Eaton Roadranger Fuller UltraShift F-406-ASW Series Installation Manual
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Eaton Roadranger Fuller UltraShift F-406-ASW Series Installation Manual

Eaton Roadranger Fuller UltraShift F-406-ASW Series Installation Manual

Fuller automated transmissions
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Fuller
Automated Transmissions
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More time on the road
®
Installation Guide
Fuller Automated Transmissions
TRIG0082
October 2007

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Summary of Contents for Eaton Roadranger Fuller UltraShift F-406-ASW Series

  • Page 1 Fuller Automated Transmissions ® More time on the road ® Installation Guide Fuller Automated Transmissions TRIG0082 October 2007...
  • Page 2 This page intentionally left blank.

  • Page 3: Table Of Contents

    Table of Contents Introduction Features About This Publication ..........1 Inside Cab Features ...........55 Suggested Tools ............2 Outside Cab Features ..........56 Auto Neutral Feature ..........57 Power Take-Off “Countershaft Driven” ......58 Installation Requirements Power Take-Off “Split shaft” ........59 Installation Requirements ........... 3 Installation Requirements ...........

  • Page 4: Introduction

    About This Publication This Eaton publication is intended to be a reference guide for the installation of the Fuller® Fx-x406x-ASW UltraShift™ Transmis- sion. General vehicle and transmission information is provided to cover the wide range of applications. This information benefits the OEM installer by providing the correct installation procedures to ensure the utmost in satisfactory operation and long service life.

  • Page 5: Suggested Tools

    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 Test Adapter Kit MD-100 Eaton Service Parts 1 (800) 826-HELP (1-800-826-4357) Part No. Description MD-200 Related Publications Troubleshooting Guide Eaton TRTS-0062...

  • Page 6: Installation Requirements

    18 gauge (0.8 mm²). When the Eaton Push Button Shift Control is used the EPL (the communications link between the Shift Control and the Transmission Controller) must be a twisted shielded pair; Belden, J-1939, or equivalent.
  • Page 7 Installation Requirements 13. Engine configuration - Prior to shipment of Eaton Transmission Systems 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 Engineering Support Group.

  • Page 8: Installation Requirements

    #12 (3/4 inch I.D.) cooler hose or comparable tubing must be used. Dipstick and Dipstick Tube Requirements Dipstick - New dipstick and tube designs are required to be approved and/or validated by Eaton as supplied by the OEM. Support Bracket - A supporting bracket to eliminate vibration is required at the upper end of the dipstick tube.

  • Page 9: Fuller Ultrashift Asw Fo-X406X-Asw

    Installation Requirements Fuller UltraShift ASW FO-x406x-ASW 226.9 226.9 226.8 226.8 [8.93] [8.93] [8.93] [8.93] 248.1 248.1 [11.18] [11.18] 274.1 274.1 213.2 213.2 [10.79] [10.79] [8.40] [8.40] OIL FILL TUBE (OEM SUPPLIED) OIL FILL TUBE (OEM SUPPLIED) FOR WET CLUTCH SECTION FOR WET CLUTCH SECTION 1-5/16-12 UN-2A FOR 1-5/16-12 UN-2A FOR...
  • Page 10 Installation Requirements Fuller UltraShift ASW FO-x406x-ASW 20.6 [0.81] 98.43 [3.875]...

  • Page 11: Flywheel/Drive Coupler

    Separate bolt on Drive Coupler is used with the Fuller UltraShift ASW transmission The flywheel must be an Eaton approved 14-inch flat design. (Same flywheel used with a 14-inch Solo clutch) Handle the Drive Coupler carefully to avoid damage to the mating surfaces.

  • Page 12: Mounting To Engine

    Installation Requirements Mounting to Engine Handling Handle the transmission carefully to avoid damage to the transmission components and to surrounding vehi- cle components. Use a hoist or transmission jack that permits precise control of transmission movement during installation. Mounting to Engine Use the three transmission lifting eyes provided, the lifting eye position must not be changed on the transmis- sion.
  • Page 13 Installation Requirements Transmission Mounting Typical Lift Points 3 POINT LIFT CHAIN WITH MINIMUM 1 TON CAPACITY TRANSMISSION LIFTING EYES 5 POINT LIFTING CHAIN WITH MINIMUM 2 TON CAPACITY...

  • Page 14: Dipstick And Tube Requirements

    Torque dipstick tube fitting (1 5/8-12) to 60-70 lbs-ft. [81-95 Nm]. Actual oil level must be within Eaton specifications according to the dipstick readings. Dipstick must be marked with “Check oil level at idle while in neutral. Use synthetic Dextron III”.
  • Page 15 Installation Requirements WetClutch Dipstick Information Cold "FULL" Level 35.6 [ 1.40 ] 64.0 [ 2.52] 15.2 [ 0.60 ] Cold "ADD" Level Approx. 1 quart Note: The first section of the dipstick tube must 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.

  • Page 16: Cooler Requirements

    Requirements Cooler Requirements General Requirements Cooler must meet Eaton application guidelines and requirements in this document unless specifically approved by Eaton Corporation. An external Oil-To-Water transmission cooler must be used with Fuller UltraShift transmissions. The maximum allowable pressure drop through the oil cooler circuit is 10 PSI at 8 GPM oil flow at normal operating temperatures.
  • Page 17 Installation Requirements Oil To Water Cooler Requirements Transmission Cooling System Without Remote Bypass WC OUT TO OIL COOLER 1-1/16 - 12 UN-2B FOR SAE-12 O-RING FITTING, 37 DEGREE FLARED FITTING (OEM SUPPLIED) TO WATER PUMP WC IN FROM OIL COOLER 1-1/16 - 12 UN-2B FOR SAE-12 WATER TO COOLER OIL COOLER...
  • Page 18 Installation Requirements Cooling Requirements Oil-To-Water Transmission Cooling System With Remote Bypass For certain applications, the recommended transmission cooler routing is to bypass the engine thermostat system. With this type of cooler routing, transmission oil temperature is more directly related to engine temperature. Listed below are conditions which may require the use of a thermostat bypass: Under certain conditions, such as extreme cold temperature operation or extended periods of low speed oper- ation, the engine alone may not generate the amount of heat required to open the thermostat.
  • Page 19 Installation Requirements Cooling Requirements Oil-To-Water Transmission Cooling System With Remote Bypass WC OUT TO OIL COOLER 1-1/16 - 12 UN-2B FOR SAE-12 O-RING FITTING, 37 DEGREE FLARED FITTING (OEM SUPPLIED) TO WATER PUMP WC IN FROM OIL COOLER WATER TO COOLER OIL COOLER 1-1/16 - 12 UN-2B FOR SAE-12 O-RING FITTING, 37 DEGREE...

  • Page 20: Lubrication Requirements

    Installation Requirements Lubrication Requirements General lubrication Requirements Synthetic Dexron® III must be used in the WetClutch section of the transmission. Oil must be filled to the proper level prior to OEM shipment. Roadranger® CD 50 must be used in the transmission gear box section of the transmission. Oil must be filled to the proper level prior to OEM shipment.
  • Page 21 Additives and friction modifiers are not recommended for use in Fuller transmissions. Note: Failure to adhere to Eaton Installation Requirements may effect Fuller UltraShift ASW performance and/or war- ranty coverage. Transmission Gear Box Capacity 6-Speed 20.75 pints (9.8 liters)
  • Page 22 Installation Requirements Lubrication Requirements Make sure lubricant is level with fill hole opening. Because you can reach lubricant with your finger does not mean lubri- cant is at the proper level. Note: Do not remove the Electric Shifter (X-Y Shifter) at any time. Hole Hole Improper Oil Level...

  • Page 23: Shift Console Space Requirements

    [3.000] 2X #8-32 UNC 83.82 32.21 57.28 [3.300] [1.268] [2.255] 22.23 [0.875] 27.00 [1.063] SERVICE 79.25 MANUAL PANEL CUT OUT DIMENSIONS [3.06] SHIFT EATON FULLER TRANSMISSIONS 168.15 [6.56] 4X R.10 MAX Mating Connector Information Packard 30-way Body 12048455 Terminal 12103881...

  • Page 24: Typical Dash Mount Configuration

    Installation Requirements Typical Dash Mount Configuration Sealed bulkhead style harness connectors must be used when running harness connections through cab floor or firewall. The shift console should be mounted to the dash using an OEM supplied mounting bezel. If no bezel is used, the OEM must ensure the Shift Control is accessible to the driver at all times.

  • Page 25: Typical Tower Mount Configuration

    See “Installation Requirements” on page 3 for details. DASH Reinforced cab floor with easily accessible Sealing bulkhead style connectors and removable through cab floor transmission access plate Aluminum = 0.250" Thick Steel = 0.125" Thick DASH SERVICE MANUAL SHIFT EATON FULLER TRANSMISSIONS Driver's Pass Seat Seat...

  • Page 26: Electrical Requirements

    Electrical Requirements Cable Conductor Size The cable outside the cab shall be a minimum of 16 gauge (1.0 mm²). The cable inside the cab shall be a minimum size of 18 gauge (0.8 mm²). Note that these sizes are minimum requirements only. Conductor size may need to be increased depending on current carrying requirements.
  • Page 27 Electrical Requirements Cable Terminals Terminals shall be sized for the correct current capacity of the circuit as stated by the manufacturer. Terminals shall be plated with tin, nickel, gold, etc. Mating terminals shall be plated with the same material. Gold plated terminals shall be required in 5 volt dry circuits.
  • Page 28 It also precludes corrosive affects from the junction. A solder point also allows for temperature induced torsional stress without rupture of the joint. Solder connections shall conform to Eaton’s workmanship specifi- cations. Flux shall clean the metal but not attack, corrode or oxidize the metal. Acid type flux shall not be used.

  • Page 29: Wiring Diagram Oem Responsibility

    Electrical Requirements Wiring Diagrams OEM Responsibility...

  • Page 30: Typical Dash Mounted System

    Dimmer Control Input (VDash) Dimmer Control Input SERVICE 1500 1000 2000 2500 MANUAL Firewall SHIFT TACH EATON FULLER TRANSMISSIONS Start Enable Relay 10 AMP Fuse Ignition Power (Switched Power) 10 AMP 12 Volt only Automatic Resetting Circuit Breaker ATA Connector (J1587 Link)

  • Page 31: Typical Tower System

    Electrical Requirements Typical Tower System The dash area location is for the following: Start Enable Relay Gear Display ATA Connector (J1587 Link) Dimmer Control Input (VDash) Ignition Power (VIGN) Dimmer Control Input 50 60 1500 1000 2000 2500 Firewall TACH Start Enable Relay 10 AMP Fuse Ignition Power...

  • Page 32: Power Harness

    Electrical Requirements Power Harness 30 AMP fuse Battery power (Non-switched power) run to starter or Battery Transmission Controller (ECU) The OEM is responsible for the design of the Main Power Harness. Note: Main power and ground must be able to carry 20 amps @ 9 volts with no more than .05 ohms. To calculate the .05 ohms, take the length of the wire from the battery or starter to transmission and multiply the ohms per foot for that wire gauge.
  • Page 33 Electrical Requirements Power Harness T2 connects to the (-) side of the Main Battery Source PACKARD BODY: 12059641 CONNECTOR SEAL: 12077383 TERMINAL: 12033997 (10-12 AWG) T1 connects to the CABLE SEAL: 12040972 (12 AWG) (+) side of the 12085024 (10 AWG) Main Battery Source PACKARD BODY:...

  • Page 34: Transmission Interface

    Electrical Requirements Transmission Interface Push Button Shift Control Push Button Control 30-way connector Transmission Controller (ECU) Transmission 18-way connector Bulkhead connector located at firewall J1939 Data Link FRONT VIEW FRONT VIEW Push Button Control (30-Way Connector) Transmission (18-Way Connector) PACKARD PACKARD Connector 12040921...
  • Page 35 Electrical Requirements Transmission Interface Transmission 18-Way Connector PACKARD Connector 12040921 Terminal 12103881 Plug 12034413 Bulkhead Connector Located at Firewall J1939 Data Link Push Button Control 30-Way Connector EPL Data Link PACKARD EPL + EPL - Connector 12048455 Terminal 12103881 Plug 12034413 EPL_Shield EPL_Shield...

  • Page 36: Typical Dash Harness

    Electrical Requirements Typical Dash Harness For transmission diagnostics Push Button Shift Control Push Button Control Gear display 30-way connector 10 AMP 12 volt only 9-way automatic resetting 10 or 15 AMP volts circuit breaker fuse battery Ignition power (switched power) run to main power lead that feeds the ignition bus J-1587 data link...
  • Page 37 Electrical Requirements Typical Dash Harness Packard Push Button Control Connector 12048455 30-wat Connector Terminal 12103881 Plug 12034413 J3 Switched Ignition J5 Dimmer Control Run to start signal from igntion switch Run to starter Solenoid FROM WIRE DESCRIPTION J1-E1 J2-3 CLOCK + J1-E2 J2-2 DATA -...

  • Page 38: Gear Display Module

    Gear Display Module Push Button Shift Control Push Button Control Gear display 30-way connector Ignition power (switched power) Pin 1 Pin 4 Top View EATON P/N 4302640 Truck Components FRONT VIEW Shift Control (30-Way Connector) Interconnection Table FROM DESCRIPTION J1-E1...
  • Page 39 Electrical Requirements Gear Display Module 55.63 [2.190] 40.89 [1.610] 33.93 [1.336] 2.0 [.08] 4.0 [.16] 2.0 [.08] 42.93 [1.690] 46.99 [1.850] Truck Components 59.69 [2.350] Panel Cut-Out Dimensions: 43.1 [1.70] X 56.1 [2.20] X 0.254 [.010] Mating Connector information: 4-way Body 1-480702-0 Terminal...

  • Page 40: Ignition Circuit Detail

    Electrical Requirements Ignition Circuit Detail Push Button Shift Control 10 AMP 12 volt only automatic resetting 10 AMP circuit breaker fuse Push Button Control 30-way connector Ignition power (switched power) run to main power lead that feeds the ignition bus 10 AMP 12 volt only 10 AMP automatic resetting...

  • Page 41: J-1587 Diagnostic Detail

    Electrical Requirements J-1587 Diagnostic Link For transmission diagnostics Push Button Shift Control Push Button Control 30-way connector 9-way volts battery J-1587 data link 6-way...
  • Page 42 Electrical Requirements Note: The diagnostic connector must be mounted on the left side of the cab and easily accessible per SAE J -1587. +12 Volts ATA (+) ATA (-) VIEW A-A +12 Volts ATA (+) ATA (-) VIEW B-B FRONT VIEW Shift Control (30-Way Connector) FROM TO 6-PIN...

  • Page 43: Dimmer Control Input Connection

    Electrical Requirements Dimmer Control Input Connection Push Button Shift Control Dimmer Control Input Push Button Control Back side 30-way connector of gauges Dash lights Note: Connect VDASH to the dash lights or running lights. This input will dim the lights on the Shift Control when the lights are on.

  • Page 44: Typical Start Enable Circuit

    Electrical Requirements Typical Start Enable Circuit Startability must meet FMVSS Standard 102, Section 3.1.3: “The engine starter shall be inoperative when the transmission shift lever is in a forward or reverse direction position.” Push Button Shift Control Run to Push Button Control starter solenoid 30-way connector Run to start...
  • Page 45 Electrical Requirements Typical Start Enable Circuit Start Enable Ground (A3) Run to Start Post of Ignition Switch Use Bosch: Relay : 0332-024-151 (+12 Volt) Relay or equivalent Schematic Mount : 3334-485-008 Run to Starter Terminal : 1901-355-917 Solenoid Start Enable Battery (C3) Start Enable Latch (A2) Start Enable Battery (C3) Run to Start Post of Ignition Switch...

  • Page 46: J-1939 Data Link Detail

    Electrical Requirements J-1939 Data Link Push Button Shift Control Push Button Control 30-way connector Bulkhead connector located at firewall Engine ECM Terminating J-1939/11 data link resistor (OEM supplied) Terminating Shield resistor termination...
  • Page 47 Electrical Requirements J-1939 Data Link Detail FRONT VIEW Shift Control (30-Way Connector) FROM DESCRIPTION J1-G1 J-1939 High + J1-G2 J-1939 Low - J1-G3 J-1939 Shield...
  • Page 48 Electrical Requirements J-1939/11 Data Link Detail Recommended Cable J-1939 (+) J-1939 (-) J-1939 Cable Part (PIN "A") (PIN "B") (PIN"C") Round Manufacturer Number Color Color Shield Champlain 23-00013-001 Yellow Green Champlain 23-00028-001 Yellow Green Raychem 2021D0311 Yellow Green Raychem 2021D0001 Yellow Green Raychem...
  • Page 49 Electrical Requirements SAE J-1939/11 Recommended Cable Termination Procedure Remove cable outer jacket approximately 25 mm. Remove foil from exposed wires to within 2 mm from cable jacket. Strip insulation from data wires 7 mm. Attach extended wire barrel socket contact to the drain wire or attach adhesive filler solder sleeve and wire to drain wire per manufacturer’s recommendations.
  • Page 50 Electrical Requirements Existing Drain Wire Splice/ Sealing Method SAE J1939/11 Recommended Cable Splice Procedure Remove cable outer jacket approximately 40-100 mm. Remove foil shield from 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.
  • Page 51 Electrical Requirements SAE J-1939/11 Recommended Cable Splice Procedure Remove cable outer jacket approximately 40-100 mm. Remove foil shield from exposed wires 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 over crimp splice.
  • Page 52 Electrical Requirements J-1939/15 (lite) Data Link Specifications Maximum 40 meter Length. Maximum 3 meter stub length. Maximum 10 modules on segment. Twisted pair (18 or 20 AWG) with 1 twist 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’...

  • Page 53: Vehicle Harness Connector For All Caterpillar Adam Iii Electronic Engines

    Electrical Requirements Vehicle Harness Connector for all Caterpillar Adam III Electronic Engines 10 11 12 13 14 15 16 17 18 19 20 21 22 23 >PEI< 24 25 26 27 28 29 30 31 32 33 36 37 38 39 40 41 44 45 46 47 48 49...
  • Page 54 Electrical Requirements Location of the J-1939 Control Data Link on Detroit Diesel DDECIII and IV Engines Electronic Control Module (ECM) Communication Connector J-1939 (+) J-1939 (-) J-1939 SHIELD FROM DESCRIPTION K1-F K4-A J-1939 High + K1-E K4-B J-1939 Low - K1-D K4-C J-1939 Shield...
  • Page 55 Electrical Requirements Location of the J-1939 Control Data Link on Cummins Engines As a part of Cummins ECU 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 connector from behind a bracket located at the rear of the engine.

  • Page 56: Body Builder Guide For Tapping Into Electrical Systems

    Electrical Requirements Body Builder Guide For Tapping into Electrical Systems Body builder electrical systems that are to be interconnected with the Fuller UltraShift ASW electrical system should adhere to the latest recommendations of SAE J1292. In addition to SAE J1292, the following recommendations should be followed. All wiring terminals should be properly insulated to prevent “short circuits”.
  • Page 57 Electrical Requirements Body Builder Guide For Tapping into Electrical Systems, Cont. The fuses and circuit breakers installed at the assembly plant are designed to protect the wiring and electrical components from overloads. Never remove a factory installed fuse or circuit breaker and replace it with a high value device. If the added electrical device causes “fuse blow”, or circuit breaker cycling, it indicates the total load is too high for the factory installed circuit protec- tion and requires revisions in the added circuit: not fuse or circuit breaker size.

  • Page 58: Features

    Features Inside Cab Features PACKARD Body 12064752 Terminal 12162595 Lock 12064753 FROM 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)

  • Page 59: Outside Cab Features

    Features Outside Cab Features PACKARD Body 12129325 Terminal 12077411 Lock 12015323 Interconnection Table FROM 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)

  • Page 60: Auto Neutral Feature

    Features Auto Neutral Feature Electrical Interface Requirements All devices mounted on the vehicle that require Auto Neutral function from the Fuller UltraShift ASW transmission must provide an electrical interface with the transmission. A switch must be used to activate the Neutral mode of the trans- mission.

  • Page 61: Power Take-Off "Countershaft Driven

    Features Power Take-Off “Countershaft Driven” Electrical Interface Requirements All countershaft driven Power Take-Off’s mounted on Fuller UltraShift ASW Transmissions must provide an electrical interface with the transmission. The PTO mounted switch is used to activate the PTO operating mode of the transmis- sion.

  • Page 62: Power Take-Off "Split Shaft

    Features Power Take-Off “Split shaft” PTO input must be a normally open switch. The switch must close to ground whenever the PTO is activated. This input (active when pin F1 is shorted to ground) activates the split shaft PTO mode of the transmission. This feature uses pin F1 of the 18-way transmission connector.

  • Page 63: Line Inspection

    Eaton recommends the use of this system to maintain the utmost in satisfactory operation and long service life. Each Fuller UltraShift ASW system installed at the OEM must pass the on line check list requirements per the Eaton line inspection Form 4013-002 prior to shipment from the OEM plant.

  • Page 64: Line Inspection, Continued

    Line Inspections Line Inspection, continued Checklist Instructions Refer to the line inspection form (4013-002) while performing the following procedure. Note: All information must be filled in at top of the form. Pre-Start Checks The following tests must be performed in one of three ways. By visually observing the power up procedure.

  • Page 65: Dyno/Road Test

    Begin with the switch in the on position. Turn the key off and back on six times within five seconds (off/on/off/on/off/on/off/on/off/on/off/on). 14. Verify engine ECU contains proper configuration settings for Fuller UltraShift operation. The engine ECU must contain the proper configuration settings. For proper engine configuration settings required for Fuller UltraSh- ift operation, contact Eaton OEM Engineering Support Group.

  • Page 66: Line Inspection

    Line Inspections Line Inspection This transmission is equipped with a neutral interlock system that when properly installed prevents the engine from starting 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”...

  • Page 67: Line Inspection Form

    ECU must contain the proper configuration settings. For proper engine configuration settings required for Fuller UltraShift operation, contact Eaton OEM Engineering Support Group. Comments: Signature: Final Inspection Date: Please send copy to: Eaton Corp, P.O. Box 4013, Galesburg, MI 49003 ATTN: Automation Installation Group Fuller UltraShift ASW OEM:...

  • Page 68: Troubleshooting

    Inspections Troubleshooting Check Trans- mission Power Circuit Service Light on Refer to Eaton Troubleshooting Guide Solid or Flashing? for flash code retrieval Dash “-” on gear If dash “-” is still on the gear display, then Display? power down, turn the key off and wait for one minute, and power up.

  • Page 69: Appendix

    Appendix Typical System Overview (Tower Mounted) Tower Mounted Diagnostic Port Shift Console Gear Display (SAE J-1587) Visable At All Times Accessible in cab 1500 VIEW Z-Z 1000 2000 2500 TACH TACH Reinforced Cab Floor Sealed Bulkhead Connectors Firewall Electronic Transmission Connector Shifter Controller...
  • Page 70 (SAE J-1587) Visable At All Times Accessible in cab 1500 VIEW Z-Z 1000 2000 SERVICE 2500 TACH TACH MANUAL SHIFT EATON FULLER TRANSMISSIONS Firewall Connector Electronic Transmission for Cab Connections Shifter Controller J-1939 Connector Transmission Power Supply Harness from Start Battery...

  • Page 71: Fuller Ultrashift Lifting Eyes And Sensor Position Fx-X406X-Asw

    Appendix Fuller UltraShift Lifting Eyes and Sensor 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 Lifting Eye 10 O'Clock Output Shaft 12 O'Clock output Shaft Speed Sensor Speed Sensor...

  • Page 72: Vendor List

    Appendix Vendor List DEUTSCH (Connectors) Industrial Products Division AMP Incorporated 37140 Industrial Ave. (Connectors) Hemet, CA 92545 P.O.Box 3608 (909) 765-2250 Harrisburg, PA 17105-3608 Fax (909) 765-2255 1-800-522-6752 www.deutschipd.com Fax (727) 986-3611 www.laddinc.com (Ladd Industries) www.amp.com BELDEN WIRE AND CABLE PACKARD Electric (HIL and J-1939 Cable) (Connectors)

  • Page 73: Quick Reference

    Crossover Pipes). Dipstick and tube must be used. Electronic vehicle speedometer must be used. Transmission Lubricant - Synthetic Dexron® III required 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 connected to reliable power and ground source.
  • Page 74 Appendix Cab Section Shift Control Requirements Shift control installation per Eaton approval. Wire harness routing 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 conventional cabs.

  • Page 75: Torque Specifications

    Features Torque Specifications Part Torque Flywheel capscrews Follow engine manufacture’s specifications transmission-to-engine capscrews” 7/16-14 37-50 Lb.ft* [50-68 Nm] 3/8-16 25-32 Lb.ft* [34-43 Nm] M10-45 26-35 Lb.ft* [35-47 Nm] Output yoke nut: 6-Speed 300-350 Lb.ft [407-475 Nm] PTO mounting capscrews: 6-bolt opening 20-25 Lb.ft* [27-34 Nm] Reverse switch (9/16-18) 20-25 Lb.ft [27-34 Nm]...

  • Page 76: Fuller Ultrashift Asw Wiring Diagram

    Appendix Fuller UltraShift ASW Wiring Diagram 30 AMP fuse Battery power (Non-switched power) run to starter Rail select Aux #1 Output motor (see OEM for wiring diagrams and correct operation) Aux #1 Input (see OEM for wiring diagrams Electric and correct operation) EPL data link shifter Gear select...
  • Page 77 Appendix Appendix For transmission diagnostics VOLUME CONTROL SERVICE SHIFT EATON FULLER TRANSMISSIONS Gear display 10 AMP 12 volt only 9-way automatic resetting 10 AMP circuit breaker volts fuse battery Ignition power (switched power) run to main power lead that feeds the ignition bus...

  • Page 78: Connector Pin Descriptions

    Features Connector Pin Descriptions Transmission Controller 18-way (Vehicle Interface Connector) 18-WAY DESCRIPTION NOTES Batt 1 ATA + GND 1 Trans batt 1 ATA - GND 2 EPL + EPL- EPL shield Aux speed 1 + Aux speed 1 - Aux input 2 Input, LO side Batt 2 Trans batt 2...
  • Page 79 Features Connector Pin Descriptions Shift Control 30-way connector 30-WAY DESCRIPTION NOTES Aux input/output 3 Input/output, LO side driver Start enable latch Start enable relay - Aux input 5 (Return) 1587 + Vdash Ignition 1587 - Start enable relay + Aux input 5 Input, LO side Aux input 6 Input, LO side...
  • Page 80 , ensuring more time on the road. Eaton Corporation • Truc k Components Operations • P . O. Bo x 4013 • K alamaz oo, MI 490 03 • U.S.A. • www .roadranger .com ©20 07 Eaton Corporation ·...

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