Eaton Transmission APSL0419 User Manual

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Page 1

Dealer Guide

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Unit Exchange Program Guide APSL0419

October 2016

Featuring U.S. and Canadian program instructions for

Fuller® Remanufactured Transmissions

Fuller New and Remanufactured Electronics

Fuller New Exchange Transmissions

Fuller Remanufactured Transmissions (Canada)

Eaton® Clutches

Eaton® Hybrid Power Electronic Carriers (PEC)

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Page 3

NOTE: This publication supercedes all other Parts

Marketing Bulletins relevant to Core & Warranty

Return Information. Including Bulletins: TPMB0101 dated 2-22-01 TPMB0104 dated 7-15-01 and any other “Unit Exchange Program Guide”

published prior to December, 2010. Check with your OEM to see if they have a return

policy that would override the policies in this

publication.

Table of Contents

Introduction

About this Publication .............................................. 4

Ordering Procedures ................................................ 4

Product Modiﬁcation ................................................ 4

Nomenclature

Automated and Manual ............................................ 5

Heavy-Duty Transmission Core Return Procedures

General Policies........................................................ 6

Transmission Core Evaluation/Deductions ............... 6

Unacceptable Cores

Examples ................................................................. 6

Medium-Duty Transmission Core Return Procedures

General Policies........................................................ 7

Transmission Core Evaluation/Deductions ............... 7

Core Return Shipping Weights ................................. 8

Transmission Core Return Shipping Weights/Values

Transmission Core Values by Model ........................ 8

Determining Transmission Core Values by Model

Web Listing .............................................................. 9

Heavy-Duty and Medium-Duty Transmission ECU Core Return Procedures

ECU Core Return Procedures, Parts Description ....10

Core Values .............................................................11

Hybrid Power Electronics Carrier (PEC)

Core Return Procedures ..........................................12

Clutch Core Return Procedures

Core Credit Allowance &

Component Value Breakdown .................................13

Core Return Procedures ..........................................13

Core Return Locations ............................................13

Core Return Identiﬁcation .......................................13

Unit Exchange Designated Core Return Locations

Designated Core Return Locations and

Approved Freight Carriers .......................................14

Warranty Information

TCWY0600, TCWY0900, TMIB0129 ........................15

Page 4

Introduction

In U.S.A:

For Reman™ Transmission and 1-800-826-HELP (4357) New Exchange Transmission

About this publication

This guide is your reference for policies, procedures and core values for transmission and clutch products offered as part of the Roadranger® Unit Exchange Program in effect at the time of publication. Except where otherwise noted, all information contained in this publication applies equally to Fuller® Transmission models and Eaton® Clutch models. Speciﬁc policies and procedures are subject to change without notice at the discretion of Eaton Corporation.

Questions concerning subjects not covered in this publication can be referred to Roadranger Call Center in the U.S. at 1-800-826-4357 and in Canada at 1-888-507-1500. In Mexico, call 001-800-826-4357.

Ordering Procedures

All orders for Roadranger unit exchange products should be placed primarily through your OEM.

“Truck down” orders may be placed directly with Eaton (before 8:00 PM Eastern Standard Time) if inventory is unavailable through your OEM. Distribution centers have been located throughout the United States to expedite your unit delivery.

NOTE: If you place your order by 1 PM EST, your order will be shipped the same day, if unit is available.

1-800-826-HELP (4357)

In Canada (until 7 p.m. EST):

All Transmissions 1-888-507-1500 Clutches 1-416-231-0131

In Mexico: 001-800-826-4357

Please refer to the parts publications shown below for speciﬁc model ordering information:

Product Reference Publication

- Fuller Reman and TRMT0951 Fuller Transmission Exchange

- Fuller Reman Transmissions APSL0011 (for Canada)

- Eaton Clutches CLFD1292

Product Modiﬁcation

Fuller Transmission –

Product modiﬁcations made without express approval by Eaton, other than to install speedometer parts, clutch housing, shift bar housing or an output yoke, may affect warranty coverage – and the facility making the modiﬁcation can be held responsible.

Eaton Clutches-

Product modiﬁcation is not allowed. The complete installation cannot be modiﬁed.

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Nomenclature – Automated

RTL O -16713 A

Eaton T

RT RTF RTO RTOF RTX RTXF

RTLO

Lightning

FR FRF FRO FROF FRLO

Improved Seal System and Involute Spline

New Nomenclature System Components

• Preﬁx – F for Fuller®: All medium-duty and heavy-duty

UltraShift® products in North America and Australia – E for Eaton: All other products (including UltraShift

outside North America and Australia) – Parenthetical letters such as (O) and (M) indicate

provisions for Overdrive, Multi-Torque and other conﬁgurations

• Model Designator – Nominal Torque Capacity (lb/ft for North America and

Australia) – Conﬁguration: alpha designator A,B,C,D…for launch

device and other system components – Design Level: numeric designator describes mechanical

and electronic design levels – Gear Ratio Set: alpha designator (unchanged) – 3-Letter Sufﬁx: denotes application and value

Heavy-Duty Automated Example

RTO — 1091OB — DM3

RT L O M - 10 9 10 A/B/C AS/DM 3

Roadranger Twin Countershaft

Low - Inertia Concept

Overdrive Model

Multi-Torque (100 lbs-ft greater capacity in top four gears)

Automated Generation

AS - AutoShift DM - UltraShift

Gear Ratio Set

Forward Speeds

x 100 = Nominal Torque Capacity

Design Level

Heavy-Duty UltraShift Example

Example: Fuller UltraShift Linehaul Efﬁcient Performance (LEP)

Prefix

F(O)(M) - 16 D 3 13 E - LEP

Brand (E or F)

Overdrive

Multi-torque

Nominal Torque Capacity (lb/ft)

Configuration

SuffixModel

Linehaul Efficient Performance

Application & Value

Ratio Set

Forward Speeds

Design Level

Medium-Duty UltraShift Example

Example: Fuller UltraShift XX (for future use as new products and signiﬁcant upgrades are introduced)

Prefix

F(O) - 6 B 3 06 B - XX

Brand (E or F)

Overdrive

Nominal Torque Capacity (lb/ft)

Configuration

SuffixModel

Future Model Value or Upgrade

Application & Value

Ratio Set

Forward Speeds

Design Level

Hybrid Power System Example

Example: Eaton Hybrid City Delivery (CD)

Nomenclature – Manual

Heavy-Duty Example

Fuller® Model Designation Prefix:

Twin Countershaft Overdrive

Roadranger®Twin Countershaft w/Forward Shift Bar Housing w/Overdrive w/Overdrive and Forward Shift Bar Housing w/Overdrive and Direct Shift Pattern w/Overdrive, Direct Shift Pattern and Forward Shift Bar Housing Low Inertia

Fuller®Roadranger®Twin Countershaft w/Forward Shift Bar Housing w/Overdrive w/Overdrive and Forward Shift Bar Housing

Ratio Set L w/One Additional Low Gear LL w/Two Additional Low Gears

Forward Speeds

Series (Design Level) 2 FR Series 4 FRLO (Lightning) Series 5 Coarse Gearing 6 Multi-Mesh Gearing 7 Helical Auxiliary Gearing and

Multi-Mesh Front Gearing

This (x) 100 = Nominal Torque Capacity

Prefix

E H - 8 E 3 06 A - CD

Brand (E or F)

Hybrid

Nominal Torque Capacity (lb/ft)

Configuration

Medium-Duty Example

F S - 6 4 0 6 A

Fuller

Synchronized

This (x) 100 = Nominal Torque Capacity

SuffixModel

City Delivery

Application & Value

Ratio Set

Forward Speeds

Design Level

Ratio Set

Forward Speeds

Design Level

Page 6

Heavy-Duty Transmission Core Return Procedures

General Policies

All cores should be returned freight collect within 12 months of purchase to the designated Eaton core return location. (See map, page 14.)

Warranty units must be returned to the designated location with completed return documentation. (See page 14 for shipping addresses.)

The value of the transmission cores returned must be equal to or less than the core value of the unit purchased. Customer will receive core value of unit returned. See core groups listed on this page. Cores cannot be “banked” or returned in excess of units purchased.

In summary:

• Only one core can be returned for every one transmission purchased having a core charge.

• The value of the core returned must be equal to or less than the core value (core group) of the transmission purchased.

If possible, return the core with the pallet and/or original container received with the unit, and properly secure the core to the pallet. Damage in shipment due to negligence in packaging will be the responsibility of the dealer.

When returning a non-warranty core, use the OEMs core consolidator or ship the core 3rd Party Eaton to the designated Eaton core return location.

Transmission Core Evaluation

1. Determine the core model. Transmission cores with mis- matched front and auxiliary sections assume the core value of the lesser model.

2. Verify that the core is complete. Warranty cores do not need to be assembled. Required items include; main case and range section, shift bar housing, and all internal components.

3. Remove and retain other external equipment and accessories.

4. See page 9 for instructions on how to locate eligible models online.

5. All transmissions with a core value are assigned to groups based upon the core value of the units.

6. Lightning core credit will only be issued against a corresponding Lightning transmission purchase or an Eaton approved Lightning transmission conversion.

Core Groups

300 1000 1500 2200 3000 4000 With each purchase of a transmission, core eligibility will be

applied against a speciﬁc core group of equal value to the core charged.

When the OEM/dealer returns a core, eligibility will be checked against the core group for the value of the core returned. If eligibility exists within that group, core credit will be applied equal to the core value of the unit returned, minus any deductions. If the OEM does not have eligibility within the core group, the core will be returned, freight collect, scrapped or offer to purchase (if preauthorized).

Transmission Core Deductions

- Failure to completely drain $100

- Failure to use approved freight carriers $100 for returned core

Page 7

Medium-Duty Transmission Core Return Procedures

General Policies

All cores should be returned freight collect within 12 months of purchase to the designated Eaton core return location. (See map, page 13.)

Warranty units must be returned to the designated location with completed return documentation. (See page 13 for shipping addresses.)

In summary:

• Only one core can be returned for every one transmission purchased having a core charge.

• The value of the core returned must be equal to or less than the core value (core group) of the transmission purchased of the transmission purchased.

When returning a non-warranty core, use the OEMs core consolidator or ship the core collect to the designated Eaton core return location using an Eaton approved freight carrier identiﬁed within the purchased unit’s core return packet. Use of any freight carrier other than those approved will result in $100 being deducted from core credit.

The following instructions are necessary to conduct proper evaluation of cores. Steam cleaning, which is recommended by Eaton prior to returning the core, should precede the evaluation to allow a more thorough and accurate inspection.

Transmission Core Evaluation

1. Determine the core model.

2. Make a thorough external inspection for visible cracks. Look closely at highly stressed areas around capscrew holes, rear transmission support studs, etc.

3. Verify that the core is complete. Warranty cores do not need to be assembled. Required items include; main case section, shift bar housing, and all internal components.

4. Remove and retain other external equipment and accessories.

5. See page 9 for instructions on how to locate eligible models online.

6. All transmissions with a core value are assigned to groups based upon the core value of the units.

7. Heavy Duty cores will not be accepted for Medium-Duty core eligibility.

Core Groups

600 800 1000 1750 With each purchase of a transmission, core eligibility will be

applied against a speciﬁc core group of equal value to the core charged.

The OEM will have 12 months to return a core against credit in any core group.

Manual transmissions received without the original serial tag will be placed in core groups based upon the part number of the output shaft.

Output Shaft Part Number Core Group

4301468 600 4304549 800

Transmission Core Deductions

- Failure to completely drain $100

- Failure to use approved freight carriers $100

Page 8

Transmission Core Return Shipping Weights

HEAVY-DUTY MECHANICAL AND APPROX. CORE SEMI-AUTOMATED MODELS/SERIES WEIGHT (LBS.)

RT-6609, 8609 480 FRLO-14410C-T2, 15410C-T2, 16410C-T2 630 RT-6613 655 T-14607, RT-8709, 8608L, 11609B/P/R, 685

12609B/P/R, 12709, 13609A, 13609B, 14709H RT-13709 690 FR-9210, 12210, 13210, 14210 695 RT-7608LL 700 FR-15210, 16210, 17210, 18210, RTO-16210C, RT-9710 705 RT-12710, RT-14609B, RT-14709 710 RT-16709B,H, RTOC-16709A 720 RTLO-13610B/T2, 11610B-T2, 12610B/T2 725 RT-6610, RTLO-14610/T2, 15610B-T2, 16610B/T2, 730

17610B-T2, 18610B-T2 RTLO-15710, 16710 735 RTLO-14613B 765 RT-11709MLL, 11909MLL, 14709MLL, 14909A/MLL, 775

16909ALL RT-13710, RTL-13710B 785 RTLO-14710, RTL-14710B/T2, RT-8908LL, 11908LL, 790

14908LL, 16908LL, 16909A/T2 RT-14715, 14915, 15715, 16915, 14708LL 800 RT-14615, 15615 805 RTLO-12713A, 14713A/T2, 12913A, 14913A 815 RTLO-16713A/T2, 16913A, 18913A/T2, 20913A, 820

RTLO-14618A, 14718B/T2, 16718/T2, 18718B/T2, 14918B, 16918B, 18918B, 20918B, 22918B

RTLO-16618A, RTLC-16609E, 11708LL 850

HEAVY-DUTY APPROX. CORE AUTOMATED MODELS WEIGHT (LBS.)

FO-14E308LL-VCS, 16E308LL-VCS, 950 17E308-LL-VCS

FO-14E309ALL-VMS, 16E309ALL-VMS, 950 17E309ALL-VMS

FO-14E318B-VXP, 16E318B-VXP, 950 18E318B-VXP, 20E318B-VXP

FO-14E313A-MHP, 16E313A-MHP, 950 18E313A-MHP, 20E313A-MHP

FO-14E318B-MXP, 16E318B-MXP, 950 18E318B-MXP, 20E318B-MXP, 22E318B-MXP

FO-14E310C-LAS, 16E310C-LAS 950 FOM-14E310C-LAS, 15E310C-LAS, 950

16E310C-LAS FM-14E310B-LAS, 15E310B-LAS 950

MEDIUM-DUTY MANUAL AND APPROX. CORE AUTOMATED MODELS WEIGHT (LBS.)

FS-5306, FS-5406, FS-6306, FS-6406 345 FSO-8406 356 F-6406N-ASW, F-6406N-AW3, FO-6406A-ASW, 602

FO-6406A-AW3, FO-8406A-ASW, FO-8406A-AW3

HEAVY-DUTY FULLY AUTOMATED APPROX. CORE MODELS/SERIES (WITH ELECTRONICS) WEIGHT (LBS.)

F-5405B-DM3, 6405B-DM3 528 FM-14D310B-LST, 15D310B-LST 892 FO-16D313E-LEP 955 FOM-16D313E-LEP 955 RTO-10910B-AS3, 12910B-AS3 821 RTO-14910B/C-AS3 873 RTO-16910B/C-AS3, 18910B-AS3 874 RTO-10910B-DM3, 12910B-DM3 885 RTO-14910B-DM3, 16910B-DM3 892 RTOM-16910B-DM3 892 RTLO-16913L-DM3 955 RTLO-1418A-AS3, 16918A-AS3, 18918A-AS3, 969 20918A-AS3, 22918A-AS3 RTLOM-16913L-DM3 955

* Notes:

1) Subtract 20 pounds for units shipped without electronics.

2) Add 20 additional pounds to DM models with inertia brake.

Page 9

Determining Transmission Core Values by Model

Only models listed on the website are acceptable for return. As models are added to the program, new core values will also be established and posted on the website: http://www.roadranger.com/rr/Aftermarket/PriceLists/index.htm

Steps:

1. Go to the website

2. Enter the transmission model number with % signs on both sides of the model number as shown below

3. Highlight the radial button on “Part Description” as shown below

4. Click on the “Submit” button.

5. In the illustration below, all FRO-16210C cores have a $2,200 core value before any deductions. The result’s page will show the “core value” in the far right hand column. If the search shows no results, the core you are

returning either a) has no core value; b) the model number was entered incorrectly.

Page 10

Transmission Electronic Core Return Procedures (Heavy- and Medium-Duty)

For dealers using core consolidators, please see your OEM’s guidelines for returning cores. For warranty return parts, please see your OEM’s guidelines for returning cores.

1. All component returns are like-for-like and one-for-one as electronic components are not interchangeable between other components.

2. Cores returned within twelve (12) months of purchase receive full core credit minus any deductions. Cores returned after twelve (12) months receive no credit.

3. Refer to the list below for deductions value. Disassembling the core is not necessary to determine core value and may result in loss of core value.

4. Except as noted above, cores must be returned per the instructions in the electronic core packet provided with the replacement part. Note the return location for electronics is different than transmission units.

Parts Description:

Gen 1, Gen 2 Controller – $250 Core Value

Gen 3 Controller – $250 Core Value

Electronic Parts Warranty:

One year unlimited mileage from date of retail sale on new, Reman and exchange electronics.

Electronic Parts Core Value and Deductions:

NOTE: All core values in USD, core value for electronics purchased in Canada will carry the currency exchange rate.

Core Value $250 Core Value – All Transmission Mounted ECUs $100 Core Value – Pushbutton System Manager $325 Core Value – Transmission ECAs Core Deductions 100% Deduction – Cracked or Broken Connectors Cracked or Broken Housings Lever Broken or Cracked

Send Electronic Cores to: (except as noted previously)

Returning warranty cores to Mechanicsburg, PA address will result in non-payment of a warranty claim.

In the U.S. return core to:

Eaton Corporation C/O Flight Systems 1225 S. Market St., Ste. 23 Mechanicsburg, PA 17055

In Canada return core to:

Eaton Truck Components Core Return Center 2160 Williams Parkway Brampton, ON Canada L6S 5X7

Freight Carrier: Purolator Terms: Collect

Lightning® ECU – $250 Core Value

System Manager – $100 Core Value

For all transmission electronics purchased directly from one of the Eaton locations in Canada, you must provide a copy of the packing slip with the core return.

DESCRIPTION WEIGHT (LBS.)

Gen 1 & Gen 2 Controller/Gen 3 9.5 Lightning ECU 5 System Manager 1.2 Push Button Controls 1 ECA 18

All Pushbutton Controls – $100 Core Value

Gen 1 ECA – $325 Core Value

Gen 2 ECA – $325 Core Value

Page 11

Electronic Item Numbers Eligible for Core Return:

PART NO. DESCRIPTION

B-1000122501RX REMAN EXCHANGE, SYS MGR ASSY B-3000423700RX REMAN EXCHANGE, SYS MGR ASSY K-2609RX REMAN EXCHANGE TRANSMISSION CONTROLLER KIT K-2856RX REMAN EXCHANGE TRANSMISSION CONTROLLER KIT K-3284RX REMAN EXCHANGE TRANSMISSION CONTROLLER KIT K-3353RX REMAN EXCHANGE TRANSMISSION CONTROLLER KIT K-3435RX REMAN EXCHANGE TRANSMISSION CONTROLLER KIT K-3439RX REMAN EXCHANGE TRANSMISSION CONTROLLER KIT K-3449RX REMAN EXCHANGE TRANSMISSION CONTROLLER KIT K-3505RX REMAN EXCHANGE TRANSMISSION CONTROLLER KIT K-3707RX KIT, REMAN EXCH TRANS CONTROLLER K-3708RX KIT, REMAN EXCH TRANS CONTROLLER K-3709RX KIT, REMAN EXCHANGE TRANSMISSION CONTROLLER K-3710RX KIT, REMAN EXCHANGE TRANSMISSION CONTROLLER K-3711RX KIT, REMAN EXCHANGE TRANSMISSION CONTROLLER K-3712RX KIT, REMAN EXCHANGE TRANSMISSION CONTROLLER K-3713RX KIT, REMAN EXCH TRANS CONTROLLER K-3714RX KIT, REMAN EXCH TRANS CONTROLLER K-3715RX KIT, REMAN EXCH TRANS CONTROLLER K-3716RX KIT, REMAN EXCH TRANS CONTROLLER K-3717RX KIT, REMAN EXCH TRANS CONTROLLER K-3736RX KIT, REMAN EXCH TRANS CONTROLLER K-3737RX KIT, REMAN EXCH TRANS CONTROLLER K-3766RX KIT, REMAN EXCH TRANS CONTROLLER K-3787 HYBRID CONTROLLER KIT (P/D) K-3787RX HYBRID CONTROLLER KIT (CD), REMAN / EXCHANGE K-3788 HYBRID CONTROLLER KIT (U) K-3788RX HYBRID CONTROLLER KIT (U/P), REMAN / EXCHANGE K-3789 HYBRID CONTROLLER KIT (UP) K-3789RX HYBRID CONTROLLER KIT (UP), REMAN / EXCHANGE K-3790 HYBRID CONTROLLER KIT (UPG) K-3790RX HYBRID CONTROLLER KIT (UPG), REMAN / EXCHANGE K-3797 TRANSMISSION CONTROLLER KIT (CD) K-3797RX TRANSMISSION CONTROLLER KIT (CD),

REMAN / EXCHANGE K-3798RX TRANSMISSION CONTROLLER KIT (U),

REMAN / EXCHANGE K-3799 TRANSMISSION CONTROLLER KIT (UP) K-3799RX TRANSMISSION CONTROLLER KIT (UP),

EMAN / EXCHANGE K-3800 TRANSMISSION CONTROLLER KIT (UPG) K-3800RX TRANSMISSION CONTROLLER KIT (UPG),

REMAN / EXCHANGE K-3911 KIT, TRANSMISSION, CONTROLLER K-3912 KIT, TRANSMISSION, CONTROLLER K-3930 KIT, ECU ASSEMBLY (VCS) K-3931 KIT, ECU ASSEMBLY (VMS) K-3932 KIT, ECU ASSEMBLY (VXP) K-3933 KIT, ECU ASSEMBLY (MXP) K-3934 KIT, ECU ASSEMBLY (MHP)

PART NO. DESCRIPTION

K-3948 KIT, TRANSMISSION CONTROLLER K-3986 HYBRID CONTROLLER KIT (T) K-3986RX HYBRID CONTROLLER KIT (T), REMAN / EXCHANGE K-3995 KIT, ECU ASSEMBLY (LAS) OD “C” K-3996 KIT, ECU ASSEMBLY (LAS) DIRECT “B” K-4019 KIT, TRANSMISSION CONTROLLER (CDG) K-4019RX TRANSMISSION CONTROLLER KIT (CDG),

REMAN / EXCHANGE K-4020 KIT, TRANSMISSION CONTROLLER (CDR) K-4020RX TRANSMISSION CONTROLLER KIT (CDR),

REMAN / EXCHANGE K-4021 KIT, TRANSMISSION CONTROLLER (EH-6E606B-P/CD) K-4021RX TRANSMISSION CONTROLLER KIT (EH-6E606B-P/CD),

REMAN / EXCHANGE K-4032 KIT, HYBRID CONTROLLER (CDG) K-4032RX HYBRID CONTROLLER KIT (CDG), REMAN / EXCHANGE K-4033 KIT, HYBRID CONTROLLER (CDR) K-4033RX HYBRID CONTROLLER KIT (CDR), REMAN / EXCHANGE K-4034 KIT, HYBRID CONTROLLER (LOW PROFILE-P) K-4034RX HYBRID CONTROLLER KIT (LOW PROFILE-P),

REMAN / EXCHANGE K-4039 KIT, HYBRID CONTROLLER (LOW PROFILE-CD) K-4039RX HYBRID CONTROLLER KIT (LOW PROFILE-CD),

REMAN / EXCHANGE K-4043 KIT, RELAY BOX / BATTERY CONTROLLER K-4043RX RELAY BOX / BATTERY CONTROLLER,

REMAN / EXCHANGE K-4065 KIT, INVERTER (EHS) K-4065RX INVERTER (EHS), REMAN / EXCHANGE K-4138 KIT, ECU ASSY (VAS) K-4139 KIT, ECU ASSY (VHP) K-4194RX KIT, REMAN EXCH TRANS CONTROLLER K-4195RX KIT, REMAN EXCH TRANS CONTROLLER K-4196RX KIT, REMAN EXCH TRANS CONTROLLER K-4197RX KIT, REMAN EXCH TRANS CONTROLLER K-4198RX KIT, REMAN EXCH TRANS CONTROLLER K-4199RX KIT, REMAN EXCH TRANS CONTROLLER K-4200RX KIT, REMAN EXCH TRANS CONTROLLER K-4210 KIT, ECU ASSEMBLY (LSE) K-4215 KIT, ECU ASSEMBLY K-4225 KIT, ECU ASSEMBLY K-4241 KIT, ECU ASSEMBLY K-4252 Gen 2 ECA KIT K-4253 Gen 2 ECA KIT K-4254 Gen 2 ECA KIT S-2818RX REMAN EXCHANGE, LIGHTNING ECU ASSY S-2973RX REMAN EXCHANGE, LIGHTNING ECU ASSY S-2989RX PUSHBUTTON ASSEMBLY, REMAN S-2990RX PUSHBUTTON ASSEMBLY, REMAN S-2991RX PUSHBUTTON ASSEMBLY, REMAN S-3005RX PUSHBUTTON ASSEMBLY, REMAN

Page 12

Hybrid Power Electronics Carrier (PEC) Medium-Duty

1. Return all PEC cores directly back to Eaton. Do not use your OEM core consolidator to return PEC cores.

2. All component returns are like-for-like and one-for-one as electronic components are not interchangeable between other components.

3. Cores returned within 90 days of purchase receive full core credit minus any deductions. Cores returned after 90 days receive no credit.

4. Refer to the list below for deductions value. Disassembling the core is not necessary to determine core value and may result in loss of core value.

5. Cores must be returned per the instructions in the PEC core packet provided with the replacement part. Note the return location for PEC is different than transmission units.

6. PEC contains high voltage energy. Use caution and proper protective equipment at all times. Only authorized personnel should handle/work on PECs. Refer to service manuals (TRSM1000 and TRSM2000) for safety alerts and procedures.

7. PEC contains hazardous material; all shipments must comply with 49CFR DOT regulations.

PEC Parts Warranty:

One year unlimited mileage from date of retail sale on Reman and exchange PECs.

Send PEC Cores to:

In the U.S.:

Eaton PEC Core Return EFLN# 002059 50 NE 42nd Street Oklahoma City, OK 73105 (Third party, use Old Dominion)

In Canada:

Eaton PEC Core Return EFLN# 2121A 2160 Williams Parkway Brampton, ON L6S 5X7 Canada Freight Terms: Collect

For all PECs purchased directly from one of the Eaton locations in Canada, you must provide a copy of the packing slip with the core return.

PEC Core Freight Return:

Return all U.S. cores using the prepaid return label included in the core return packet. PEC contains hazardous material; all shipments must comply with per 49CFR DOT regulations.

PEC Parts Core Value and Deductions:

NOTE: All core values in USD, core value for PEC purchased in Canada will carry the currency exchange rate.

CORE VALUE $6500

$200 each Deduction Cracked or Broken Connector $300 Deduction Dented/Cracked/Broken Housing $300 Deduction Painted Housing $500 Deduction Not Shipped in Crate/Original Container

Received with Unit $500 Deduction Failure to use Approved Freight Carrier 75% Reduction PEC Opened/Disassembled $100 Deduction Green Tag Not Filled out or Attached to

Core

WEIGHT PART NUMBER DESCRIPTION (LBS./KG)

2 Battery K-4041, K-4041R, K-4127 (A-8103) PEC Assembly Kit 342/155

K-4042, K4042R, K-4128 (A/8104) PEC Assembly Kit 342/155 K-4053R Reman MY08 PEC (UPG) 342/155 K-4116, K-4116R, K-4132 (A-8254) PEC Assembly Kit 342/155 K-4117, K-4117R, K-4133 (A-8257) PEC Assembly Kit 342/155

4 Battery K-4136 (A-8149) PEC Assembly Kit 507/230

PEC battery assembly

Page 13

Clutch Core Return Procedures

New Clutches

Eaton does not accept any cores against new purchases. Any cores received ahead of reman purchases will be held for 30 days. If reman purchases are made within the 30 days, credit will be issued against the reman purchase. After 30 days, cores ahead of reman purchases that have not been used, will become the property of Eaton Corporation and no credit will be given.

Reman Clutches

Eaton will credit dealers the following amounts through the O.E.M. for reman core credit:

$50 for Cast Solo Advantage 15.5”; $60 for 14” Cast EasyPedal™ or Stamped Angle Spring®; $100 for 15.5” Cast Easy Pedal Advantage; $60 for 15.5” DM; $50 for 14” Solo.

Note: Eaton no longer accepts any old style Cast Angle Spring cores.

Eaton will issue credit providing the following conditions are met:

1. Cast Easy-Pedal, Cast Solo or Stamped Angle Spring clutches remanufactured by Eaton have been purchased.

2. 14” and 15.5”clutch core credits will be issued in equal quantities up to and not to exceed the quantity purchased.

3. Size and type of clutch cores must match the size and type of clutches that were ordered. For example, a 15.5” Easy Pedal can oly be returned for a 15.5” Easy-Pedal.

4. Core returns must be approved by one of our core return centers, and they must be Eaton’s Stamped Angle Spring, Easy-Pedal, Solo, or DM. Other products are not acceptable.

5. Cores must be returned within 360 days of the original remanufactured clutch purchase. Cores submitted in excess of purchases will be held 30 days for credit against future purchases, after 30 days, cores will become the property of Eaton Corporation and no credit will be issued.

6. Credit will be issued strictly on our acceptance. We reserve the right to refuse any cores that are not in reusable condition. Disposition of material is to be indicated on the core return form. If material is requested back, we will return it freight collect to your location.

Complete assembly is required for 100% credit. No partial credits will be issued.

The Following Will Constitute No Credit Being Allowed:

1. Not Eaton/Fuller

2. Disassembled

3. Welded

4. Broken/Cracked

5. Old Style Cast Angle Spring 14”, 15.5” or 14” and 15” ValueClutches™, or Solo 14”

6. Customer Modiﬁed Core

7. Excessive Rust

Core Return Procedures

Cores may be returned by third party billing (Eaton), within the Continental U.S. only, on shipments of eight quantities or more. All clutch core shipments under the eight quantities must be shipped freight prepaid. The shipping documents should be marked:

“CORES - CORE ITEM NO. 17850, USED AUTO PARTS, VALUE FOR RECONDITIONING ONLY, AT CLASS 60”

Use core return form supplied by Eaton. A packing list should also be sent listing the cores being returned, along with customer’s address and telephone number.

Third party billing shipments must be shipped via Eaton approved carriers.

Core Return Location:

U.S. Alotech, Inc. 751 S. Church St., Suite B Goldston, NC 27252 Phone: (919) 774-1297

In Canada, contact OE core consolidator or call 416-213-0131.

Eaton Clutch Core Return Identiﬁcation

The number of visible cover assembly springs indicates which cores Eaton will accept.

• 9-Spring Easy-Pedal Style Cores Accepted

• 6-Spring Cast Angle Spring Style Cores NOT Accepted

• Solo Cores Accepted

• DM Cores Accepted

DM Clutch

Figure 4: Excessive Rust

Non Accepted Style

Cast angle spring clutches have 6-springs visible on the back of the cover assembly.

Accepted Style

Easy-Pedal clutches have 9-springs visible on the back of the cover assembly.

Solo Clutch

Solo clutches have a visible wearindicator tab.

Page 14

Unit Exchange Designated Core Re turn Locations*

*Non-warranty returns only. See note on page 15 for warranty returns.

Instructions: Please return core to the collection facility designated for your area. Use only freight carriers listed by area for the return of cores. Use of an unauthorized freight carrier will result in a $100 deduction on core credit. See page 8 for

correct shipping weight. Please note that information provided below is not intended to replace existing core return procedures already available from your OEM. If more information is needed call 1-800-826-4357. In Canada, call 416-213-0131.

Canadian Western Shipments

Includes all shipments originating west of, but not including,

Brandon, Manitoba.

Ship to:

Eaton Truck Components 124-10725 25th St NE Calgary, AB Canada T3N 0A4

Approved freight carriers:

Manitoba (west of Brandon) -

Canadian Freightways

Alberta, British Columbia and Saskatchewan - Canadian

Freightways

Canadian Eastern Shipments

Includes all shipments east of, and including Brandon, Manitoba.

Ship to:

Eaton Truck Components 1455 Michael St. Unit ‘1’ Ottawa, Ontario Canada K1B 3R3

Approved freight carriers: Northern Ontario - Manitoulin Transport Southern Ontario - EPIC Express

Quebec - Cabano Maritime Provinces - Day &

Ross Manitoba (east of Brandon) - Canadian Freightways

All U.S. PEC Core Returns

Eaton PEC Core EFLN# 002059 50 NE 42nd Street Oklahoma City, OK 73105 (Third party, use Old Dominion)

All Canadian PEC Core Returns

Eaton PEC Core EFLN# 2121A 2160 Williams Parkway Brampton, ON L6S 5X7 Canada

All U.S. Transmission Core Returns (Non-Warranty Returns Only)

Ship to:

ATC Drivetrain 5201 SW 36th Street Oklahoma City, OK 73179

Electronic Core Returns

In U.S. ship to:

Eaton Corporation c/o Flight Systems 1225 S. Market St., Ste. 23 Mechanicsburg, PA 17055

In Canada ship to:

Eaton Truck Components Core Return Center 2160 Williams Parkway Brampton, ON Canada L6S 5X7

Freight Carrier: Purolator Terms: Collect

All U.S. Clutch Core Returns

Ship to:

Alotech, Inc. 751 S. Church St., Suite B Goldston, NC 27252

Canadian Clutch Core Returns

See your OE core consolidator or call 416-213-0131.

To select proper US-only freight carrier to return transmission, go to

www.eatonroute.com

Instructions:

1. Enter www.eatonroute.com

2. Click “Access Eaton Route Guide Here”

3. Enter shipping information (origin address)

4. Click “3PP Only” box

5. Enter “002070” in “Ship to” information location box and click on the binoculars.

6. Enter weight (must be less than 12,000 lbs.)

7. Click “Get Route”

Page 15

Warranty Information

Knowing and understanding Roadranger warranty is the responsibility of the vehicle owner. It is also the responsibility of the selling dealer to identify the Roadranger products in the vehicle and inform the purchaser of the warranty for those products, based on the vehicle vocation, at the time of sale.

The combined use of the Roadranger Warranty Manual TCWY0600 and the Roadranger Warranty Guide TCWY0900 expresses Eaton component time and mileage warranty coverage for the Roadranger system products.

TCWY0600, Roadranger Warranty Manual

Note: Printed copies of this document are not controlled.

Please refer to the electronic copy on Roadranger.com for the most up-to-date information.

The Roadranger Warranty Manual TCWY0600 documents the speciﬁcs of Roadranger product warranty. This manual includes:

• Product Warranty Statements for the Eaton Truck Group

• Warranty terminology

• Warranty programs

• Claim procedures and claim information

• Important information regarding claim approval

• Component repair or replacement guidelines

• Labor hour guidelines (SRT’s)

• Limits, exclusions, and requirements

• Other important resources

TCWY0900, Roadranger Warranty Guide

Roadranger component warranty is identiﬁed using the Roadranger Warranty Guide TCWY0900. The Warranty Guide explains Roadranger vocation deﬁnitions, component time and mileage limits per vocation, aftermarket component / part warranties, and extended purchase warranty options. You can access this guide on www.eaton.com/roadranger.

How do I deﬁne my vocation coverage?

1. Review all the “Vocational Deﬁnitions” listed and select the one that most accurately describes the use and conﬁguration of the vehicle.

2. Ensure your vehicle vocation is listed in the “Typical Vehicle Types” under the selected Vocational Deﬁnition.

3. Once the vocation is deﬁned refer to the “Product Time and Mileage Coverage per Vocation” section.

4. Identify the component in question using the product model number for the time and mileage coverage.

5. Refer to and understand any notes that pertain to a speciﬁc coverage (i.e. lube requirements).

6. If you cannot determine coverage, contact your Roadranger Representative or call the Roadranger Call Center at the time of sale at 1-800-826-HELP (4357).

TMIB0129, Warranty Part Return

Service bulletin TMIB0129 contains shipping (routing) instructions for warranty part and unit returns. Available on www.eaton.com/roadranger.

Page 16

Unit Exchange Program Guide

SUPPORT

BACKED BY

For spec’ing or service assistance, call 1-800-826-HELP (4357) or visit www.eaton.com/roadranger. In Mexico, call 001-800-826-4357.

Roadranger: Eaton and trusted partners providing the best products and services in the industry, ensuring more time on the road.

Eaton

Vehicle Group 13100 E. Michigan Ave. Galesburg, MI 49053 USA 800-826-HELP (4357) www.eaton.com/roadranger

Note: Features and specifications listed in this document are subject to change without notice and represent the maximum capabilities of the software and products with all options installed. Although every attempt has been made to ensure the accuracy of information contained within, Eaton makes no representation about the completeness, correctness or accuracy and assumes no responsibility for any errors or omissions. Features and functionality may vary depending on selected options.

Eaton, Fuller, Roadranger, Solo and UltraShift are registered trademarks of Eaton. All trademarks, logos and copyrights are those of their respective owners.

Eaton Transmission APSL0419 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual