Eaton UltraShift PLUS EO-11E406B-PV Installation Manual Download

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Installation Guide

Eaton Medium-Duty

UltraShift® PLUS Transmissions

TRIG0996 EN-US

September 2014

Eaton UltraShift® PLUS PV Performance Transmissions

EO-11E406B-PV

EO-11E406B-PVER

Summary of Contents for UltraShift PLUS EO-11E406B-PV

Page 1: ...Installation Guide Eaton Medium Duty UltraShift PLUS Transmissions TRIG0996 EN US September 2014 Eaton UltraShift PLUS PV Performance Transmissions EO 11E406B PV EO 11E406B PVER ...

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Page 4: ...h Option 17 Reverse Switch 17 Mounting Transmission to Engine Using Rear Supports 18 ECA Engine Speed Sensor Requirements 19 Threaded Engine Speed Sensor Installation Requirements 19 Lubrication Requirements and Specifications Eaton UltraShift PLUS PV Transmission Gear Box Lubrication Requirements 20 Warnings and Cautions 20 Operating Temperatures 20 Transmission Oil Level 21 Transmission Componen...

Page 5: ...ecommendations Mating Connector and Terminal Recommendations 52 Electrical Sealing Recommendations 52 Harness Design Recommendations 52 Harness Routing Recommendations 52 Harness Attachment Recommendations 53 Contact Lubrication Recommendation 53 Additional Harness Design Recommendations 53 Electrical Juncture Recommendations 55 Troubleshooting Recommendations Harness Troubleshooting and Test Equi...

Page 6: ... Inspection and Initial Starting Requirements Pre Start Inspection 82 Before Cranking Engine 83 Grade Sensor Calibration Process Requirements 84 Grade Sensor Calibration Tool 84 Shift Input Device Combination 85 ServiceRanger PC based Diagnostic Tool 85 Line Inspection Forms Eaton UltraShift PLUS PV Models 86 OEM Wiring Connector Harness 87 Diagnostic Procedure 88 Appendix Torque Specifications 91...

Page 7: ... used throughout this manual to call attention to procedures where carelessness or failure to follow specific instructions may result in personal injury and or component damage Departure from the instructions choice of tools materials and recommended parts mentioned in this publication may jeopardize the personal safety of the service technician or vehicle operator Warning Failure to follow indica...

Page 8: ...Engineering Support Group for approval prior to any OEM build A design package consists of the following information Battery power and ground Detailed drawing of battery power and ground scheme Individual harness drawings Construction detail of individual wiring harnesses including harness routing location and clipping points Wiring schematic High level schematic of how this transmission interface...

Page 9: ...on Corporation Transmission Div Kalamazoo MI 49003 Fuller R E Newton meters Overdrive O X 100 Newton meters ECA clutch control same as HD Gear Ratio Set Number of Speeds 1 1 E 4 0 6 B P V E R Passenger Vehicle Electromagnetic Retarder Same Gear Design Level as all MD automated current products Park HV uses 5 because they actually use a different mainshaft Mechicanical Electronic E Newton meters Ov...

Page 10: ...and engine torque The OEM is required to perform a grade sensor calibration procedure upon initial vehicle start up to support this system A PTO input is available on this transmission The OEM is recommended to provide a connector and wiring from the transmission ECU 38 way with the PTO wires installed A High Capacity Inertia Brake HCIB is located on the transmissions PTO opening This device is in...

Page 11: ...r Kit J 49111 Clutch Alignment Tool Liberty Circuits Corporation 269 226 8743 Part No Description 500 432 Pull To Neutral Box 500 442 Grade Sensor Calibration Box Deutsch 951 765 2250 Part No Description DTT 20 02 Hand Crimping Tool Low Power Pins size 20 DTT 12 00 Hand Crimping Tool High Power Pins size 12 Service Publications TRSM0930 Service Manual for External components TRTS0930 Troubleshooti...

Page 12: ... DEUTSCH Connectors Industrial Products Division 3850 Industrial Ave Hemet CA 92545 951 765 2250 Fax 951 765 2255 www deutschipd com insidesales ipd deutsch net www laddinc com Ladd Industries Delphi Connection Systems Connectors 1265 North River Rd MC 11C Warren OH 44483 USA 330 373 3630 Fax 330 373 7774 www delphi com RAYCHEM Wire Electronics OEM Components Division 300 Construction Drive Menlo ...

Page 13: ...a United States Telma Retarder Inc 870 Lively Boulevard Wood Dale IL 60191 1 800 797 7714 www telmausa com China Telma Vehicle Braking System Co Ltd No 9 factory 533 Yuanzhong Rd Nanhui Shanghai China 210300 86 13818963597 www telma retarder com cn ...

Page 14: ...ature Requirements on page 22 Cab Floor Access Plate Requirements 1 A cab floor access plate is required for access and removal of components from the transmission top Plate size minimum 15 x12 shall be sufficient to allow removal of the Transmission Electronic Control Unit or the Electric Shifter 2 Access plate requirement applies to any vehicle configuration even though only a front engine confi...

Page 15: ...hift Label Requirements 1 The shift label should be located in the cab so that it is visible in the driver seat 2 Shift labels are available for shift devices in Chinese and English 3 The OEM must match the label with the installed shift device ...

Page 16: ...ith 30 way packard connector with body 15492553 and terminals 12103881 12 2 48 38 74 40 76 1 525 1 605 75 2 2 96 29 6 1 16 37 54 1 478 83 8 3 30 172 7 6 80 164 1 6 46 101 98 4 015 60 6 2 39 9 59 378 166 62 6 56 PANEL CUT OUT DIMENSIONS 4X R 10 MAX 77 72 3 06 2X 8 32 UNC ...

Page 17: ...8 1 1 33 1 3 69 2 7 81 3 2 41 1 6 28 1 1 18 7 43 1 7 30 1 2 28 1 1 33 1 3 69 2 7 18 7 8 3 262 10 3 13 2 52 89 3 5 111 3 4 38 124 4 9 173 6 8 18 7 8 3 262 10 3 13 2 52 89 3 5 111 3 4 38 124 4 9 173 6 8 Low Gear Position Neutral Position Reverse Gear Position 27 0 9 0 4 M6 x 1 Use M6x1 Mounting Screws 23 31 lb in 2 5 3 5 Nm 4 Places ...

Page 18: ...atory to ensure adequate bearing life Pilot bearing failure usually results in a warranty claim for drag or clutch noise This results in a claim against Eaton Clutch Below is a list of the recommended Pilot Bearings All of these bearings have Viton seals and a high temperature grease in addition to a C3 fit It is acceptable to use synthetic high temperature grease and a C5 fit if desired If the su...

Page 19: ... 3 Put aligning tool with disc into flywheel Verify aligning tool pilot is through the pilot bearing 4 Slide clutch assembly over aligning tool and two guide studs 5 Install lock washers and 8 7 16 14 x 2 grade 5 or better mounting bolts finger tight Replace studs with lock washers and bolts Progressively tighten bolts in a crisscross pattern starting with a lower bolt Torque the 395mm to 40 50 lb...

Page 20: ...14 Clutch Interface 395mm Mounting Bolts and Shipping Bolts Shipping Bolts 4 8 7 16 14 x 2 1 4 Torque 40 50 lbs ft 54 68 NM NOTE Remove shipping bolts after mounting bolts are installed ...

Page 21: ...be rotated to line up a locating pin with a notch in the housing in order to install the ECA into the clutch housing Install the ECA onto the housing while matching the splines of the ECA motor to the shaft Install 1 3 8 24 nylon lock nut or nut with washer to secure the ECA to the housing Torque to 25 35 ft lb 34 47 Nm Install 3 3 8 16 cap screws Torque to 25 35 ft lb 34 47 Nm 34 47 25 35 ...

Page 22: ...damaging the clutch 4 Make sure the shipping bolts are installed before removing the clutch or clutch damage will occur The other option is to remove the ECA by using the following Instructions Refer to the following procedure in the event the Elec tronic Clutch Actuator assembly requires removal and replacement ECA Removal 1 Cut tie straps which secures the ECA harness if applicable 2 Disconnect ...

Page 23: ...erall system reliability Note No mechanical speedometer The rear bearing cover will offer three 3 push in sensor openings at 3 9 and 12 o clock positions The 12 o clock position is reserved for Eaton for the direction and speed sensor assembly The 3 and 9 o clock positions are reserved for the OEM to install a speed sensor The tone wheel has 16 teeth as standard Reverse Switch Reverse Switch Optio...

Page 24: ...lation Rotate the output shaft yoke while sliding the input shaft into the clutch to line up the splines If the transmission is properly aligned and the clutch splines are properly aligned very little force is required to slide the input shaft through the clutch and into the pilot bearing If interference is encountered move the transmission away from the engine to investigate the cause The use of ...

Page 25: ...n Requirements Thread speed sensor into the engine bellhousing until it touches the flywheel then back sensor out approximately 1 2 turn to set gap Set gap between sensor and flywheel to 0 055 inches 0 020 Hold the sensor in place and tighten the 3 4 16 jam nut to 15 lbs ft 20 3 Nm Connect engine speed sensor connector to the mating connector on the transmission and fasten harness to the ECA cover...

Page 26: ...y kind added later to the oil can result in unpredictable consequences No liability of any kind will be accepted by Eaton for any damage resulting from the use of such additives Do not mix lubricants of different grades Use clean containers when transferring lubricant from the bulk storage to the transmission Containers used for antifreeze or water should be cleaned prior to use Do not re use lubr...

Page 27: ...any oil residue Make sure that the transmission lubricant is level with the bottom of the fill opening 3mm Note Being able to reach the lubricant with your finger does not indicate that the lubricant is at the proper level On heavy duty transmissions one inch of lubricant equals about nine pints of oil DO NOT remove the Electric Shifter XY Shifter to fill the transmission with oil Transmission mus...

Page 28: ... air gap between the heat source and these transmission components cannot be achieved the OEM must provide proper methods of heat shielding to ensure this limit is not exceeded The components and systems to be protected would include but not limited to the Shift Motors Sensors Solenoids Inertia Brake Wire Harness Transmission Controller ECA and the Transmission Case Right Side View ...

Page 29: ...23 Transmission Interface Transmission Interface Top View 34 47 25 35 ...

Page 30: ...24 Transmission Interface Left Side View ...

Page 31: ...hicle Design Implementation of a vehicle design to produce a defined functional output Vehicle Function Verification that a design produces a defined functional output Service Lamp Diagnostic Lamp to indicate transmission fault detection to the operator Shift Control Power Power supplied from the TCM to either the PBSC or Eaton Shift Lever a k a Cobra Eaton Shift Lever Eaton resistive ladder shift...

Page 32: ...load of 30 amps for a nominal 12 volt vehicle power system 18 0 volts DC at a steady state load of 30 amps for a nominal 24 VDC system at the ECA connector For ECA optimal shift quality the vehicle shall provide a minimum of 11 0 volts DC at steady state load of 30 amps at the ECA connector For full ECA subsystem operation the vehicle power system shall provide and electrical system that at 120 C ...

Page 33: ...32 31 25 9 3 4 10 TRN1 J1 DRC26 38S02 P017 ELECTRONIC CONTROL UNIT 691961A GEN 3 EATON TRANSMISSION STARTER FRAME RAIL ELECTRICAL STUD FUSE ECU POSITIVE FUSE ECU IGNITION 87a 87 30 85 86 IGNITION BUS RELAY VEH BATTERY POSITIVE VIGN VIGN VEH_POSITIVE FUSE IGNITION FEED FUSE VEHICLE POSITIVE TRANSMISSION BATTERY POSITIVE AND NEGATIVE CONNECTIONS ARE MADE TO ISOLATED POWER TERMINALS THESE TERMINALS A...

Page 34: ...0 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 35 13 37 38 36 22 26 32 31 25 9 3 4 10 TRN1 J1 DRC26 38S02 P017 ELECTRONIC CONTROL UNIT 691961A GEN 3 EATON TRANSMISSION STARTER FRAME RAIL ELECTRICAL STUD FUSE ECU POSITIVE FUSE ECU IGNITION 87a 87 30 85 86 IGNITION BUS RELAY VEH BATTERY POSITIVE VIGN VIGN VEH_POSITIVE FUSE IGNITION FEED FUSE VEHICLE POSITIVE TR...

Page 35: ...re Description J5 J1 36 Battery Negative J6 J7 B Battery Positive J7 A J1 38 Positive Fused J6 connects to the side of the Main Battery Source J5 connects to the Ground side of the Main Battery Source J6 J5 Transmission ECU Connector Vehicle Interface J1 J7 OEM responsible for overcurrent protection on this line ...

Page 36: ... Positive J7 A J1 C ECA Positive Fused ECA Pin Out 3 Way Connector A Plugged Not Used B Battery Negative C Battery Positive Fused J6 connects to the 12 Volt side of the Main Battery Source J5 connects to the Ground side of the Main Battery Source J6 J5 J1 OEM responsible for overcurrent protection on this line J7 A B C ...

Page 37: ...erface Typical ECA Circuit ECA Pin Out 3 Way Connector A Plugged Not Used B Battery Negative C Battery Positive Fused Transmission ECU 30 29 1 2 1 2 Fuse Battery power Non switched power run to starter or battery Engine Flywheel Speed Sensor B C 13 A B C ...

Page 38: ...23 17 31 24 25 29 30 15 16 26 20 34 27 28 32 33 18 19 7 3 8 9 1 2 10 6 11 12 4 5 22 21 38 36 37 13 14 35 Front View Transmission ECU Connector Vehicle Interface Transmission ECU Connector Vehicle Interface J1 Ignition Key Switch Run to main power lead that feeds the ignition bus OEM responsible for overcurrent protection on this line ...

Page 39: ...sing device for the TCM Vehicle Power shall have a nominal break current of 30 A or greater Recommend use of 30 Amp Fuse ATO or equivalent for the TCM connection to Vehicle Power The fusing device for the TCM Vehicle Power shall be dedicated to the TCM Vehicle Power interface The fusing device for the ECA Vehicle Power shall have a nominal break current of 40 A or greater Recommend use of 40 Amp F...

Page 40: ...he TCM Deutsch connector s size 12 pins shall be nickel plated terminals Note These circuits are power circuits The TCM Deutsch connector s size 20 pins shall be gold plated terminals Note These circuits are signal level circuits The TCM Deutsch connector s terminal shall be compliant with Deutsch s terminal requirements for the DRC26 38S01 P017 connector body The TCM Deutsch connector s terminal ...

Page 41: ...dy Eaton recommends Deutsch part number DT04 2P E003 The OEM shall use the Deutsch W2PA wedge The OEM shall use Deutsch Size 16 gold plated contacts Eaton recommends Deutsch part number 1060 16 0144 The insulation outside diameter of the connector shall comply with Deutsch requirements for the selected connector shell The wire gauge shall comply with the Deutsch requirements for the selected conta...

Page 42: ...ess cable wire diameters shall be compliant with the following insulation diameter requirements Mating torque for the 30 way PBSC jackscrew shall conform to torque requirements found in the Appendix under Torque Specifications Seal Range Diameter mm in Contact Size Description TXL1 AWG GXL1 AWG SXL1 AWG 2 00 2 40 0 079 0 094 12103881 Signal Ø 18 20 Ø 1 96 2 64 0 077 0 104 425 00 00 872 Signal 16 1...

Page 43: ...the connector jackscrew threads including NyoGel 760G Rational The use of such compounds may affect jackscrew torque and prevent proper sealing of the connector Minimum wire gauge of 18 AWG shall be used for transmission signals except where mechanical reliability of 20 AWG wire harnessing can be demonstrated All crimp contacts for connectors mating with Eaton components shall meet the supplier of...

Page 44: ... or SAE J1939 15 All nodes on the bus must conform to the applicable bus architecture SAE J1939 11 or SAE J1939 15 If a J1587 data link is provided on the vehicle it shall conform to SAE J1708 physical layer requirements During all normal operation conditions the voltage potential between all J1939 node reference grounds shall not exceed 2 0 volts DC Note A J1939 node reference ground shall be con...

Page 45: ...1 G J1587 __ B BATTERY __ A GROUND __ C J1939 HIGH __ D J1939 LOW Battery For Transmission Diagnostics J1587 Data Link 10 11 C D B F G A 9 way A F J E G H D C B 23 17 31 24 25 29 30 15 16 26 20 34 27 28 32 33 18 19 7 3 8 9 1 2 6 12 4 5 22 21 38 36 37 13 14 35 10 11 J1 Front View TCM Connector Vehicle Interface J1939 Low J1939 High TCM Connector Vehicle Interface ...

Page 46: ...w J1 3 A J1939 High J1 1 C J1939 Shield used only for SAE J1939 11 Terminating Resistor J1939 15 data link OEM supplied Terminating Resistor Other Modules J1 Engine ECU Transmission ECU 23 17 31 24 25 29 30 15 16 26 20 34 27 28 32 33 18 19 7 8 9 2 10 6 11 12 4 5 22 21 38 36 37 13 14 35 1 3 TCM Connector Vehicle Interface 1 ...

Page 47: ...t lever is in a forward or reverse direction position TCM J1 32 shall provide signal to the high side of the relay coil TCM J1 4 shall provide signal to the low side of the relay coil TCM J1 26 shall provide signal from the relay contact providing power to the Starter Solenoid Relay This signal shall not be interrupted by the vehicle system between the Start Enable Relay and the Starter Solenoid R...

Page 48: ...Enable Battery 32 Run to Starter Solenoid Relay BATT KEY SWITCH ACC OFF START Relay Schematic Start Enable Latch 26 Start Enable Ground 4 Front View 23 17 31 24 25 29 30 15 16 20 34 27 28 33 18 19 7 3 8 9 1 2 10 6 11 12 5 22 21 38 36 37 13 14 35 32 26 4 Ignition Power switched power Run to main power lead that feeds the ignition bus OEM responsible for overcurrent protection on this line Transmiss...

Page 49: ...wer Battery or VIGN Optional Indicator Lamp Transmission ECU 38 Way Connector Vehicle Interface PTO Active Switches Battery Negative or Frame Ground 18 PTO Switch 34 Return Additional PTO Active Switches 24 29 30 15 16 26 20 34 32 33 19 7 3 8 9 1 2 6 11 12 4 5 22 21 38 36 37 13 14 35 10 17 23 Front View Transmission ECU Connector Vehicle Interface 31 25 28 27 18 Pin Side View 34 ...

Page 50: ...nnected to the return side of switch or relay The return side shall be isolated from vehicle ground Switch or Relay contacts shall be able to reliably make contact with wetting current of 5 mA and a contact closure voltage of 4 5 volts Typical Switched PTO Input From Description J1 18 PTO Signal Input J1 34 PTO Return Transmission ECU 38 Way Connector Vehicle Interface 18 PTO Switch 34 Return 24 2...

Page 51: ...h TCM J1 33 shall be connected to the return side of the switch The return side shall be isolated from vehicle ground Switch or Relay contacts shall be able to reliably make contact with wetting current of 5 mA and a contact closure voltage of 4 5 volts Note Contact the brake manufacturer for additional pressure switch requirements Typical Auto Neutral Switch Input Description From To Auto Neutral...

Page 52: ...tem with Eaton PBSC From To Description J1 27 C2 F2 HIL LOW Proprietary CAN J1 28 C2 F1 HIL HIGH Proprietary CAN J1 25 C2 J3 Shift Control Power Minus J1 31 C2 C1 Shift Control Power Plus C2 B3 Dimmer Control Input 27 28 25 31 31 24 25 29 30 15 16 26 20 34 27 28 32 33 18 19 7 3 8 9 1 2 6 11 12 4 5 22 21 38 36 37 13 14 35 10 17 23 Front View TCM Connector Vehicle Interface Dimmer control input Push...

Page 53: ... in Section 5 Typical System with Eaton Shift Lever Note See Dimmer Control Input Requirements for PBSC and Eaton Shift Lever in this section for additional requirements Typical System Wiring with OEM Resistive Ladder Shift Device From To Description J1 15 F2 B Shift Control Input Mode Auto J1 16 F2 A Shift Control Input Mode Manual J1 17 F2 C Shift Control Input Mode Common J1 23 F3 A Service Lam...

Page 54: ...ts J1 23 C2 6 Service Light Output J1 16 C2 8 Shift Control Input Mode Manual J1 14 C2 7 Shift Control Input Mode Common 2 25 31 15 16 17 23 14 31 24 25 29 30 15 16 26 20 34 27 28 32 33 18 19 7 3 8 9 1 2 6 11 12 4 5 22 21 38 36 37 13 14 35 10 17 23 Front View Transmission ECU Connector Vehicle Interface J1 C2 Bulkhead connector located at firewall 3 4 1 8 2 6 5 7 3 4 1 8 2 6 5 7 Back side of gauge...

Page 55: ...esistor to less than 1 2 VDC at TCM pin J1 16 with respect to J1 17 The OEM shall indicate a non neutral state request by providing an impedance of 10 000 ohms 1 across TCM J1 16 and J1 17 Typical System Wiring with OEM SAE J1939 Shift Input Device 23 17 31 24 25 29 30 15 16 26 20 34 27 28 32 33 18 19 7 8 9 2 10 6 11 12 4 5 22 21 38 36 37 13 14 35 1 3 TCM Connector Vehicle Interface Front View J1 ...

Page 56: ... Lamp TCM Connection Requirements Note This section refers to Service Lamps powered from J1 23 of the TCM Wiring for Service Lamp wiring shall provide power for up to a 1 watt to an incandescent lamp load at nominal vehicle battery voltage Note An LED indicator may also be used TCM J1 23 shall be connected to the source side of the Service Lamp The return side of the lamp shall be connected to veh...

Page 57: ...amps may be driven from a switch Note Some switches have extended limits Minimum whetting current is based on environmental temperature profile and how often the switch is actuated The value is a conservative estimate based on historical use of ball switches Typically less whetting current is required for proper operation Environmental validation is required to determine actual minimum whetting cu...

Page 58: ...factors The ability to remove the connector without cutting tie wraps The ability for the tie wrap to only bind the harness sheath as opposed to individual wires going into the connector shell The length of an unanchored section of harness should be no more than 12 in 30 48 cm Eaton has provided several harness routing brackets that can be used for clipping vehicle routed components These harness ...

Page 59: ...al Harness Design Recommendations Recommend the distance of the SAE J 1939 bus between the TCM and ECM should be short as possible Recommend wiring types for the Deutsch connector DRC26 38 S01 18 AWG GXL max 18 AWG TXL min for Communication and control wires 12 AWG GXL or 14 AWG SXL for Power Supply wires 12 AWG GXL or 14 AWG SXL for V Ignition wires Recommend cable for the 3 Way Metri Pack connec...

Page 60: ...ommended Conduit Recommended SAE J 1939 15 Cable Recommended SAE J 1939 15 Bus Connector System Deutsch 0528 004 3805 Back Shell Deutsch P N 0528 005 3805 Low Profile Backshell Conduit OEM Delfingen Delfingen Conduit P N R 69246 round R 69246 round R 72506 profile Recommended Cable Manufacturer Cable Part Number Round J 1939 PIN A Color J 1939 PIN B Color Champlain 15 07353 Yes Yellow Green Ref Bo...

Page 61: ...hanical connection points to Eaton transmission components and other critical components such as ABS system and Engine Control system Troubleshooting Recommendations Harness Troubleshooting and Test Equipment Design Recommendations Opening a switch contact or the main power link is the recommended method of interrupting power Recommend not removing fuses as the method of disconnecting power to the...

Page 62: ...e The above routing and attachment points are recommended for best transmission reliability Caution To prevent damage to the harness ties need to be made after the transmission is placed into the frame Transmission ECU Connector Vehicle Harness Transmission ECU Connector Transmission Harness ...

Page 63: ...er Reference SAE Wire Nominal Outside Diameter mm Nominal Outside Diameter Inch Size mm Size No TXL GXL SXL TXL GXL SXL 0 8 18 1 98 2 39 2 72 0 08 0 09 0 11 1 16 2 24 2 59 3 05 0 09 0 10 0 12 2 14 2 62 2 97 3 58 0 10 0 12 0 14 3 12 3 25 3 63 4 14 0 13 0 14 0 16 5 10 3 96 4 45 4 95 0 16 0 18 0 20 ...

Page 64: ... Battery power Non switched power run to Battery Terminating resistor Transmission Controller ECU A F J E G H D C B Bulkhead connector located at firewall Back side of gauges Dash lights Dimmer control input J 1939 Low J 1939 High OEM Ignition Key Switch Runs to main power lead that feeds the ignition bus OEM responsible for overcurrent protection on this line 40 AMP fuse Battery power Non switche...

Page 65: ...P fuse Battery power Non switched power run to Battery Terminating resistor Transmission Controller ECU A F J E G H D C B Bulkhead connector located at firewall Back side of gauges Dash lights Dimmer control input J 1939 Low J 1939 High OEM Ignition Key Switch Runs to main power lead that feeds the ignition bus OEM responsible for overcurrent protection on this line 40 AMP fuse Battery power Non s...

Page 66: ...wer Non switched power run to Battery Terminating resistor Transmission Controller ECU A F J E G H D C B Bulkhead connector located at firewall Back side of gauges Dash lights Dimmer control input J 1939 Low J 1939 High OEM Ignition Key Switch Runs to main power lead that feeds the ignition bus OEM responsible for overcurrent protection on this line 40 AMP fuse Battery power Non switched power run...

Page 67: ...9 13 30 29 A B A B 1 2 1 2 40 AMP fuse Battery power Non switched power run to Battery Engine Flywheel Speed Sensor B C C E C E 3 2 33 1 4 2 W 027 W27 OS_SPEED_MEG W 029 W29 OS_SPEED_SIG W 028 W28 OS_SPEED_POS Terminating Resistor Rail select sensor Gear select sensor Input shaft speed sensor 18 19 20 10 11 12 7 8 A B C A B C 21 22 Directional output shaft speed sensor 30 AMP fuse Battery power No...

Page 68: ...er solenoid Return Auto Neutral Auto Neutral Return 10 AMP only manual resetting circuit breaker 10 AMP fuse or J 1587 data link 30 87 86 85 Bulkhead connector located at firewall Battery For transmission Diagnostics per SAE Standard C D B F G A 9 way A F J E G H D C B J1939 Low J1939 High Ignition Key Switch Runs to main power lead that feeds the ignition bus OEM responsible for overcurrent prote...

Page 69: ...er Minus 7 Plugged 26 Start Enable Latch 8 Plugged 27 HIL Low Proprietary CAN 9 Plugged 28 HIL High Proprietary CAN 10 J1587 Plus 29 Plugged 11 J1587 Minus 30 Plugged 12 Aux trans signal 31 Shift Control Power Plus 13 Aux trans return 32 Start Enable Relay Plus 14 Shift Control Input Mode Common Neutral Return 2 33 AutoNeutral Return 15 Shift Control Input Mode Auto 34 PTO Return 16 Shift Control ...

Page 70: ...hift Control Power Minus 4 Shift Control Power Plus 5 Dash Lights 6 Service Light Output 8 Shift Control Input Mode Manual 7 Shift Control Input Mode Common 2 3 Way Description A No Connection Plugged B Ground C Battery From To Description J1 27 C2 F2 HIL LOW Proprietary CAN J1 28 C2 F1 HIL HIGH Proprietary CAN J1 25 C2 J3 Shift Control Power Minus J1 31 C2 C1 Shift Control Power Plus C2 B3 Dimmer...

Page 71: ...n Eaton UltraShift PLUS PV model Unused data in a PGN is broadcast as Not Available The inability the transmission control unit to broadcast valid data will result in Error Indicator or Not Available being broadcast For specific message formatting and broadcast rate see SAE J1939 71 and SAE J1939 73 Active Diagnostic Trouble Codes DM1 PGN 65226 Source Address 3 Transmission 1 Parameter Name SPN Ma...

Page 72: ...214 FMI 1215 SPN Conversion Method 1706 Occurrence Count 1216 Electronic Transmission Controller 1 ETC1 PGN 61442 Source Address 3 Transmission 1 Parameter Name SPN Transmission Driveline Engaged 560 Transmission Shift In Process 574 Transmission Output Shaft Speed 191 Engine Momentary Overspeed Enable 606 Progressive Shift Disable 607 Transmission Input Shaft Speed 161 Electronic Transmission Con...

Page 73: ...ress 3 Transmission 1 Parameter Name SPN Engine Override Control Mode 695 Engine Requested Speed Control Conditions 696 Override Control Mode Priority 897 Engine Requested Speed Speed Limit 898 Engine Requested Torque Torque Limit 518 Message Counter 4206 Message Checksum 4207 Torque Speed Control 1 TSC1 Retarder PGN 0 Source Address 3 Transmission 1 Parameter Name SPN Engine Override Control Mode...

Page 74: ...on 60 Transmission Shift Finger Rail Actuator 1 772 Transmission Shift Finger Gear Actuator 1 773 Transmission Range High Actuator 768 Transmission Range Low Actuator 769 Transmission Splitter Direct Actuator 770 Transmission Splitter Indirect Actuator 771 Transmission Inertia Brake Actuator 787 Electronic Transmission Controller 4 ETC4 PGN 65221 Source Address 3 Transmission 1 Parameter Name SPN ...

Page 75: ...dress 3 Transmission 1 Parameter Name SPN ECU Part Number 2901 ECU Serial Number 2902 ECU Location 2903 ECU Type 2904 ECU Manufacturer Name 4304 Vehicle Electrical Power 1 VEP1 PGN 65271 Source Address 3 Transmission 1 Parameter Name SPN Battery Potential Power Input 1 168 168 Keyswitch Battery Potential 158 158 ...

Page 76: ...49 Cab Controller Primary 0 Engine 1 17 Cruise Control 23 Instrument Cluster 1 33 Body Controller Note First Source Address supported with valid data is latched for power cycle Source Address sending valid Brake Switch data will be monitored for valid Clutch Switch and Parking Brake Switch data Wheel Based Vehicle Speed can be sent from a different Source Address then that sending Brake Switch dat...

Page 77: ...oller 1 EBC1 PGN 61441 Source Address 11 Brakes System Controller Parameter Name SPN ASR Engine Control Active 561 ASR Brake Control Active 562 Anti Lock Braking ABS Active 563 ABS Off Road Switch 575 ASR Off ROad Switch 576 ASR Hill Holder Switch 577 Electronic Brake Controller 5 EBC5 PGN 64964 Source Address 11 Brakes System Controller Parameter Name SPN Hill Holder Mode 2912 ...

Page 78: ...5 531 Engine Percent Torque At Point 5 543 Engine Speed At High Idle Point 6 532 Engine Reference Torque 544 Engine Maximum Momentary Override Speed Point 7 533 Electronic Engine Controller 1 EEC1 PGN 61444 Source Address 0 Engine 1 Parameter Name SPN Engine Torque Mode 899 Driver s Demand Engine Percent Torque 512 Actual Speed Percent Torque 513 Engine Speed 190 Electronic Engine Controller 2 EEC...

Page 79: ...ddress 15 Retarder Engine 41 Retarder Exhaust Engine 1 Parameter Name SPN Retarder Enable Brake Assist Switch 571 Actual Retarder Percent Torque 520 Engine Temperature 1 ET1 PGN 65262 Source Address 0 Engine 1 Parameter Name SPN Engine Coolant Temperature 110 Retarder Configuration RC PGN 65249 Source Address 15 Retarder Engine 41 Retarder Exhaust Engine 1 Parameter Name SPN Reference Retarder Tor...

Page 80: ...ction System has Shutdown Engine 1110 Engine Protection System Approaching Shutdown 1109 Vehicle Distance VD PGN 65248 Source Address Global Parameter Name SPN Total Vehicle Distance 245 Time Date TD PGN 65254 Source Address Global Parameter Name SPN Seconds 959 Minutes 960 Hours 961 Month 963 Day 962 Year 964 Local minute offset 1601 Local hour offset 1602 ...

Page 81: ...ntial Voltage 168 Upon change or 15 s while fault active Transmitter System Diagnostic Code and Occurrence Count Table 194 On Request Clutch Cylinder Position 33 Transmission Synchronizer Brake Value 54 Transmission Actuator Status 2 57 Shift Finger Actuator Status 58 Shift Finger Gear Position 59 Shift Finger Rail Position 60 Transmission Actuator Status 1 63 Vehicle Enabling Component Status 66 ...

Page 82: ...e to clearly see the display from the normal driving position continuously during vehicle operation Gear Display shall be capable of displaying messages within 2 seconds of ignition key on In order to provide real time feedback of the selection shifting engagement process of transmission the device shall be able to display the received message within 75 Milliseconds Whenever bus communications are...

Page 83: ...2 20 50 32 2 3 32 20 51 33 3 4 32 20 52 34 4 5 32 20 53 35 5 6 32 20 54 36 6 7 32 20 55 37 7 8 32 20 56 38 8 9 32 20 57 39 9 10 49 31 1 48 30 0 11 49 31 1 49 31 1 12 49 31 1 50 32 2 13 49 31 1 51 33 3 14 49 31 1 52 34 4 15 49 31 1 53 35 5 16 49 31 1 54 36 6 17 49 31 1 55 37 7 18 49 31 1 56 38 8 F 32 20 70 46 F F fault CA 67 43 C 65 41 A CA clutch abuse L 32 20 76 4C L L low gear ST 83 53 S 84 54 T...

Page 84: ...d interface requirements Engine Engine Configuration The engine ECU shall contain the proper configuration settings For the proper engine configuration settings required for Eaton Automated Transmission operation refer to TRIG0910 the Engine Configuration Settings Installation Guide on roadranger com under the literature center Fan Drive Requirements The required practice is for the engine fan to ...

Page 85: ... a message within 2 seconds of ignition key on In order to provide real time feedback of the selection shifting engagement process of transmission the device shall respond to the received message within 75 milliseconds Whenever bus communications are active and anytime ETC2 PID 226 message is not received within 5 seconds of the last valid message annunciator shall be silent Whenever bus communica...

Page 86: ...ft PTO device is used the PTO input switch must be located on the Split Shaft PTO PTO Configurations Countershaft PTOs may be used in conjunction with a Split Shaft PTO device however the configuration must be set to Split Shaft PTO The transmission ECU contains configuration software for PTO mode The default mode is set to Countershaft PTO operation which also supports Through Shaft PTO operation...

Page 87: ...rrect transmission shift tables 3 Perform any necessary corrective action prior to the dyno or road testing 4 The DYNO ROAD TEST section is used to verify that all transmission systems are functional and the Drivers Manual and Shift Label are supplied in the cab 5 With a record of transmission related information and repairs made to each unit the OEM is able to track and correct repeated quality i...

Page 88: ...ed vehicle movement for new installations always set the parking brake prior to turning the ignition key ON and also prior to attempting START Improper installation of the OEM Start Enable Circuit could result in enabling the vehicle to be started in gear Pre Start Inspection and Initial Starting Requirements Pre Start Inspection Verify the transmission has been filled with the correct amount and ...

Page 89: ...de 68 grade sensor calibration fault during initial power up If the system detects active faults other than 27 and 68 refer to the diagnostic procedure in this manual Once the engine has been started the transmission automatically initiates a clutch adjustment procedure During the clutch adjustment procedure the operator will be unable to select an active operating mode for the transmission The sh...

Page 90: ...s set to proper ride height Engine shall not be running during the grade sensor calibration There are three options for completing the grade sensor calibration The process for each option is listed below Your OEM may implement any of these processes Grade Sensor Calibration Tool 1 Key On 2 Engine shall not be running 3 Plug grade sensor calibration tool into 9 pin diagnostic connector 4 Push the b...

Page 91: ...rated 8 Select N on the shift input device the gear display should no longer be flashing an F ServiceRanger PC based Diagnostic Tool 1 Turn ignition switch to On 2 Plug 9 pin connector into dash port 3 Click on ServiceRanger icon to launch program 4 Click on Go To and select Service Routines Note All available Service Routines will be shown 5 Click on the Start button next to Grade Sensor Calibrat...

Page 92: ...lay DYNO Road Test Checks 1 Verify the engine doesn t crank in any position other than neutral 2 Verify forward and reverse gear not obtained without service brake applied 3 Verify all forward and reverse gears are obtained with engine control 4 Verify engine ECU contains proper configuration settings 5 Verify transmission temperature gauge is functional if equipped 6 Verify gear display module wo...

Page 93: ...r 10 3 in lb 1 1 0 33 Nm NyoGel 760G lubricant is recommended on connector contacts No lubricant or foreign material on connector jackscrew No contaminants on connector contacts Harness anchor points within 6 in 15 24 cm of connectors No unanchored length of harness greater than 12 in 30 48 cm No sharp bends in the harness Tie wraps on Harness Jacketing only Harness not anchored to objects that ar...

Page 94: ...ion software to latest available level Caution To avoid damaging the TECU use an Eaton approved communications adapter and ensure all satellite systems are disabled before updating software 5 Retrieve and record the transmission fault codes and FMIs and their occurrences and timestamps If Active fault codes are present go to Step H If no Active fault codes are present perform the Main Case Control...

Page 95: ...des are present match the vehicle symptoms from the test drive and Driver Questionnaire to the Symptom Driven Diag nostics Index on page 10 1 Key on with engine off 2 Connect ServiceRanger 3 Retrieve Snapshot and VPA data by creating a Service Activity Report within ServiceRanger 4 Retrieve and record the transmission fault codes and FMIs and their occurrences and timestamps If fault codes are pre...

Page 96: ...66 67 74 Priority 3 13 14 17 21 22 29 43 44 46 51 52 56 57 58 64 65 68 83 Priority 4 41 42 45 71 72 73 Troubleshoot the fault code with the highest priority level If more than one fault code within a level applies troubleshoot Active fault codes before Inactive fault codes If only Inactive fault codes are present trou bleshoot the fault code that has the highest occurrence count or most recent tim...

Page 97: ... in 1 58 1 8 Nm 3 ECA Capscrews 25 35 lbs ft 34 47 Nm 3 8 16 1 ECA stud Nylon Lock Nut 25 35 lbs ft 34 47 Nm 3 8 24 A 3 8 24 nut with washer may be used in place of a nylon lock nut 1 ECA Engine Speed Sensor Jam Nut 15 lb ft 20 N m 3 4 0 045 0 015 1 Main Shaft Speed Sensor Capscrew 8 10 lb ft 10 8 13 6 Nm 1 4 20 1 Input Shaft Speed Sensor Capscrew 8 10 lb ft 10 8 13 6 Nm 1 4 20 1 Lubricant fill pl...

Page 98: ... Updates September 2014 1 ECA Mounting torque changes and added PV ECA Removal instructions Pages 15 90 2 Changes to J1939 Start Enable Type requirements Page 40 3 Rewrote Grade Sensor calibration procedure for ServiceRanger 4 Page 84 4 Updated Diagnostic Procedure from TRTS0940 Pages 87 88 89 ...

Page 99: ...This Page Intentionally Blank ...

Page 100: ...oducts with all options installed Although every attempt has been made to ensure the accuracy of information contained within Eaton makes no representation about the completeness correctness or accuracy and assumes no responsibility for any errors or omissions Features and functionality may vary depending on selected options For spec ing or service assistance call 1 800 826 HELP 4357 or visit www ...

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Eaton UltraShift PLUS EO-11E406B-PV, Installation Manual

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