Driver Instructions
Contents
1. Lubrication Fuller Transmissions are designed so that the internal parts operate in an oil circulating bath created by the motion of the gears and shafts All parts will be properly lubricated if these procedures are closely followed e Maintain oil level Inspect regularly e Follow maintenance interval chart e Usethe correct grade and type of oil e Buy from a reputable dealer For additional lubrication information see TCMT0021 Maintain Proper Oil Level Make sure oil is level with the filler opening Being able to reach oil with your finger does not mean oil is at proper level One inch of oil level is about one gallon of oil When adding oil never mix engine oils and gear oils in the same transmis sion Oil Level Proper Oil Level Improper Oil Level Hole Hole gt Service and Maintenance Oil Filter HIGHWAY USE For transmissions equipped with oil filter Inspect filter for leaks or P N 4304827 damage replace as necessary OFF HIGHWAY USE For transmissions equipped with oil filter Change filter every two years P N 4304827 If your vehicle has a transmission oil filter you must change the filter when fluid or lubricant is changed The use of lubricants not meeting these requirements will affect warranty coverage Additives and friction modifiers must not be introduced Never mix engine oils amp gear oils in the same transmission For a list of Eaton Approved Sy2. Ratio Step Amount of change between two gear ratios expressed as a percentage Example The ratio step from 1st gear to 2nd gear is 3596 Shift Button The button on the side of the shift knob used to change gears Synchronous The point at which the input gearing speed engine speed matches the output gearing speed road speed and a shift can occur without grinding 22 Copyright Eaton Corporation 2012 Eaton hereby grant their customers vendors or distributors permission to freely copy reproduce and or distribute this document in printed format It may be copied only in its entirety without any changes or modifications THIS INFORMATION IS NOT INTENDED FOR SALE OR RESALE AND THIS NOTICE MUST REMAIN ON ALL COPIES 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 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
3. and services in the industry ensuring more time on the road Eaton Corporation Vehicle Group PO Box 4013 Kalamazoo MI 49003 USA 800 826 HELP 4357 www eaton com roadranger Printed in USA E TeN Roadranger Powering Business Worldwide SUPPORT
4. Driver Instructions Video Instruction Available Instructional videos are available for download at no charge at roadranger com Videos are also available for purchase To order call 1 888 386 4636 Ask for item RRSDOO02 Fuller Heavy Duty Transmissions TRDRO630 December 2010 E T N Powering Business Worldwide BACKED BY Roadranger SUPPORT General Information Warnings and Cautions A WARNING Read the entire driver instructions before operating this transmission Set the parking brakes before starting a vehicle always be seated in the driver s seat move the shift lever to neutral and depress the master clutch If the engine cranks in any gear other than neutral or without the master clutch depressed service your vehicle neutral safety start circuit immediately Before working on a vehicle or when leaving the cab with the engine running place the transmission in neutral set the parking brakes and block the wheels Do not release the parking brake or attempt to select a gear until the air pres sure is at the correct level When parking the vehicle or leaving the cab always place the shift lever in neutral and set the parking brakes If your vehicle is equipped with a remote throttle before operation the trans mission must be in neutral TOWING To avoid damage to the transmission during towing disconnect the driveline Table of Contents General Information How to Use This Manual reson
5. TH SPLITTER SELECTOR IN 0D PRE SELECT RANGE SHIFTS MOVE RANGE SELECTOR BEFORE MOVING SHIFT LEVER UPSHIFTING Neutral START WITH RANGE SELECTOR DOWN SHIT 0 12 54 RAISE RANGE SELECTOR DOWNSHIFTING j MOVE RANGE SELECTOR DOWN DO NOT CHANGE RANGE WHILE MOVING IN REVERSE PUT TRANSMISSION IN NEUTRAL WARNING RTOO amp RTOOF Eaton Fuller Roadranger 13 SPEED p RANGE Transmissions DEEP REDUCTION SELECTOR DO NOT RANGE SHIFT WITH SPLITTER SELECTOR IN OD PRE SELECT ALL RANGE SHIFTS A MOVE RANGE SELECTOR BEFORE MOVING SHIFT LEVER UPSHIFTING START WITH RANGE SELECTOR DOWN 2 15 RAISE RANGE SELECTOR G MOVE RANGE SELECTOR DOWN DONOT CHANGE RANGE WHILE MOVING IN REVERSE PUT TRANSMISSION IN NEUTRAL WARNING Shift Controls Range Valve A 3546 with Two Position Selector Valve A 4491 4494 Up for HI Range Rearward for Direct Splitter Control Range Lever Button Down for LO Range Forward for Overdrive Roadranger Valve A 4900 Rearward for Direct Up for HI Range Splitter Control Button Range Lever Forward for Overdrive Down for LO Range Transmission Features Range Shift The range lever selects LO or HI range It is used once during an upshift sequence and once during a downshift Preselect A IMPORTANT Always preselect all range shifts when upshifting or downshifting Preselec tion requires that the range lever is moved to t
6. ailable to reduce operating temperatures when the above conditions are encountered Service and Maintenance Oil Cooler Chart Transmission Oil Coolers are Recommended With engines of 350 and above Required With engines 399 and above and GCW s over 90 000 Ibs With engines 399 and above and 1400 lbs ft or greater torque With engines 450 and above Service and Maintenance Preventive Maintenance Note Item numbers refer to the illustration 1 Air System and Connections e Check for leaks worn air lines loose connections and cap screws 2 Clutch Housing Mounting e Check all capscrews of the clutch housing flange for looseness 3 Clutch Release Bearing Not Shown e Remove hand hole cover and check radial and axial clearance in release bearing e Check relative positive of thrust surface of release bearing with thrust sleeve on push type clutches 4 Clutch Pedal Shaft and Bores e Pry upward on shafts to check wear e fexcessive movement is found remove clutch release mecha nism and check bushing on bores and wear on shafts 20 Service and Maintenance 21 5 Lubricant e Change at specified service intervals e Use only the types and grades recommended Filler and Drain Plugs e Remove filler plugs and check level of lubricant at specified intervals Tighten filler and drain plugs securely Capscrews
7. and Gaskets e Check all capscrews especially those on P T O covers and rear bearing covers for looseness which would cause oil leakage e Check P T O opening and rear bearing covers for oil leakage due to faulty gasket Shift Lever e Check for looseness and free play in housing If lever is loose in housing proceed with check number 9 Shift Lever Housing Assembly e Remove air lines at slave valve and remove the shift lever hous ing assembly from transmission e Check tension spring and washer for set and wear e Check the shift lever spade pin and slot for wear e Check bottom end of shift lever for wear and check slot yokes and blocks in shift bar housing for wear at contact points with shift lever Reference Definitions Glossary of Terms for Transmission Operation The following terms are used in describing the transmission operating proce dures Break Torque Releasing engine power or load from the transmission and drivetrain by releasing throttle or depressing clutch pedal Double Clutch The shifting technique used when moving the shift lever to the next lever position Procedures Depress clutch pedal move lever to neutral let up clutch pedal acceler ate or decelerate engine to obtain synchronous depress clutch pedal again and move lever into gear Preselect Moving the shift button just prior to starting the shift The shift button should not be moved while the shift lever is in neutral
8. clutch with the gear shift lever in the neutral position the operator is able to control the RPM of the mainshaft gears since they are regulated by engine RPM This procedure enables the operator to match the RPM of the mainshaft gears with those of the mainshaft driven by the vehicle s rear wheels Initial Start Up Special Instructions A WARNING Before starting a vehicle always be seated in the driver s seat move the shift lever to neutral and set the parking brakes A CAUTION Before moving a vehicle make sure you understand your shift pattern config uration A shift label should be in your vehicle s cab If not refer to General Information to order one Procedure 1 Make sure the shift lever is in neutral and the parking brakes are set 2 Turn on the key switch start the engine 3 Allow the vehicle air pressure to build to the correct level Refer to your Operator and Service Manual supplied with the truck 4 Apply the service brakes 5 Make sure the range lever is down in the LO range position and the splitter control button is rearward Range Lever MUST be SM down in the LO Range position for LO And Splitter Control Range Button Rearward in Direct Depress the clutch pedal to the floor Move the shift lever into desired initial gear Release the parking brakes on the vehicle Slowly release the clutch pedal and apply accelerator OND Upshifting In the following instructio
9. he needed position before start ing the shift Preselected range shifts are completed automatically as the lever is moved through neutral and into the next gear Preselecting all range shifts prevents damage to the transmission and provides for smoother shifts Splitter Shift The splitter control button selects HI range direct or HI range overdrive It is used in each HI range speed ratio Optional Equipment For easier and faster gear engagement while the vehicle is standing still some Fuller transmissions may be equipped with either a Countershaft Brake or a Clutch Brake Countershaft Brake Used with push type clutches The control button is mounted on the shift lever just below the shift knob To operate disengage the clutch press down the control button and shift into LO or reverse This is an air operated mechanical brake which slows down the transmission gearing by forcing a piston against the countershaft PTO gear Never use the Countershaft Brake when upshifting or downshifting Use only for initial gear engagement when the vehicle is standing still Clutch Brake Used with pull type clutches The clutch brake is applied by fully depressing the clutch pedal to the floor board When applied the brake slows down and can stop the transmission front box gearing It is a disc type brake incorpo rated into the clutch and transmission drive gear assemblies Never use the Clutch Brake when upshifting or downshifting Use o
10. hift BarHousing 14613A TEES Ratio Set Forward Speeds 5 Conventional Gearing 6 Multi Mesh Gearing 7 Helical Auxiliary Gearing This x 100 Nominal Torque Capacity General Information Models in this series provide thirteen forward speeds and two reverse con sisting of a 5 speed front section and a 3 speed auxiliary section The auxiliary section contains LO and HI range ratios plus an overdrive splitter gear General Information The 1st position in the front section is used only as a starting gear The other four ratios are used once in LO range and once again in HI range Each of the four ratios when used in HI range can be split with the overdrive splitter gear After shifting out of the 1st position you use the easy Roadranger repeat H shift pattern LO range and HI range are selected with the Range Knob Range Lever It is used once during the upshift sequence and once during the down shift sequence Always preselect the range shift After preselection the transmission will automatically make the synchronizer range shift as the shift lever passes through neutral When in HI range the ratios can be split by using the Splitter Control Button The Direct Rearward position gives the 5th 6th 7th and 8th speed ratios the Overdrive Forward position splits each of the HI range speed ratios Therefore eight progressive HI range ratios can be obtained Shift Pattern Diagram A shift pattern diagram shou
11. i ea 1 Identification Tag tte a 2 Model Designation seca occaeca cnn 3 General Informatiori x e e ter t t ree 4 Operation Shift Patterm DIagFam te t ente P tte i ees 4 Shift Lever POSILIOTIS i eee te e tee t ite td 5 Shift Controls s 2 oca aute ndn ER anu 7 TRANSMISSION Features ga 8 Range SHI oie pec Pct etat tia 8 e oem tede eere 8 Splitter Shift eroe tr mee edet igi 8 Optional Equipmeht ie rte dete E 9 eio eiae 10 Double Clutching Procedure 11 Up tci e etus 12 te adage abuts eme 13 Service amp Maintenance LUBRICATION taedet tene duet editt 16 Maintain Proper Oil Level ssennnn 16 Ol tit other edet Mai rettet 17 Transmission Operating Angles sese 18 Operating Temperatures with Oil Coolers 18 Qil Cooler Chal iie teet etta 19 Preventive Maintenance 20 Reference Definitions Glossary of Terms for Transmission OPS atl OMe ioc e esit req s 22 General Information Purpose This manual is designed to provide detailed information necessary for the proper drivi
12. ld be in your vehicle If it has been lost a replace ment may be obtained by writing to Eaton Corporation Truck Components Global Marketing Services P O Box 4013 Kalamazoo MI 49003 www roadranger com Please specify shifting controls used and transmission model number when making request Operation Shift Lever Positions RT amp RTF Fuller Roadranger 13 SPEED RT HI 5 7 ee DO NOT CHANGE RANGE WHILE MOVING IN REVERSE NEVER SHIFT TO LO RANGE FROM Sth UNDERDRIVE SELECT UNDERDRIVE SPLIT IN 5 6 7 8 ONLY NOT CHANGE RANGE WHILE MOVING IN REVERSE SPLITTER MUST BE IN DIRECT FOR LO RANGE SPLIT 5 6 7 8 ONLY DO NOT CHANGE RANGE WHILE MOVING IN REVERSE MUST BE iN DIR FOR LO RANGE AG 9 UE SPLIT 5 6 7 8 ONLY Operation RT amp RTF Eaton Fuller Roadranger 13 SPEED rn Transmissions SPLITTER SELECTOR RANGE MAY BE SHIFTED SELECTOR HI IN 5 6 7 8 ONLY DO NOT RANGE SHIFT D WITH SPLITTER 1 SELECTOR IN 0D 3 PRE SELECT ALLRANGE SHIFTS E MOVE RANGE SELECTOR BEFORE MOVING SHIFT LEVER UPSHIFTING Neutral START WITH RANGE SELECTOR DOWN 10 1 2 3 4 RAISE RANGE SELECTOR DOWNSHIFTI NG MOVE RANGE SELECTOR DOWN DO NOT CHANGE RANGE WHILE MOVING IN REVERSE PUT TRANSMISSION IN NEUTRAL WARNING RTO RTOF RTOX amp RTOXF Eaton Fuller Roadranger 13 SPEED Transmissions SPLITTER SELECTOR MAY BE SHIFTED HI IN 5 6 7 8 ONLY DO NOT RANGE SHIFT WI
13. ng techniques of the Fuller transmissions listed on the cover How to Use This Manual Driver instructions are divided into two sections Transmission Operation and Service and Maintenance Transmission Operation contains information on driving techniques along with shift patterns Service and Maintenance con tains informatio that deals with basic service and maintenance such as iden tification tags and lubrication information The two sections are laid out with a general heading at the top outside edge of each page followed by more specific headings labeling the information To find the information you need refer to the Table of Contents or page through the book section that covers what you need General Information Transmission Tag and Location Identification Tag PIO Code Eaton Fuller DO NOT REMOVE OR DESTROY THE TRANSMISSION IDENTIFICATION TAG Transmission model designation and other transmission identification infor mation are stamped on the transmission tag To identify the transmission model designation and serial number locate the tag on the transmission and then locate the numbers as shown example RTLO 14610B Record transmission identification data Have these reference numbers handy when ordering replacement parts or requesting service information General Information Model Designation Nomenclature RTOX Kodra Twin Countershaft Overdrive DirectShiftPattern Forward S
14. nly for initial gear engagement when the vehicle is standing still e Always select an initial starting gear that provides sufficient reduc tion for the load and terrain e Always use normal double clutching procedures when making lever shifts e Never slam or jerk the shift lever to complete gear engagements e Never coast with the shift lever in the neutral position e Never move the range lever with the shift lever in neutral while the vehicle is moving e Never make a range shift while moving in reverse e Never downshift at too high of a road speed e nmostcases depending on the engine and axle ratios you can save valuable fuel by operating the vehicle at less than governed RPM while cruising in top gear e Never move the shift lever to the LO speed gear position while oper ating in HI range e Never make a splitter shift while moving in reverse e Do not lug engine below peak torque 1200 RPM Driving Tips Double Clutching Procedure When ready to make a shift 1 2 3 4 9 Depress the pedal to disengage the clutch Move the gear shift lever to neutral Release the pedal to engage the clutch See Note e UPSHIFTS Decelerate engine until engine RPM and road speed match e DOWNSHIFTS Accelerate engine until engine RPM and road speed match Quickly depress pedal to disengage clutch and move gear shift lever to next gear speed position Release pedal to engage clutch Note By engaging the
15. ns it is assumed that the driver is familiar with oper ating heavy duty trucks and tractors and can coordinate the movement of the shift lever and clutch pedal to make smooth gear engagements while upshift ing or downshifting Always double clutch when making lever shifts A CAUTION Never move the range lever or the splitter control button with the shift lever in neutral while the vehicle is moving 1 Move the shift lever double clutching to the next gear position in LO range Range Shift LO to HI Range Direct 4th to 5th DIR 2 Whenin last gear position for LO range and ready for the next upshift pull up the Range Lever and move the shift lever double clutching to the next higher speed position according to your shift pattern As the shift lever passes through neutral the transmission will automatically shift from LO to HI range A CAUTION Never move the shift lever to the LO speed gear position after HI range prese lection or at anytime the transmission is in HI range Splitter Shift HI Range Direct to HI Range Overdrive 5th DIR to 5th OD 3 Move the splitter control button into the forward overdrive position 4 Then immediately release the accelerator depress the clutch pedal once to break torque release the pedal to reengage clutch and accelerate the engine The transmission shifts from direct to over drive when synchronous is reached Combination Range Shift and Splitter Shift HI Range Overdrive t
16. nthetic Lubricants see TCMT0020 or call 1 800 826 HELP 4357 Buy from a reputable dealer For a complete list of approved and reputable dealers see TCMT0020 or write to Eaton Corporation Truck Components Global Marketing Services P O Box 4013 Kalamazoo MI 49003 www roadranger com Service and Maintenance Transmission Operating Angles If the transmission operating angle is more than 12 degrees improper lubrica tion will occur The operating angle is the transmission mounting angle in the chassis plus the percent of upgrade expressed in degrees For operating angles over 12 degrees the transmission must be equipped with an oil pump or cooler kit to insure proper lubrication Operating Temperatures with Oil Coolers The transmission must not be operated consistently at temperatures above 250 F However intermittent operating temperatures to 300 F do not harm the transmission Operating temperatures above 250 F increases the lubricant s oxidation rate and shortens its effective life When the average operating tem perature is above 250 F the transmission can require more frequent oil changes or external cooling The following conditions in any combination can cause operating tempera tures of over 250 F Operating consistently at slow speed High ambient temperatures Restricted air flow around transmission Exhaust system too close to transmission High horsepower operation External oil coolers are av
17. o HI Range Direct 5th OD to 6th DIR 5 Immediately depress the clutch and move the gear shift lever to neu tral Release the clutch depress again move the gear shift lever into sixth gear and move the splitter control button rearward into the direct position Release the clutch pedal and accelerate A CAUTION Never move the splitter control button or the range lever with the shift lever in neutral while the vehicle is moving 6 Continue upshifting through the shift pattern Double clutching dur ing lever shifts single clutch during split shifts while the shift lever is in the same position Downshift Procedure In the following instructions it is assumed that the driver is familiar with oper ating heavy duty trucks and tractors and can coordinate the movement of the shift lever and clutch pedal to make smooth gear engagements while upshift ing or downshifting Always double clutch when making lever shifts A CAUTION Never move the range lever or the splitter control button with the shift lever in neutral while the vehicle is moving Splitter Shift HI Range Overdrive to HI Range Direct 8th OD to 8th DIR 1 Move the splitter control button into the rearward direct position 2 Then immediately release the accelerator depress the clutch pedal once to break torque release the pedal to reengage clutch and accelerate the engine The transmission shifts from overdrive to direct when synchronous is reached Combina
18. tion Range Shift and Splitter Shift Range Direct to Range Overdrive 7th DIR to 6th OD 3 4 Move the splitter control button into the forward overdrive position Then immediately move the shift lever double clutching to the next lower gear position If the splitter control button is not moved the transmission will be in 7th direct once the final clutch engage ment is made Continue downshifting through HI range Double clutching during lever shifts single clutch during split shifts while the shift lever is in the same position Range Shift from HI Range Direct to LO Range 5th DIR to 4th 6 While in HI range direct and ready for the next downshift preselect LO range push the range preselection lever down A CAUTION When downshifting from HI range to LO range the splitter control button must be in the rearward direct position and the shift to the direct position completed before making the range shift The shift to LO range cannot be make with the splitter control button in the forward overdrive position 7 Continue moving the shift lever double clutching to the next desired gear position in LO range As the shift lever passes through neutral the transmission automatically shifts from HI range to LO range Continue downshifting double clutching to the next desired gear position in LO range Service and Maintenance Proper lubrication procedures are the key to a good all around maintenance program
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