Eaton Fuller RTLO-11610B User manual

Installation Guide
Eaton Fuller®Heavy-Duty Transmissions
TRIG0070
October 2007
RTLO-11610B
RTLO-11610B-T2
RTLO-12610B
RTLO-12610B-T2
RTLO-12713A
RTLO-12913A
RTLO-13610B
RTLO-13610B-T2
RTLO-14610A
RTLO-14610B
RTLO-14610B-T2
RTLO-14613B
RTLO-14618A
RTLO-14713A
RTLO-14718B
RTLO-14913A
RTLO-14918B
RTLO-14918B-T2
RTLO-15610B
RTLO-15610B-T2
RTLO-16610B
RTLO-16610B-T2
RTLO-16618A
RTLO-16713A
RTLO-16713A-T2
RTLO-16718B
RTLO-16913A
RTLO-16913A-T2
RTLO-16918B
RTLO-16918B-T2
RTLO-17610B
RTLO-17610B-T2
RTLO-18610B
RTLO-18610B-T2
RTLO-18718B
RTLO-18718B-T2
RTLO-18913A
RTLO-18913A-T2
RTLO-18918B
RTLO-18918B-T2
RTLO-20913A
RTLO-20918B
RTLO-20918B-T2
RTLO-22918B
RTLOC-16909A-T2
RTLOF-11610B
RTLOF-11610B-T2
RTLOF-12610B
RTLOF-12610B-T2
RTLOF-12713A
RTLOF-12913A
RTLOF-13610B
RTLOF-13610B-T2
RTLOF-14610B
RTLOF-14610B-T2
RTLOF-14613B
RTLOF-14618A
RTLOF-14713A
RTLOF-14718B
RTLOF-14913A
RTLOF-14918B
RTLOF-14918B-T2
RTLOF-15610B
RTLOF-15610B-T2
RTLOF-16610B
RTLOF-16610B-T2
RTLOF-16618A
RTLOF-16713A
RTLOF-16713A-T2
RTLOF-16718B
RTLOF-16913A
RTLOF-16913A-T2
RTLOF-16918B
RTLOF-16918B-T2
RTLOF-17610B
RTLOF-17610B-T2
RTLOF-18610B
RTLOF-18718B
RTLOF-18913A
RTLOF-18913A-T2
RTLOF-18918B
RTLOF-18918B-T2
RTLOF-20913A
RTLOF-20918B
RTLOF-20918B-T2
RTLOF-22918B
RTLOFC-16909A-T2

Warnings and Cautions
Warnings and Cautions
The description and specifications contained in this service publication are current at the time of printing.
Eaton Corporation reserves the right to discontinue or modify its models and/or procedures and to change specifications at any
time without notice.
Important Notice
Any reference to brand name in this publication is made as an example of the types of tools and materials recommended for use
and should not be considered an endorsement. Equivalents may be used.
Always use genuine Eaton replacement parts.
Every effort has been made to ensure the accuracy of all information in this guide. However, Eaton makes no expressed or
implied warranty or representation based on the enclosed information.
This symbol is 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.
Failure to follow indicated
procedures creates a high risk of personal
inj ury to the servici ng technici an.
Failure to follow indicated
procedures may cause component
damage or malfunction.
Highly recommended procedures for
proper service of this unit.
Note: Additional service information not
cover ed in the service pr ocedures .
Tip: Helpful removaland installation
procedures to aid in the service of this unit.
WARNING
CAUTION
IMPORTANT

Table of Contents
Table of Contents
Warnings and Cautions
Warnings and Cautions ...............................................i
General Information
How to Use This Manual ............................................1
Installation Requirements
Requirements .............................................................2
Space Requirements ..................................................3
10-speed Valve Location ........................................3
9- / 13-speed Valve Location ..................................5
18-speed Valve Location ........................................6
Lubrication Requirements ..........................................8
Air Supply Requirements ..........................................10
9-speed Pneumatic Diagrams ...............................11
10-speed Pneumatic Diagrams .............................12
13-speed Pneumatic Diagrams .............................13
18-speed Pneumatic Diagrams .............................14
Transmission Mounting Requirements ....................15
Mounting Transmission to Engine ........................16
Using Rear Supports ............................................17
Typical Rear Support Designs ...............................17
Electrical Requirements
Top 2 Valve Electrical Requirements ........................ 18
Wiring Diagram OEM Responsibility ........................ 19
Caterpillar Programming ...................................... 19
Detroit Diesel Programming ................................. 21
Line Inspection
Line Inspection and Road Test Instructions .............26
Line Inspection Form ............................................... 27
Troubleshooting ....................................................... 28
Appendix
Wiring Diagrams ...................................................... 29
Caterpillar ............................................................. 29
Detroit Diesel ........................................................ 31
Torque Specifications .............................................. 33
Suggested Tools ...................................................... 34
Related Publications ................................................ 34
Application Forms .................................................... 35

1
General Information
How to Use This Manual
This Eaton Publication is intended to be a reference guide for the installation of all Top 2 series transmissions. As much general
vehicle and transmission information has been given for covering 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.
For specific engine information, contact engine OEM.
Specific OEM installation requirements are shown in each section.
Failure to adhere to Eaton installation requirements may effect transmission performance and/or warranty coverage.
Top 2 transmissions installed at OEM facilities must meet the requirements for standard manual Eaton Fuller transmissions out-
lined in Form FUL-169. Applications outside of these requirements must be approved by Eaton Engineering using Form FUL-170.
All information contained in this manual was accurate at the time of printing. With each new application, engine manufacturers
should be contacted to make sure desired engines are compatible with the Top 2 system.

2
Installation Requirements
Installation
Requirements
Requirements
All Top 2 transmission systems installed at OEM facilities must meet the requirements for standard manual Eaton Fuller
Transmissions outlined in Form FUL-169 and be approved using the Eaton Automated Transmission Application
Approval Form FUL-170. Both forms can be found in the Appendix.
1. Air Dryer Requirements - A high quality commercially available vehicle air dryer is required to be used in conjunction
with Top 2 systems.
2. Clutch Requirements - Spring dampened clutches are required for all applications.
3. Electrical Requirements - All wires are to be a minimum of 16 gauge GXL.
4. Integral Coolers - Reference Form FUL-169 Note 2 for transmission cooler requirements.
5. Line Inspection - All Eaton Top 2 transmission systems installed at OEM plants must pass the requirements outlined in
the “Line Inspection Form” prior to shipment.
6. Lubrication Requirements - Transmission oil should meet specifications as outlined in TCMT-0020 (Roadranger Prod-
ucts Approved Lubricants) and TCMT-0021 (Roadranger Products Lubrication Manual).
7. Power Connections - All ECMs will have redundant power and ground pins. If no redundancy is available, a relay con-
nection similar to the one on page 29.
8. Valve Spatial Requirements - The Top 2 solenoid valve requires a minimum of 2” clearance from any high temperature
devices (i.e. exhaust crossover pipes).

3
Installation Requirements
Space Requirements
10-speed Valve Location
Note: Refer to “Transmission Mounting Requirements” for Valve Spatial Requirements.

4
Installation Requirements
Installation
Requirements
MODEL LENGTH “A” LENGTH “B” LENGTH “C”
11610 815.1 (32.09) 200.4 (7.89) 67.8 (2.67)
12610 815.1 (32.09) 200.4 (7.89) 67.8 (2.67)
13610 815.1 (32.09) 200.4 (7.89) 67.8 (2.67)
14610 823.2 (32.41) 208.5 (8.21) 75.9 (2.99)
15610 823.2 (32.41) 208.5 (8.21) 75.9 (2.99)
16610 823.2 (32.41) 208.5 (8.21) 75.9 (2.99)

5
Installation Requirements
9- / 13-speed Valve Location
Note: Refer to “Transmission Mounting Requirements” for Valve Spatial Requirements.

6
Installation Requirements
Installation
Requirements
18-speed Valve Location
Note: Refer to “Transmission Mounting Requirements” for Valve Spatial Requirements.
MODEL LENGTH “A” LENGTH “B” LENGTH “C”
12713 815.1 (32.09) 200.4 (7.89) 43.9 (1.73)
14713 823.2 (32.41) 208.5 (8.21) 51.8 (2.04
16713 823.2 (32.41) 208.5 (8.21) 46.5 (1.83)
12913 840.7 (33.09) 226.1 (8.9) 69.6 (2.74)
14913 840.7 (33.09) 226.1 (8.9) 69.6 (2.74)
18913 840.7 (33.09) 226.1 (8.9) 69.6 (2.74)

7
Installation Requirements
MODEL LENGTH “A” LENGTH “B” LENGTH “C”
14918 840.7 (33.09) 226.1 (8.9) 69.6 (2.74)
16918 840.7 (33.09) 226.1 (8.9) 69.6 (2.74)
18918 840.7 (33.09) 226.1 (8.9) 69.6 (2.74)
20918 840.7 (33.09) 226.1 (8.9) 69.6 (2.74)
22918 840.7 (33.09) 226.1 (8.9) 69.6 (2.74)

8
Installation Requirements
Installation
Requirements
Lubrication Requirements
Eaton Fuller transmissions are designed so the internal parts operate in a bath of lubricant circulated by the motion of gears and
shafts. Thus, all parts will be amply lubricated if these procedures are closely followed:
• Use Roadranger CD50 or equivalent E500 synthetic per Eaton publication TCMT-0021.
• When adding lubricant, types and brands of lubricant should not be mixed because of possible incompatibility.
• Use clean lubricant and clean containers when filling the transmission. Containers that have been used for antifreeze or
water should not be used for transmission lubricant.
• Additives and friction modifiers are not recommended for use in Eaton Fuller transmissions.
Includes all Roadranger Approved comparable synthetic lubricant.
Proper Lubricant Level
Note: Failure to adhere to Eaton Installation Requirements may effect transmission performance and /or warranty coverage.
Note: The quantity for proper fill level will vary from model to model.
Make sure lubricant is level with fill hole opening. Because you can reach lubricant with your finger does not mean lubricant is at
the proper level. (On heavy duty transmissions, one inch of lubricant level equals about 8 pints of oil).
Recommended Lubricant
Type Grade (SAE) Temperature
Roadranger CD50
Transmission Fluid
50 ALL
Transmission Capacity
9-Speed 28 pints (13.2 liters)
10-Speed 26 pints (12.3 liters)
13/18-Speed 28 pints (13.2 liters)
Improper Oil Level
Hole
Proper Oil Level
Hole

9
Installation Requirements
Proper Lubrication Levels as Related to Transmission Installation Angles
If the transmission operating angle is more than 12 degrees, improper lubrication can occur. The operating angle is the transmis-
sion mounting angle in the chassis plus the percent of upgrade (expressed in degrees).
For example: If you have a 4 degree transmission mounting angle, then 8 degrees (or 14 percent of grade) is equal to the limit of
12 degrees. If you have a 0 degree mounting angle, the transmission can be operated on a 12 degree (21 percent) grade.
Note: The chart shows the effect a lubricant level 1/2” below normal can have on safe operating angles. Operating the vehicle
1/2” low on lubricant reduces the safe degree of grade by approximately 3 degrees (5.5 percent).
Note: For transmissions with cooler’s installed, make sure lubricant is level with fill hole opening, run the truck, stop and check
lubricant level. Lubricant must be level with fill hole.
12o
11o20'
10o13'
9o16'
8o
6o51'
5o48'
4o35'
3o 26'
2o18'
1o8'
0o
0o1o2o3o4o5o6o7o
22
20
18
16
14
12
10
8
6
4
2
0
Transmission Mounting Angle
Dotted line showing "2 Quarts Low" is for reference only.
Not recommended.
Proper Lubrication Levels are Essential!
Percent Grade Converted to Degrees
Limitations for Proper Lubrications
Percent of Grade
TRANSMISSION OIL LEVEL 1/2" BELOW FILLER HOLE
2 QUARTS LOW
TRANSMISSION OIL LEVEL TO BOTTOM OF FILLER HOLE

10
Installation Requirements
Installation
Requirements
Air Supply Requirements
1. It is required to use a high quality commercially available air dryer in the air supply line before the transmission.
2. Minimum air requirement for the transmission is 65 PSI.
3. A minimum of 1/4” diameter air supply line is required.
4. The transmission air supply is required to be routed from the air tank, which supplies air to either the front or rear vehi-
cle service brakes, with a gauge indicator in the cab.
5. Transmission airlines should not be routed or attached at the bottom air tank fittings to avoid any chances of introduc-
ing moisture into the airline.
6. Care should be used when routing the air supply to avoid kinks and close contact to heat sources.
7. The transmission air supply must be connected to the air filter/regulator mounted on the range cylinder cover.
Note: The air filter/regulator must not be removed during installation.
8. Air additives such, as alcohol devices should not be permitted to enter the transmission air supply. Additives could
cause damage to air system components, which could lead to degraded transmission performance.
SERVICE TANK
Air
Drying
Compressor
Do not tie wrap air line
to wire harness on transmission
CAUTION

11
Installation Requirements
9-speed Pneumatic Diagrams
Note: Only solid lines are connected by the OEM. Dashed lines are already plumbed.
Roadranger
valve
HI Range Inactive
LO Range Pressured
HI Range Pressured
LO Range Inactive
5/32" or 1/8" air line
1/4" air hose
1/4" air hose
HI Range Inactive
LO Range Pressured
Range
Cylinder
1/4" air hose
Constant regulated
air (55-65 PSI)
Air filter/
regulator
Constant regulated
air (55-65 PSI)
1/4" air hose
Splitter
Cylinder
5/32" air line
Lock High
Except During
Top 2 Function
Top 2
Solenoid
Valve
HI Split Pressured
LO Split Inactive
5/32" air line
5/32" air line
Constant regulated
air (55-65 PSI)
5/32" or 1/8" air line
Slave
Valve
HL
SP
SL
P1 P2
S
EXH

12
Installation Requirements
Installation
Requirements
10-speed Pneumatic Diagrams
Note: Only solid lines are connected by the OEM. Dashed lines are already plumbed.

13
Installation Requirements
13-speed Pneumatic Diagrams
Note: Only solid lines are connected by the OEM. Dashed lines are already plumbed.

14
Installation Requirements
Installation
Requirements
18-speed Pneumatic Diagrams
Note: Only solid lines are connected by the OEM. Dashed lines are already plumbed.

15
Installation Requirements
Transmission Mounting Requirements
Handling
Handle the transmission carefully to avoid damage to the transmission components and surrounding vehicle components.
1. Use a hoist or transmission jack that permits precise control of transmission movement during installation.
Transmission Preparations
Always remove banding and protective wrapping from the transmission and inspect for shipping damage as soon as possible
upon receiving.
2. If a thread-in electronic speedometer system is used, tighten sensor or sensor lock nut to 35 lbs-ft. [47 N•m], (3/4-16
threads). If a push-in electronic speedometer system is used, Eaton P/N 14142 (O-ring) and Eaton P/N 71206 (silicon
lubricant) are used to seal the sensor.
3. To remove, reposition, or replace rear bearing cover, apply Eaton Sealant P/N 71205 or equivalent to threads and tighten
main shaft rear bearing cover capscrews to 35-45 lbs-ft. [47-61 N•m] (3/8-16).
Output Yoke/Flange Installation
Note: The output yoke/flange is supplied with the transmission. If the output Yoke/flange must be replaced, the following proce-
dure should be followed. (For detailed instructions, refer to the proper transmission model service manual.)
Select the proper output yoke per specified application, remove plastic cover, and inspect the slinger (gold anodized ring) and
seal surface for damage or contamination. Do not use the yoke/flange if the slinger or seal surface is damaged such as dents,
nicks, or scratches.
1. Prior to installation, remove all contamination such as styrofoam particles, dust, dirt, or rust in the machined surface of
the yoke/flange.
2. Place the yoke/flange over the transmission output shaft end and rotate it to line up the splines. Take care not to bump
any machined surface of the yoke/flange against the output shaft. Push the yoke all the way onto the output shaft and
onto the seal with one continuous motion.
3. Thread the tail shaft nut onto the tailshaft until nylon insert is engaged on the tailshaft thread. Secure yoke/flange and
tighten the tailshaft nut to 450-500 lbs-ft. [610-678 N•m].

16
Installation Requirements
Installation
Requirements
Mounting Transmission to Engine
Use the two transmission lifting eyes provided. The lifting eye position must not be changed on the transmission.
Note: For lifting eye and sensor retaining bolt locations, see Appendix. These bolts can not be used for brackets or for any other
purpose.
1. Use a two point lift chain or transmission jack with a minimum capacity of 1500 lbs.
2. Inspect the engine to transmission mating surfaces for damage or debris prior to installation. Make sure engine fly-
wheel housing face, transmission clutch housing face, input shaft, etc. are free of paint, debris, rust, and any type of
damage before installation.
3. Input Shaft To Clutch Alignment: The transmission is shipped from Eaton with the transmission in gear. The transmis-
sion must be in gear in order to rotate the input shaft by turning the output shaft/yoke.
4. Adjust the lift chain or transmission jack to obtain the same relative angle as the engine. The face of the engine flywheel
housing and the face of the transmission clutch housing must be parallel during installation. If the transmission is prop-
erly aligned and the clutch is installed properly, very little force is required to slide the input shaft through the clutch and
into the pilot bearing.
5. If interference is encountered, move the transmission away from the engine to investigate the cause. The use of exces-
sive force to overcome misalignment may cause damage to the transmission input shaft and the clutch.
6. Rotate the output shaft/yoke while sliding the input shaft into the clutch to line up the splines.
7. Once the transmission is seated against the engine flywheel housing, align the clutch housing bolt holes with the engine
flywheel housing bolt holes and install all capscrews and tighten finger tight.
Note: The clutch housing must be flush against the engine flywheel housing before tightening any capscrews. Do not use the
capscrews to seat housing.
8. Tighten four capscrews at 90° intervals around the clutch housing, then tighten the remaining transmission mounting
capscrews using the recommended torque specifications.
Note: Do not tighten any mounting capscrews until all capscrews have been installed and finger tightened. Do not remove the
transmission support chain or jack until all mounting bolts have been tightened.

17
Installation Requirements
Using Rear Supports
The OEM is responsible for determining if rear transmission support is required.
1. The transmission nodal mounting pads are approved to be used as a rear engine support location.
2. The OEM is responsible for nodal mount design.
3. Torque transmission nodal mount capscrews (3/4-10 UNC) to 180-190 lbs. ft. [224-258 N•m] of torque
Typical Rear Support Designs