceRanger...

Page 63: ...ecessary corrective action prior to dyno or road testing 4 The DYNO ROAD TEST section is used to verify that all transmission systems are functional the clutch is cali brated properly and the driver i...

Page 64: ...omatically provides for clutch wear The system will initiate a clutch calibration once per each vehi cle power up when certain vehicle conditions are right Of these conditions the most important ones...

Page 65: ...en driving the problem is that the dynamometer decelerates too quickly 7 Verify through normal operation that the engine brake if equipped functions correctly per the manufacturer s specifications 8 V...

Page 66: ...ing with the transmission in gear Failure to preform installation pre start checks may result in the engine cranking immediately when ignition is moved to the START position or to the ON position To p...

Page 67: ...perature gauge is functional if equipped 7 Verify gear display module DDM works correctly 8 Shift Control panel lights functional 9 Verify no transmission oil leaks 10 Transmission diagnostic port acc...

Page 68: ...uide for flash code retrieval If dash is still on the gear display then power down turn the key off and wait for one minute and power up Verify Start Enable Relay circuit is installed correctly Verify...

Page 69: ...ectors Electronic Shifter Transmission Controller Transmission To Vehicle Interface Harnesses Transmission Power Supply Harness from Start Battery Source Transmission Interface Harness Vehicle Interfa...

Page 70: ...nsmission Controller Transmission To Vehicle Interface Harnesses Transmission Power Supply Harness from Start Battery Source OEM Interface Connector J 1939 Connector Firewall Connector for Cab Connect...

Page 71: ...r Position Fx x406x ASW Note Bolts used for retaining sensors or lifting eyes are not to be used for any other purpose or have any other brackets attached to them Lifting Eye 12 O Clock output Shaft S...

Page 72: ...mpcable com DEUTSCH Connectors Industrial Products Division 37140 Industrial Ave Hemet CA 92545 909 765 2250 Fax 909 765 2255 www deutschipd com www laddinc com Ladd Industries PACKARD Electric Connec...

Page 73: ...equired in WetClutch section of transmission Eaton Roadranger CD50 or equivalent required in transmission gear box Electrical Section Electrical Dual Power required Main Power and ground must be conne...

Page 74: ...ing per Eaton approval OEM is responsible for rigidly mounting the shift control pedestal Access plate on the floor board is easily removable Sealed connectors required at shift control pedestal on co...

Page 75: ...ft 27 34 Nm Reverse switch 9 16 18 20 25 Lb ft 27 34 Nm Neutral switch cap 3 4 16 20 25 Lb ft 27 34 Nm ECU Connector Bolt 20 30 Lb in 2 25 3 39 Nm Lubricant fill plug 6 Speed 3 4 NPT 45 55 Lb ft 61 7...

Page 76: ...1 D2 H1 H2 K2 K3 J2 J3 C1 C2 C3 A1 A3 B1 E2 B3 E1 Terminating resistor J1 J2 J3 A B C A B C EPL data link Bulkhead connector located at firewall Gear select motor Rail select motor Electric shifter Au...

Page 77: ...side of gauges Dash lights Dimmer control input C A B E 12 volts battery For transmission diagnostics Start enable relay Run to start signal from ignition switch Run to starter solenoid Ignition power...

Page 78: ...AY DESCRIPTION NOTES A1 Batt 1 A2 ATA A3 GND 1 B1 Trans batt 1 B2 ATA B3 GND 2 C1 EPL C2 EPL C3 EPL shield D1 Aux speed 1 D2 Aux speed 1 D3 Aux input 2 Input LO side E1 Batt 2 E2 Trans batt 2 E3 Aux i...

Page 79: ...gnition C2 1587 C3 Start enable relay D1 Aux input 5 Input LO side D2 Aux input 6 Input LO side D3 Aux output 3 Output LO side driver E1 Gear display clock E2 Gear display data E3 Gear display Return...

Page 80: ...r trusted partners providing the best products and services in the industry ensuring more time on the road 20 07 Eaton Corporation All rights reserved Printed in US A Copyright Eaton and Dana Corporat...

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