Eaton Procision 7-Speed Dual Clutch Transmission TRIG0990 EN-US

Transcription

1 Installation Guide Eaton Procision 7Speed Dual Clutch Transmission TRIG0990 ENUS June 2016 EDCO9N107AXX EDCO6F107AXX

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3 Warnings and Cautions Introduction and General Information Warnings and Cautions 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.! Warning: Failure to follow indicated procedures creates a high risk of personal injury to the servicing technician. Caution: Failure to follow indicated procedures may cause component damage or malfunction. Important: Highly recommended procedures for proper service of this unit. Note: Additional service information not covered in the service procedures. Important Notice Tip: Helpful removal and installation procedures to aid in the service of this unit. Any reference to brand names 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. The description and specifications contained in this service publication are current at the time of printing. Warnings and Cautions Eaton reserves the right to discontinue or modify its models and/or procedures and to change specifications at any time without notice. i

4 Table of Contents Section 1: Introduction / General Information Introduction and General Information... i Warnings and Cautions...i Important Notice...i About this Manual... 1 OEM Design Responsibility...1 Application Approval...1 Transmission Identification Tag...2 Product Identification...2 Product Familiarization... 3 Features of Eaton Procision Transmissions...3 Suggested Tools/Publications... 4 Vendor List... 5 Section 2: Vehicle Space Claim Shift Label Requirements... 6 Eaton Shift Console Space Requirements... 7 Vehicle Space Claim... 8 Eaton Procision Transmission...8 Section 3: Clutch Interface Eaton Procision Damper Installation Section 4: Transmission Interface Transmission Interface Mounting Transmission to Engine...15 Lubrication Requirements and Specifications Eaton Procision Transmission Lubrication Requirements...16 Warnings and Cautions...16 Transmission Oil Level...17 Cooler Requirements Transmission Component Temperature Requirements...21 Section 5: Electrical System Interface Electrical Wiring Requirements Power Requirements...22 Mating Connector and Terminal Requirements...22 Electrical Sealing Requirements...23 Network Communications Requirements...23 Vehicle Service Requirements for Electronics...23 Harness Routing Requirements...24 OEM System Integration Requirements...25 Electrical Wiring Recommendations Contact Lubrication Recommendations...27 Harness Design Recommendations...27 Electrical Juncture Recommendations...27 Vehicle Harness Troubleshooting and Test Equipment Recommendations...27 ii

5 Table of Contents Section 5: Electrical System Interface (Continued) Electrical Circuits and Components Transmission Control Module (TCM) (P/N )...28 OEM Interface Connections Way Vehicle Connector Way Body Connector...30 Typical Start Enable Relay Circuit...31 Control Area Network (CAN) Communications...31 Transmission Range Sensor (TRS)...33 Lever Specifications...34 EPS Shift Selector Cable Linkage Installation Instructions...35 Procision Push Button Shift Console...39 Power TakeOff (PTO)...40 Reverse Output Signal...44 Neutral (Range) Output Signal...45 Synchronized Wake Up (Optional)...46 Force/Hold/Momentary Neutral...47 Alternate Shift Strategy Switch (Optional)...49 Service Ports...50 Wiring Diagrams OEM Responsibility Procision 7Speed Dual Clutch Transmission 12 Volt with Pushbutton Shift Controller...51 Procision 7Speed Dual Clutch Transmission 12 Volt with Transmission Range Sensor...52 Procision 7Speed Dual Clutch Transmission Body Connector Wiring Diagram...53 SAE J1939 Data Link Broadcast Messages SAE J1939 Data Link Received Messages Gear Display Alert Tone...66 End of Line...67 Table of Contents iii

6 General Information About this Manual This Eaton publication is intended to be a reference guide for the installation of the Eaton Procision 7Speed Dual Clutch Transmission. 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. For additional transmission information, see the Suggested Tools section in this manual. For specific engine information, contact the engine OEM. Failure to adhere to Eaton Installation Requirements will affect transmission performance and/or warranty coverage. Eaton Procision Transmissions are compatible with electronically governed engines equipped with a J1939 data link and certified by Eaton Corporation. Transmissions installed at OEM facilities shall meet and be approved by Eaton Application Engineering. Contact Eaton Application Engineering or your OEM Application Engineering department for the proper Application form. All applications shall be submitted for approval. Throughout the document, the use of the words shall and will represent two diverse and specific meanings. The use of the word shall corresponds to a requirement to which the OEM must adhere. When the word will is used, it shows information to let the OEM know what Eaton will be doing. OEM Design Responsibility! Important: The vehicle Original Equipment Manufacturer (OEM) shall be responsible for producing parts that meet the requirements of this document. Refer to the OEM System Integration section for details. OEM facilities shall submit a design package to Eaton Corporation OEM Engineering Support Group for approval prior to any OEM build. A design package consists of the following information. Transmission cooling system: Cooler type and capacity, cooler hose(s) routing and clipping. 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: Highlevel schematic of how this transmission interfaces with the vehicle. Application Approval Eaton Procision Transmission Systems installed at OEM facilities must meet the requirements and be approved using the Eaton Transmission Application Approval Form. Please contact Eaton Application Engineering or your OEM's Application department for the latest Application form. Driveline Torque Requirements Driveline angular acceleration and driveline torque shall not exceed requirements stated in Eaton Application Guideline specification TRAG2600. Applications and PTO Applications Refer to Application Guidelines Manual TRAG2600 and PTO Torque Limits TMIB0127 for PTO application guidelines. Every effort has been made to ensure the accuracy of the information contained in this manual. However, Eaton Corporation makes no warranty, either expressed or implied, based on the information provided. With each new application, engine manufacturers should be contacted to make sure desired engines are compatible with these systems. 1

7 General Information Transmission Identification Tag All Eaton Procision Transmissions are supplied with component identification tags. All tags are located on the right front of the transmission. Care should be taken not to damage the identification tag during the installation process. General Information Do not remove the identification tag. Model Serial Assembled In Eaton Transmissions Eaton Corporation Kalamazoo, MI USA Product Identification Nomenclature Eaton Procision Transmissions E D C O 9 N A X X Eaton Dual Clutch Overdrive Torque Capacity (N m) x 100 Series Ratio Set Forward Speeds Design Level E D C O 6 F A X X Eaton Dual Clutch Overdrive Torque Capacity (ftlb) x Series Ratio Set Forward Speeds Design Level 2

8 General Information Product Familiarization Note: The Eaton Procision system has been designed to be 12/24 volt capable, however at this time 24volt systems are not approved. Features of Eaton Procision Transmissions A MEIIR circuit is not required for Eaton Procision Transmissions. Eaton Procision Transmissions are 12/24 volt capable. Procision Module is integral to the transmission. Oil filters: One external cartridge type contained in a spin on cup to be changed at the lube interval and one internal sump filter designed for life of the transmission; Lube interval of 150,000 miles or 3 years. Eaton Procision transmissions are compatible with ABS and ATC or ASR. Hill Start Aid is not required or suggested with Eaton Procision Transmissions. A 2bolt end yoke retaining design has been implemented. Transmission rear supports are not required on Eaton Procision Transmissions. The OEM is responsible for determining if rear supports are needed. With Eaton Procision Transmissions it is acceptable to configure a vehicle for a J1939 Start Enable Type in place of a Start Enable Relay. Refer to Start Enable Requirements in the Electrical System Interface section. The transmission provides intelligent urge to move. This feature manages urge to move based on brake switch and grade inputs. This system requires passive sealing on the clutch housing to ensure no foreign debris enters the clutch area. This requires the OEM ensure that all openings in the flywheel housing are plugged. A 26 tooth spline on the input shaft is standard for all Eaton Procision transmission models. Precise lube technology adopted to reduce churning losses and enhance fuel economy performance. All Aluminum enclosure except for sump pan. The Eaton Procision Transmission can be equipped with an optional fluid level sensor. The sensor measures the fluid level on level ground with the engine running and above 20 C fluid temperature. The information is transmitted from the transmission via a standard SAE J1939 message. If the fluid level is measured to be out of range a diagnostic procedure will manage the operation of the transmission. A 6bolt PTO opening is available on either side of all Eaton Procision Transmissions. Transmissions utilize a new Eaton Procision TCM and technology. OEM Interface connections: There are two Delphi 20 way connectors that mate with the TCM, one Vehicle connector and one Body connector. The Eaton Procision transmission is capable of supporting Force/Hold/Momentary Neutral. See the Force/Hold/Momentary Neutral section. Mechanical transmission interface dimensions are close to typical MD transmissions, which simplifies the OEM s integration effort. Reduced oil capacity requirement reduces weight/cost. Productspecific J1939 messaging. * Option Available for parking brake provision 3

9 General Information Suggested Tools/Publications O.E. Tool & Equipment Group/KentMoore SPX Corporation 1(800) KentMoore Part no. Description Volt/Ohm Meter (Standard commercially available VOM) O.E. Tool & Equipment Group/KentMoore SPX Corporation 1(800) KentMoore Part no. Description J43318 Eaton Test Adapter Kit Liberty Circuits Corporation (269) Part No. Description Grade Sensor Calibration Box KLine Special Service Tools Part No. Description RR1037TR Clutch Damper Alignment Tool Deutsch Part No. Description HDT Hand Crimping Tool Low Power Pins (size 20) HDT Hand Crimping Tool High Power Pins (size 12) Service Publications TRSM0990 Service Manual TRTS0990 Troubleshooting Guide TRDR0990 Driver Instructions Dearborn Group Technology Part No. Description DGDPA IV PLUS Protocol Adaptor Nexiq Technologies Part No. Description Prolink GRAPHIC Scan Tool HD Scan Tool Kit For more information, contact your OEM quality representative. General Information 4

10 General Information Vendor List EATON VEHICLE CONTROLS BUSINESS UNIT J1939 Auto Shift Display Contact Phone Number: BELDEN WIRE AND CABLE (HIL and J1939 Cable) BRANDREX CO. (J1939 Cable) CHAMPLAIN CABLE CO. RAYCHEM (J1939 Cable) (Wire) KLine Special Service Tools (Transmission Service Tools) LIBERTY CIRCUITS CORPORATION 630 East Walnut Kalamazoo, MI (269) DELPHI PACKARD ELECTRIC SYSTEMS (Connectors) TE CONNECTIVITY DEUTSCH (Connectors) (Connectors) (Ladd Industries) 5

11 Vehicle Space Claim Shift Label Requirements 1. The shift label shall be located in the cab so that it is visible in the driver seat. 2. Shift labels are available for multiple shift devices, for PBSC and for TRS. 3. The OEM shall match the label with the installed shift device. Eaton Transmissions Vehicle Space Claim 6

12 Vehicle Space Claim Eaton Shift Console Space Requirements! Important: The OEM shall provide a 2digit gear display. There is no gear information on PBSC [.48] 29.6 [1.16] [ ] 2X #832 UNC 9.59 [.378] 60.6 [2.39] [4.015] 75.2 [2.96] [1.478] [6.46] Mates with 30way packard connector with body # and terminals # [6.80] PANEL CUT OUT DIMENSIONS [3.06] 83.8 [3.30] [6.56] 4X R.10 MAX Packard connector to Push Button Controller torque is lbs. in. [ N m] 7

13 Vehicle Space Claim Vehicle Space Claim Eaton Procision Transmission! Warning: The OEM shall not remove fasteners from any gasketed surface as the potential for leaks is created by doing so. Note: All fasteners used in the aluminum housing shall have a 2x diameter thread engagement, for example, M10 = 20 mm thread engagement. Vehicle Space Claim 8

14 9 Vehicle Space Claim

15 Clutch Interface Eaton Procision Damper Installation Procision Damper P/N: ! 1. Clean engine flywheel surface (if required) and ensure that bolt hole threads are in good condition. 2. Ensure pilot bearing is installed per OEM guidelines and is of the correct ID size (25mm or 30mm ID). 3. Insert the MD Procision Damper Alignment Tool (P/N RR1037TR) into the pilot bearing. 4. Slide an MD Procision Damper (P/N ) onto the Alignment Tool until the Damper Mounting Plate is flush with the engine flywheel friction surface. 5. Align the Holes by rotating the Damper Assembly on the Alignment Tool. Caution: When rotating the damper support the alignment tool to prevent it from walking out of the bearing allowing damper to fall. 6. Install (QTY = 12) 3/8 16 UNC x 1.25 Grade 5 or better bolts w/split lock washers. 7. Thread by hand until snug to ensure no crossthreading. 8. Torque all 12 bolts to 3540 lbft. 9. After bolt torques are confirmed, remove the Alignment Tool. Clutch Interface 10

16 Transmission Interface Transmission Interface Handling Handle the transmission carefully to avoid damage to the transmission components and surrounding vehicle components. Use a hoist or transmission jack that permits precise control of the transmission movement during installation. Transmission Preparations Note: An optional push in speed sensor can be made available upon OEM request. The tone wheel has 16 teeth as standard. No mechanical speedometer. Lifting Eye Do not remove or attach anything to ECM fasteners Lifting Eye Output Shaft Speed Sensor 11

17 Transmission Interface Parking Brake An optional transmission configuration with provision for a driveline 9X3 parking brake can be ordered. Note: Only Bosch s 9X3 NonServo Dual Anchor Driveline Parking Brake is approved for use with Procision. For other parking brake models, Eaton Application Approval is required. Transmission Interface 12

18 Transmission Interface! Caution: Do not exceed 150N*m [110lbf*ft] when tightening 4 x 1/213parkingbrake mounting fasteners to prevent damage to transmission threads (based on class 8.8 uncoated fastener with minimum thread engagement of 1.5x nominal thread diameter). 13

19 Transmission Interface Transmission Interface 14

20 Transmission Interface End Yoke Retaining Design All Eaton Procision Transmissions have a two bolt retainer plate design to fasten and retain the end yoke. A dual spindle driver is recommended to install the yokes. If a dual spindle is not available, special care shall be exercised to snug each bolt to ftlb prior to attaining full torque of ftlb. For reference, these bolts are M12 x 1.25 x 55 mm Grade Mounting Transmission to Engine Use the two transmission lifting eyes provided. The lifting eye position shall not be changed on the transmission. Use a 2point lift chain or transmission jack with a minimum capacity of 800 lbs. Inspect the engine to transmission mating surfaces for damage or debris prior to installation. Make sure the engine flywheel housing face, transmission housing face, input shaft, etc. are free of paint, debris, rust, and any type of damage before installation. Input Shaft to Damper Alignment The input shaft normally will index itself to the damper splines, in the event that it will not, pull the transmission back turn the input shaft and try again. 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 housing shall be parallel during installation. If the transmission is properly aligned and the input shaft splines are properly aligned, very little force is required to slide the input shaft through the damper. If interference is encountered, move the transmission away from the engine to investigate the cause. The use of excessive force to overcome misalignment may cause damage to the transmission input shaft and the damper. 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 cap screws and tighten finger tight. Note: The damper housing shall be flush against the engine flywheel housing before tightening any cap screws. Do not use the cap screws to seat housing. Note: Do not tighten any mounting cap screws until all cap screws have been installed and finger tightened. Do not remove the transmission support chain or jack until all mounting bolts have been tightened. 15

21 Transmission Interface Lubrication Requirements and Specifications Eaton Procision Transmission Lubrication Requirements The Eaton Procision Transmission lubricant is a unique fluid. It was specially designed to provide smooth, wet clutch operation and superior gear and bearing protection in Eaton Procision Transmissions. Using a fluid not approved by Eaton will result in failures and loss of warranty coverage. Eaton requires the use of a transmission lubricant that is of an approved PS278 specification. A list of approved lubricants and suppliers can be found in the Approved Lubricant Supplier Manual, TCMT0020. Not using the required lubricant will result in degraded performance and shortened life of the product. Refer to the Lubrication Manual, TCMT0021, for the latest information regarding lubrication requirements. Note: Eaton recommends the use of Eaton Procision Transmission fluid. Only lubricants that are approved Eaton specification PS278 shall be used in the Eaton Procision Transmission. Note: Failure to adhere to Eaton installation requirements may affect the transmission performance and / or warranty coverage. Transmission Interface Required Lubricant Eaton Procision Transmission Fluid Approved Eaton specification PS278 lubricant Warnings and Cautions Before working on a vehicle, place transmission in neutral, set brakes and block wheels. Do not introduce additives and / or friction modifiers. Additives of any 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 reuse lubricant. Failure to use the required lubricant will affect the transmission performance and the warranty coverage. SAE 15W40 viscosity grades are not allowed in Eaton transmissions. Automatic Transmission Fluids (ATFs) are not allowed in Eaton Procision Transmissions. 16

22 Transmission Interface Transmission Oil Level Transmission Oil Level Transmission Dipstick and Tube Based on fluid compatibility concerns, use of an off the shelf grommet material, such as Dorman p/n will not work with the Eaton transmission. Grommet PN can be ordered or Eaton recommends a grommet material (spec below) or equivalent. MATERIAL: SAE J200 / ASTM D2000 M3DH710A26B36Z1Z2 (Z1= OPTIONAL HARDNESS 75±5 SHORE A. Z2= ORIGINAL ELONGATION 150% MINIMUM) OPT MATERIAL: ASTM D2000 M3 DH810 A26B16E016E036F17 17

23 Transmission Interface Transmission Interface 18

24 Transmission Interface Procision Transmission Fluid Fill Check Procedure Note: An initial oil fill of 12 liters plus "X" (X = to the volume of the cooler hoses and the cooler), minimum is required prior to starting the engine. 1. Make sure vehicle is in a safe area on level ground. 2. Place the engine at a low idle RPM. 3. If vehicle is equipped with park pawl feature, place the transmission in P (Park). 4. Apply parking brake, if present, and make sure brake is properly engaged. 5. Apply the emergency brake, if present, and make sure it is properly engaged. 6. Take any other steps necessary to keep the vehicle from moving (chock wheels if required). 7. If vehicle has a transmission without park pawl feature, place the transmission in N (Neutral). 8. With the engine at a low idle, remove the dipstick from the fill tube and wipe clean. 9. Insert the dipstick into the fill tube so that the cap is properly seated. Remove the dipstick and check fluid level reading. Repeat procedure to verify a consistent level reading. Note: Operating level must be within the RUN band on the dipstick. 10. If fluid level is not within the RUN band, add or drain as required to bring fluid level to within the proper RUN band. 19

25 Transmission Interface Cooler Requirements The Eaton Procision Transmission requires an external cooler for normal operation. Transmissions must not be operated at temperatures above 250 F (121 C). Operation at temperatures above 250 F (121 C) causes loaded gear teeth temperatures to exceed 350 F (177 C), which will ultimately destroy the heat treatment of the gears. The following conditions, in any combination, can cause operating temperatures of over 250 F (121 C): Operating consistently at high / low speeds High ambient temperatures High horsepower operation Restricted airflow around transmission Excessive use of exhaust brake Exhaust system proximity to transmission High power PTO operation for extensive periods while stationary High engine RPM for extensive periods Transmission Interface External oil coolers are required to reduce operating temperatures. The end user is ultimately responsible for maintaining transmission lube temperatures below 250 F (121 C). Detailed Procision Transmission Cooler requirements: Engine Speed: 1000 RPM Oil Flow: 28 l/min (7.4 GPM) Water Flow: 100 l/min (26.4 GPM) Water Temp (inlet): 90 C (194 F) Oil Temp (inlet): 120 C (248 F) Oil Temp (outlet): 95.3 C (204F) Cooler Capacity: 693 W/C (21.9 BTU/min/F) Heat Load: 21 kw (1195 BTU/min) Pressure Drop The maximum pressure drop through the transmission cooler is 10 8 GPM of oil flow (at normal operating temperatures). Transmission cooler and cooler lines must withstand operating pressure up to 300 PSI. Cooler Lines The cooler and cooler connecting lines shall be free of debris, dirt, grease, etc., before being attached to the transmission. If these conditions exist, cooler lines must be flushed or cleaned. A minimum of #12 (3/4 inch I.D.) cooler hose or comparable tubing must be used. Oil cooler ports are located at the bottom front of the transmission and are marked Out and Return. Both ports are M22 x 1.5 ISO Metric Straight Thread ORing Ports. 20

26 Transmission Interface! Transmission Component Temperature Requirements The temperature limit for all components is 250 F (121 C), with the exception of the TCM enclosure which has an upper temperature limit of 221 F (105 C). Do not exceed! If sufficient air gap between the heat source and the transmission cannot be achieved, the OEM shall provide proper methods of heat shielding to ensure this limit is not exceeded. The components and systems to be protected would include, but are not limited to, sensors, wire harness, transmission controller, oil cooler and hoses, and the transmission case. 21

27 Electrical System Interface Electrical Wiring Requirements Note: Power refers to both Power Positive and Power Negative supply. (This is typically Battery Plus and Battery Negative.) Note: Switched Ignition refers to power that is enabled with ignition key operation. Power Requirements The vehicle shall have a negative ground power system. The vehicle primary power system shall be either of the following types: 12 or 24 volt. If a disconnect switch is used for the Engine Control Module (ECM), it shall be configured such that it also removes power to the Transmission Control Module (TCM). The OEM shall provide power wiring to the TCM such that the differential voltage (TCM negative subtracted from TCM Positive, for each individual power line) shall exceed 9 VDC at a steady state load of 15 amps as configured for a 12volt base system (18 VDC at a steady state load of 15 amps as configured for a 24volt base system). The OEM shall provide 2 independent power positive supply lines, each capable of sustaining the power requirements. These lines shall be continuous between the TCM Vehicle Connector and a power source such that a single point failure does not disrupt power to the TCM. The OEM shall provide 2 independent power negative supply lines, each capable of sustaining the power requirements. These lines shall be continuous between the TCM Vehicle Connector and a power source such that a single point failure does not disrupt power to the TCM. The OEM shall provide Switched Ignition wiring to the TCM such that the differential voltage (TCM negative subtracted from TCM Switched Ignition input) shall exceed 9 VDC at a steady state load of 1 amp as configured for a 12volt base system (18 VDC at a steady state load of 1 amp as configured for a 24volt base system.) The OEM shall provide power to the TCM that does not exceed a steady state voltage of 32 volts DC. Power and Switched Ignition shall meet the minimum performance criteria of ISO for transients, pulses, and engine start waveforms. The OEM shall provide switched ignition power to the TCM such that it provides 1 amp at 12 volts DC. Power and switched ignition to the TCM shall not be disconnected during the engine start process. Engine Start Interlock shall meet FMVSS 102 Section standards: The engine starter shall be inoperative when the transmission shift lever is in a nonneutral position. See Typical Start Enable Relay Circuit on page 28. Electrical System Interface Mating Connector and Terminal Requirements Connectors shall be designed for use in the heavyduty industry, conforming to SAEJ2030 and SAEJ1455. Connectors shall be verified by the OEM to be fully mated. Connector latches shall be verified by the OEM to be completely locked upon installation. Terminal Position Assurance (TPA) and Connector Position Assurance (CPA) devices shall be used on connector systems that support those devices. When interfacing to Eaton components, use connector systems, contacts, crimp tools and materials specified within Eaton documentation or an Eaton approved equivalent. Mating halves of terminal systems shall use plating materials that are compatible with each other for contact performance, wear, and metallurgy. Terminal plating material selection shall be suitable for the circuit characteristics of current load, voltage signal level, and reliability in application. 22

28 Electrical System Interface Required wire size: The cable for the Delphi 20way connector B ( ) shall be 18 (0.8 mm 2 ) TXL insulation for all wires. The cable for the Delphi 20way connector V ( ) for Pins 5, 6, 15 and 16 shall be 16 (1 mm 2 ) TXL insulation. The cable for the Delphi 20way connector V ( ) for all Pins EXCEPT 5, 6, 15 and 16 shall be 18 (0.8 mm 2 ) TXL insulation. Note: All cable sizes are per SAE J1128 crosssectional copper and insulation specifications. Note: Cable crosssectional area and insulation are specified to ensure proper connector cable sealing and current carrying capacity. Electrical Sealing Requirements Separable connectors outside of the cab shall be sealed per SAEJ2030 standards. Unused connectors shall have sealed mating connectors or plugs. Unused terminal cavities shall have sealed mating connectors or plugs. Seals shall be selected based upon cable outer diameter and connector cavity specifications. No antiseize, lubricating or foreign compound shall be applied to the TCM connector jackscrew threads. The use of such compounds may affect jackscrew torque and prevent proper sealing of the connector. Network Communications Requirements Note: The use of either Shielded or Unshielded Twisted Pair shall be an OEM decision based upon Electromagnetic Compliance (EMC) validation testing. Eaton requires Controller Area Network (CAN) communication with the vehicle engine. When the Eaton Push Button Shift Console is used, a CAN network independent of the SAE J1939 CAN network is required to be implemented on the vehicle. The Eaton Proprietary CAN data link cable, connectors, and termination shall meet the performance and assembly requirements of J1939/15 (Unshielded Twisted Pair). Eaton provides the OEM option of supporting CAN communications utilizing the SAE J1939 CAN physical layer with shielded twisted pair data cable (SAE J1939/11) or unshielded twisted pair data cable (SAE J1939/15). For shielded, twistedpair installations (STP), the data link cable, connectors, and termination shall meet the performance and assembly requirements of SAE J1939/11. For unshielded, twistedpair installations (UTP), the data link cable, connectors, and termination shall meet the performance and assembly requirements of SAE J1939/15. Twisted pair requirements: 2 Cables = 10 Twists / 25.4 cm 3 Cables = 8 Twists / 25.4 cm Size 16 (1 mm 2 ) and 18 (0.8 mm 2 ) Cable Only Vehicle Service Requirements for Electronics Battery Positive and Negative circuits to the Eaton Procision TCM must be disconnected prior to any type of welding on the vehicle. Battery Negative must be disconnected prior to removal or installation of TCM harness connectors. Removal and / or replacement of a battery shall not disturb the terminating connectors of the TCM. 23

29 Electrical System Interface Harness Routing Requirements Harness and inline connectors shall be anchored to prevent free movement. An anchor point shall be no further than 6 in [15.24 cm] (Recommended 3 in [7.62 cm]) from a connector. The length of an unanchored section of harness should be no more than 12 in [30.48 cm]. Eaton has provided several threaded bosses to which vehicle components can be clipped. The OEM shall not mount additional components to TCM, transmission brackets, mounting studs or lifting eyes under any circumstances without Eaton approval. This includes cap screws used to fasten rear housing, bearing covers and PTO covers. Removal of these will compromise transmission system operation and overall system reliability. Contact Eaton engineering to discuss OEM mounting requirements, or options such as an addition by Eaton of a bracket or mounting stud. Tie wrap application and tightness shall conform to Section of IPC/WHMAA620 Requirements and Acceptance for Cable and Wire Harness Assemblies, January 2002 revision or later. Tie wrap application shall meet the Target and Defect of a Class 3 product per IPC/WHMAA620. Use tie wraps on harness covering only, not individual wires. Do not anchor harness with tie wraps in contact with wire insulation. Tie wraps shall not pull on the harness such that connector cable seals are distorted. Cable anchors shall be installed in a manner that prevents cables from exerting excess strain on the connector body. The bend radius of a harness bundle shall be greater than 6 times the diameter of the harness bundle. Exceptions require Eaton Engineering approval. The bend radius of an individual cable shall be greater than 2.5 times the diameter of the individual cable. Exceptions require Eaton Engineering approval. Harness installation shall utilize fixed clip points, for example, Fir trees, Jclips and Pclips. Harness routing shall not interfere with oil fill plugs, hydraulic fittings, PTO openings, lifting eyes, sensor locations or manufacturing fixtures. The OEM shall utilize the Eaton supplied transmission vehicle harness bracket, The bracket will receive two wire harness branches encased with Delphi P/N R72221 convoluted tubing or equivalent. The TCM mating end of the vehicle harness shall be divided into two distinct branches, one for each 20way TCM connector. The vehicle wire harness shall be secured to the bracket with tiewraps. The following view illustrates and its mounting location. Electrical System Interface Figure 1. OEM Harness Routing Clipping Bracket 24

30 Electrical System Interface OEM System Integration Requirements Gear Display The OEM shall provide a twodigit alphanumeric gear display either as part of a smart dash or an independent display. The display shall properly display all J1939 messages shown in the Gear Display section in this manual. Tone Module The required tone module is incorporated into the Eaton PBSC. If any other type of shift control is used a tone generator capable of executing transmission broadcast J1939 messages is required. See the Alert Tone section in this manual. Indicator Lamps Red and yellow transmission indicator lamps are required on the dash. The lamps shall respond to transmission broadcast J 1939 messages. Transmission Range Sensor The OEM shall provide the shift lever, the shift cable and the transmission mounted shift arm. The wiring between the Transmission Range Sensor and the Vehicle Connector at the TCM form part of the Chassis Wiring Harness and are the responsibility of the OEM. See the Transmission Range Sensor section in this manual. Accelerator Pedal The Accelerator Pedal input is a critical input to the transmission system as it is the means of determining driver intent, and the system will interpret accelerator pedal values of greater than 2% as a request for the vehicle to launch. The vehicle shall provide accurate J1939 information on the pedal status, and the pedal output shall not exceed 2% if the pedal is not pressed. The accelerator pedal shall also be diagnosed (e.g., a 2nd input from the pedal to confirm pressed), and the status communicated via J1939. Service Brake The service brake is an important input to the transmission system, the vehicle shall provide uptodate and accurate information on the status of the service brake switch over J1939, including any diagnostic status (e.g., Faulted). Park Brake The park brake is an important input to the transmission system, the vehicle shall provide uptodate and accurate information on the status of the park brake switch over J1939, including any diagnostic status (e.g., Faulted). Engine The engine shall provide an upper limit of no more than 3 seconds duration for torque control requests from the EPS system. The TSC1 J1939 message from the EPS system provides the rolling counter and checksum, per the latest J1939/71 specification, to support diagnosis of communication from the EPS system. 25

31 Electrical System Interface (M6) For OEM Use (M8) For OEM Use (M10) For OEM Use Vehicle Connector Body Connector Electrical System Interface 26

32 Electrical System Interface Electrical Wiring Recommendations Contact Lubrication Recommendations Eaton recommends the use of NyoGel 760G on all electrical contacts. The preferred method of application is to use a metered dispensing mechanism that places the material on the socket of the connector. It is also preferred that the material be placed immediately prior to connector mating to reduce the probability of contamination. For further information, contact your Eaton OEM Engineering Support Group. Harness Design Recommendations Splices shall be ultrasonically welded and encapsulated and sealed to meet SAEJ1455. Convoluted Conduit shall have a service temperature of at least 257 F (125 C) and be made of a material that mitigates chafing of the wire insulation. Braided Loom shall have a service temperature of at least 280 F (138 C). Coverage: A minimum of 10 picks per inch / maximum of 12 picks per inch. Electrical Juncture Recommendations Do not use more than 3 ring terminals per mounting stud. Terminals such as ring, bullet, spade, etc., shall be sized for the correct current capacity of the circuit as stated by the manufacturer. Terminals shall be plated and noninsulated. Mated terminal plating shall be selected such that it prevents galvanic corrosion between contacting surfaces. Sleeves shall be insulated with a double wall shrink tubing. Sealing dielectric grease over the top of the ring is recommended. Do not use lock washers or star washers for contact surfaces. Terminal crimps and crimp tooling shall meet or exceed terminal manufacturer's specifications. Vehicle Harness Troubleshooting and Test Equipment Recommendations Consult the Eaton Procision Transmission Service Manual (TRSM0990) for proper harness troubleshooting procedures. The removal of fuses is not recommended as the method of disconnecting power from the TCM. Making and breaking a circuit through tinplated terminals (e.g., ring terminals, fuses) will destroy the plating on the terminal. Opening a switch contact on the main power link is the recommended method of interrupting power. Harness Probing Damage Alert Never puncture cable insulations with a probe to verify voltage or to check continuity. Removing 20way connectors that are being supplied with power is not recommended. Damage to the wire insulation can lead to immediate or future failures of the harness or electronic control unit due to short circuits, water entry or corrosion. Note: If a connection to the harness or TCM is required before vehicle installation, Eaton recommends the use of a connector with a springloaded contact rather than a standard mating connector. The springloaded contact is intended to make the electrical connection with the tip of the terminal without touching the mating surface. This will protect the terminal plating, the NyoGel 760G, and retain the original durability and reliability of the connector system. 27

33 Electrical System Interface Electrical Circuits and Components Transmission Control Module (TCM) (P/N ) The electrical subsystem of the Eaton Procision Transmission is controlled by the Transmission Control Module (TCM). The TCM monitors activity on various I/O ports and performs functions accordingly. The TCM is mounted to the left side of the transmission. OEM Interface Connections There will be two Delphi 20way connectors that mate with the TCM. The Delphi 20way Vehicle Connector (Delphi P/N Index Key V) is configured to receive 16 circuits utilizing 0.8 mm2 (18 AWG) TXL wire and 4 circuits utilizing 1.0 mm2 (16 AWG) TXL wire. The four 1.0 mm 2 (16 AWG) circuits are for the TCM Power and Ground circuits. These circuits are located in cavities are 5, 6, 15 and 16 of the Vehicle Connector (See the respective charts below for more detail). The Vehicle Connector is dark gray in color. The Delphi 20way Body Connector (Delphi P/N Index Key B) is configured to receive 20 circuits that utilize 0.8 mm2 (18 AWG) TXL wire. (See the respective charts below for more detail.) The Body Connector is light gray in color. All unused connector cavities shall be plugged to prevent water intrusion. Both connectors use the Delphi plug (Delphi P/N ). Use as required. The transmission will be delivered with two green environmental shipping caps (Delphi P/N ) installed. In all vehicle configurations, the environmental cap located on the Vehicle Connector of the TCM shall be removed and discarded to allow for the installation of the OEM harness. In some vehicle configurations, installation of a Body Connector may not be required. In these instances, the environmental cap shall remain on the TCM to protect the TCM pins from the elements. When the Body Connector is present in the OEM Vehicle Harness, the environmental cap located on the Body Connector of TCM may be discarded. A Connector Position Assurance (CPA) (Delphi P/N ) shall be used to secure the fully engaged connector lever lock in the latched position. Electrical System Interface 28

34 Electrical System Interface 20Way Vehicle Connector Vehicle Connector Pin Out Vehicle Connector Pin No. Wire AWG Circuit Description TCM Vehicle Connector V1 18 PNL CAN C High Component Delphi Part # Quantity V2 18 PNL CAN C Low Connector Body V3 18 TRS Output 1 Terminal (*Special Crimp Specification) V4 18 Start Enable Negative Secondary Look V5 16 Battery Negative 1* Connector Position Assurance (CPA) V6 16 Battery Positive 1* Cable Seal V7 18 Plugged (not used) Backshell Cover V8 18 Protected Power Return * Refers to Power Requirements on page 22. V9 18 TRS Output 2 / Push Button Mode Indicator Note: All unused connector cavities shall be plugged to V10 18 Ignition Wakeup (Input) prevent water intrusion. Both connectors use the Delphi V11 18 J1939 CAN A High plug (Delphi P/N ). Use as required. V12 18 J1939 CAN A Low V13 18 J1939 CAN A Shield V14 18 Start Enable Positive V15 16 Battery Negative 2* V16 16 Battery Positive 2* V17 18 Protection Power (Output) V18 18 Analog Return V19 18 TRS 5.0 Volt Supply V20 18 Synchronization Wakeup 29

35 Electrical System Interface 20Way Body Connector Body Connector Pin Out Body Connector Pin No. Wire AWG Circuit Description TCM Body Connector B1 18 Reverse Output 3 Component Delphi Part # Quantity B2 18 PTO Engage Output 2 Connector Body B3 18 Range Output 1 Terminal (*Special Crimp Specification) B4 18 Hold/Force Neutral Input 2 Secondary Look B5 18 Body I/O Return (RTN_1) Connector Position Assurance (CPA) B6 18 Hold/Force Neutral Input 1 Cable Seal B7 18 CAN B High Backshell Cover B8 18 CAN B Low Note: All unused connector cavities shall be plugged to prevent B9 18 PNL CAN C Low water intrusion. Both connectors use the Delphi plug (Delphi P/N B10 18 PNL CAN C High ). Use as required. B11 18 Service Vbatt B12 18 Service Ignition B13 18 Service Ground B14 18 Body I/O Return (RTN_2) B15 18 PTO Request Input 3 B16 18 PTO Confirm B17 18 Alternative Shift Strategy Input 5 B18 18 Alternate Shift Strategy Out B19 18 J1939 CAN A Low B20 18 J1939 CAN A High Electrical System Interface 30

36 Electrical System Interface Engine Start and Engine Starter Interlock Function Engine start function is the responsibility of the OEM vehicle system. Eaton provides an Engine Starter Interlock function that is active once the transmission determines that starter operation is allowed per United States Federal Register, 49 CFR Part 571, Federal Motor Vehicle Safety Standards (FMVSS); Standard No. 102; Transmission Shift Position Sequence, Starter Interlock, and Transmission Braking Effect, Section S3.1.3: Starter interlock. Except as provided in S through S , the engine starter shall be inoperative when the transmission shift position is in a forward or reverse drive position. The Eaton Starter Interlock function is provided through two mechanisms. Engine starter interlock function using a relay contact inserted in the engine starter enable circuit path (Engine Start Enable Relay). Engine starter interlock function using a control message communicated from the transmission to the vehicle engine start controller over the SAE J1939 Controller Area Network (CAN).! Important: J1939 Start Enable Type The J1939 ETC7 SPN 2900 Transmission Crank Enable message may be used to enable cranking without a relay. This feature can be configured with VEPS or ServiceRanger 4. A representation of the minimum implementation of the Start Enable Relay circuit for Procision is shown in Figure 2 Engine Start Enable Relay for Procision. The OEM shall provide the circuit connecting the Eaton Procision TCM (V14 and V4) to the Start Enable Relay. The Start Enable Relay driver circuit is a high side and low side driver pair designed to provide a fault tolerant control of the starter enable circuit. The driver is intended to provide a nominal 0.14 ampere for a 12volt system relay coil and 0.07 ampere for a 24volt system relay coil. The OEM shall be responsible for overcurrent protection of the switched ignition input on the switched contact side of the Start Enable Relay. Figure 2. Engine Start Enable Relay for Procision +Battery Start Enable Positive (V14) ACC Off Ignition Start Key Switch Start Enable Negative (V4) A Run to Starter Solenoid Relay Connector V (TCM mating end) From To Description V14 86 Start Enable Positive V4 85 Start Enable Negative 31

37 Electrical System Interface Control Area Network (CAN) Communications The CAN A data link shall be utilized for network communications between the TCM and other components on the vehicle, such as the Engine Control Module (ECM). The PNL data link shall be utilized for proprietary network communications between the TCM and the push button controller. Both the CAN A data link and the PNL data link shall conform to either SAE J1939/11 or SAE J1939/15. Other Modules Engine ECM Transmission TCM Terminating Resistor J1939/15 Data Link (OEM Supplied) Terminating Resistor Electrical System Interface Connector V (TCM mating end) From To Description V11 A CAN A High V12 B CAN A Low V13 C CAN A Shield 32

38 Electrical System Interface Transmission Range Sensor (TRS) The Transmission Range Sensor (TRS) is utilized on transmissions with the park pawl feature. The TRS measures the angular rotation of the transmission mounted shift arm located on the Procision Transmission. The angular rotation is generated by the actuation of the shift lever mounted inside the cab. The OEM shall provide the shift lever, the shift cable and the transmission mounted shift arm. The OEM supplied shift lever shall provide the internal travel stops at the end of the available modes, for example, PRNDHL (park unit). The TRS is not used on every Procision Transmission and may not be present if the Driver Interface Device communicates directly with the EPS TCM via CAN/PNL. The OEM provided shift lever shall have an additional release feature at the lever (button, lift collar) and shall lock in P, R, N and D modes unless this feature is actuated. The OEM shall provide a service brake interlock feature with the shift lever so that the lever cannot be moved from the Park position if the service brake is not pressed. TRS mating connector specifications described in table below. OEM supplied TRS wire harness circuits shall be 18gauge TXL wire at the 20way connector for sealing purposes. 33

39 Electrical System Interface Lever Specifications! Important: Retain internal shaft by holding shift lever away from the end of stroke while tightening to prevent internal component damage. Electrical System Interface Detent Lever Angular Rotation With Degrees 34

40 Electrical System Interface EPS Shift Selector Cable Linkage Installation Instructions Shift Linkage Adjustment: The internal detent mechanism of the transmission is the primary positioning devise of the vehicle shift linkage system. The customer shift selector assembly must be installed to accommodate this fact. Therefore, the shift selector assembly and cable must move the transmission detent from position to position without binding. The objective of the installation instructions is to have the shift selector assembly positions centered as closely with the internal transmission detent positions as possible. 1. Shut off engine, set parking brake and block wheels to prevent vehicle movement. 2. Remove cable swivel from transmission shift lever if needed and install shift lever to internal shift shaft with M10 x 1.5 nut. Retain internal shaft by holding shift lever while tightening to prevent internal component damage. Do not use power tools to install. 3. Place shift selector assembly and transmission shift lever in Neutral position (N), see figure below. Note: Retain internal shaft away from end stops while installing M10 Nut. Do not use power tools to install. 35

41 Electrical System Interface 4. At the transmission end of the shift cable, push the cable to the gate end stop of the shift selector assembly to take up all slack in cable and shifter interlock. Make note of the amount of the endplay relative to the hole in the shift lever; see figure below. 5. Again at the transmission end of the shift cable, pull the cable to the gate end stop of the shift selector assembly. Make note of the amount of the endplay relative to the hole in the shift lever; see figure below. Electrical System Interface 6. Determine the midpoint of the total endplay resulting from Steps 4 and 5; see figure below. 36

42 Electrical System Interface 7. Install the swivel on the threaded cable assembly so that it is centered at the endplay midpoint position in Step 6; see figure below. 8. Insert the swivel into the shift lever hole. The swivel should not bind in any direction in the shift lever hole. Repeat Steps 4 through 6 if a binding condition is present. 9. Install the attachment pin to the swivel and install jam nut. Once the jam nut is tightened, the swivel should not bind in the shift lever hole; see figure below. Torque jam nut to 8.5 N m (75 lbin), verify no binding exists. If binding occurs, adjust the jam nut or return to Step 4 and repeat. 10. Using the shift selector assembly in the cab, shift the linkage through all positions. Verify that the shift lever on the transmission achieves the proper detent position and that the swivel is free in each position. The shift cable should not be binding in any position. 37

43 Electrical System Interface Note: The wiring between the Transmission Range Sensor and the Vehicle Connector V form part of the Chassis Wiring Harness and are the responsibility of the OEM. Connector V Transmission Range Sensor Electrical System Interface Connector V (TCM mating end) From To Description TE Connectivity TRS V3 TRS2 Signal Output 1 Component Part No. Quantity V9 TRS3 Signal Output 1 Connector Body V18 TRS4 Return Terminal V19 TRS1 Power 38

44 Electrical System Interface Procision Push Button Shift Console The Procision application offers a Push Button Shift Console style driver interface device (Eaton Part Number ). The Push Button Shift Console allows driver input to select Reverse, Neutral, Drive, Low, and Manual modes. The Procision transmission system is designed to operate correctly and safely with Driver Interface Devices that include a confirmation signal on the driver mode request. Eaton Driver Interface Devices for Procision meet this requirement. The Push Button Shift Console module shall be mounted on an interior surface, accessible to the driver. The Push Button Shift Console module will be compatible with either 12 or 24volt systems. The OEM shall install a data link between the Eaton Push Button Shift Console module and the Transmission Control Module (TCM) which complies with SAE J1939/15 unshielded twisted pair cable. Terminating resistors will be provided internally within the system. The OEM shall use Packard 30way and corresponding accessories or equivalent. Wires connecting to the Push Button Shift console circuitry shall be able to withstand 0.1 amps for a 12volt DC system. An 18 AWG TXL cable is required at the TCM 20way connector for sealing purposes. Push Button Shift Control F2 F1 J3 C1 H H2 F1 F2 C J3 B3 Connector V (TCM mating end) Front View Shift Control (30Way Connector) Packard From To Description Connector V9 H2 Mode Indicator (PWM) Terminal V17 C1 Protected Power (Output) Plug V8 J3 Protected Power (Return) V1 F1 PNL CAN C High (Input) V2 F2 PNL CAN C Low (Input) Dash B3 Vehicle Dashboard Illumination Control 39

45 Electrical System Interface Power TakeOff (PTO) The Eaton Procision Transmission is designed to provide an enhanced acknowledgment for PTO applications. Procision TCM will receive a PTO Request from the vehicle to enter into a PTO mode. If the TCM deems that conditions are suitable for PTO operations, the TCM will supply a PTO Engage output to allow the PTO engagement. A confirmation from the PTO returns to the TCM via the PTO Confirm line to complete the loop. The Procision TCM has the functionality to support two PTOs at the same time (one direct wire control and one over the J1939 network or both over the J1939 network). PTO operation requires a single pole double throw switch. Consult PTO manufacturer for power requirements needed for fuses, switches and wires on PTO circuitry. TCM Request and Confirmation circuit lines will provide 1 milliamp of current for both 12volt and 24volt vehicle systems. The TCM Engage circuit load shall draw no more than 0.50 amps with 16 volts applied for a 12 volt vehicle system or 32 volts applied for a 24 volt system. An 18 AWG TXL cable is required at the TCM 20way connector for sealing purposes. The Procision TCM will also support PTO request via SAE J1939 protocol. The diagram shows the inactive state for both options: Electrical System Interface 40

46 Electrical System Interface Inside or on Dashboard PTO w/confirm Switched to Chassis GND VBATT (Fused) SW01 SW03 SW02 SW04 B14 (RTN_2) B15 (PTO REQUEST) DPST B5 (RTN_1) Switches shown in inactive posistion VBATT PTO Engage Relay B2 (PTO ENGAGE) B16 (PTO CONFIRM) 87A L+ L PTO Lamp/LED PTOPower PTOConfirm PTO 01 Contact Customer Support Engineering for additional options PTOGround CHASSIS GROUND PTO with Confirm Switched to Chassis From To Description Notes TCM B14 DPST SW01 PTO Request DPST SW02 TCM B15 PTO Request Vbatt DPST SW03 PTO Power Vbatt should be fused to protect wiring to PTO and PTO. DPST SW04 PTO Engage Relay 30 PTO Engage TCM B5 PTO Engage Relay 86 PTO Engage PTO Engage Relay 85 TCM B2 PTO Engage PTO Engage Relay 87 PTO PTOPower PTO Engage PTO PTOGround Chassis GND PTO Ground PTO PTOConfirm. Vbatt B16 PTO Lamp L() PTO Confirm Splice PTO Lamp L(+) PTO Confirm Vbatt should be fused to protect Lamp circuit. 41