Eaton Fuller Roadranger Driver Instructions Download

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More time on the road

Fuller

Heavy Duty Transmissions

Driver Instructions

Fuller Heavy Duty Transmissions

TRDR0630

September 2007

Video Instruction Available

Instructional videos are available for download at no
charge at roadranger.com

Videos are also available in DVD format for $20. To
order, call 1-888-386-4636. Ask for item # RRSD0002

Summary of Contents for Fuller Roadranger

Page 1: ...ctions Fuller Heavy Duty Transmissions TRDR0630 September 2007 Video Instruction Available Instructional videos are available for download at no charge at roadranger com Videos are also available in DVD format for 20 To order call 1 888 386 4636 Ask for item RRSD0002 ...

Page 2: ... 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 Every effor...

Page 3: ...ures 8 Range Shift 8 Preselect 8 Splitter Shift 8 Optional Equipment 9 Driving Tips 10 Double Clutching Procedure 11 Initial Start Up 12 Upshifting 13 Service Maintenance Lubrication 16 Maintain Proper Oil Level 16 Oil Filter 17 Transmission Operating Angles 18 Operating Temperatures with Oil Coolers 18 Oil Cooler Char 19 Preventive Maintenance 20 Reference Definitions Glossary of Terms for Transm...

Page 4: ...smission Operation contains information on driving techniques along with shift patterns Service and Maintenance con tains information items that deal with basic service and maintenance such as identification 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 t...

Page 5: ...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 ...

Page 6: ...clature R T O X F 1 4 6 1 3 A Ratio Set Forward Speeds 5 Conventional Gearing 6 Multi Mesh Gearing 7 Helical Auxiliary Gearing This x 100 Nominal Torque Capacity Roadranger Twin Countershaft Overdrive Direct ShiftPattern Forward Shift Bar Housing ...

Page 7: ...t 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...

Page 8: ...5 Operation Shift Lever Positions RT RTF RTO RTOF RTXO RTXOF RTOO RTOOF ...

Page 9: ...AY BE SHIFTED IN 5 6 7 8 ONLY DO NOT RANGE SHIFT WITH SPLITTER SELECTOR IN OD MOVE RANGE SELECTOR BEFORE MOVING SHIFT LEVER START WITH RANGE SELECTOR DOWN SHIFT LO 1 2 3 4 RAISE RANGE SELECTOR SHIFT 5 6 7 8 SHIFT 8 7 6 5 MOVE RANGE SELECTOR DOWN SHIFT 4 3 2 1 LO HI LO UPSHIFTING DOWNSHIFTING DO NOT CHANGE RANGE WHILE MOVING IN REVERSE Neutral 20161 WARNING PUT TRANSMISSION IN NEUTRAL BEFORE STARTI...

Page 10: ...ctor Valve A 4491 4494 Roadranger Valve A 4900 Up for HI Range Down for LO Range Range Lever Rearward for Direct Forward for Overdrive Splitter Control Button Up for HI Range Down for LO Range Range Lever Rearward for Direct Forward for Overdrive Splitter Control Button ...

Page 11: ... Preselection requires that the range lever is moved to the needed position before starting 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 overdr...

Page 12: ...ich 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 s...

Page 13: ...ver move the range lever with the shift lever in neutral while the vehicle is moving Never make a range shift while moving in reverse Never downshift at too high of a road speed In most cases 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 Never move the shift lever to the LO speed gear position while ...

Page 14: ...ne until engine RPM and road speed match 4 Quickly depress pedal to disengage clutch and move gear shift lever to next gear speed position 5 Release pedal to engage clutch By engaging the 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 reg ulated by engine RPM This procedure enables the operator to match the RPM...

Page 15: ...arking 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 6 Depress the clutch pedal to the floor 7 Move the shift lever to desired i...

Page 16: ...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 CAUTION Never move the shift lever to the LO speed gear position after HI range preselection or at anytime the transmission is in HI range Splitter shift HI Range Direct to HI Range Overdrive 5th DIR to 5th ...

Page 17: ...to make smooth gear engagements while upshift ing or downshifting Always double clutch when making lever shifts 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 rel...

Page 18: ...fting 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 for ward overdrive position 7 Continue moving the shift lever double clutching to the next desired gear position in LO range As the shift lever pa...

Page 19: ...sely followed Maintain oil level Inspect regularly Follow maintenance interval chart Use the correct grade and type of oil Buy from a reputable dealer For additional lubrication information see TCMT 0021 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 ...

Page 20: ...ion For a list of Eaton Approved Synthetic Lubricants see TCMT 0020 or call 1 800 826 HELP 4357 Buy from a reputable dealer For a complete list of approved and reputable dealers see TCMT 0020 or write to Eaton Corporation Truck Components Global Marketing Services P O Box 4013 Kalamazoo MI 49003 www roadranger com HIGHWAY USE For transmissions equipped with oil filter P N 4304827 Inspect filter fo...

Page 21: ...es 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 t...

Page 22: ...hart Transmission Oil Coolers are Recommended With engines of 350 H P and above Required With engines 399 H P and above and GCW s over 90 000 lbs With engines 399 H P and above and 1400 lbs ft or greater torque With engines 450 H P and above ...

Page 23: ...of the clutch housing flange for looseness 3 Clutch Release Bearing Not Shown Remove hand hole cover and check radial and axial clearance in release bearing Check relative positive of thrust surface of release bearing with thrust sleeve on push type clutches 4 Clutch Pedal Shaft and Bores Pry upward on shafts to check wear If excessive movement is found remove clutch release mecha nism and check b...

Page 24: ...uld cause oil leakage Check P T O opening and rear bearing covers for oil leakage due to faulty gasket 8 Shift Lever Check for looseness and free play in housing If lever is loose in housing proceed with check number 9 9 Shift Lever Housing Assembly Remove air lines at slave valve and remove the shift lever hous ing assembly from transmission Check tension spring and washer for set and wear Check ...

Page 25: ...tral 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 Ratio Step Amount of change between two gear ratios expressed as a percentage Example The ratio step from 1st gear to 2nd gear i...

Page 26: ... more time on the road 2007 Eaton Corporation and Dana Corporation All rights reserved Printed in USA Copyright Eaton and Dana Corporation 2007 EATON AND DANA CORPORATION hereby grants it customers vendors or distributors permissions to freely copy reproduce and or distribute this document in printed format It may be copied only in its entirety without any changes or modi fications THIS INFORMATIO...

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