Eaton Fuller Heavy Duty Transmissions
Contents
1. Accelerate through the current gear when the next gear is desired Preselect by moving the shift button rearward immediately break torque by releasing the throttle and depressing the clutch pedal then using proper Double Clutching techniques move the shift lever to the next desired gear position Downshift Used for gear changes 9th to 8th 7th to 6th 5th to 4th and 3rd to 2nd As the vehicle decelerates and a downshift is required With the throttle still applied preselect by moving the shift button forward immediately break torque by releasing the throttle and depressing the clutch pedal then use proper Double Clutching techniques move the shift lever to the next desired gear position Do not attempt a downshift at too high of an engine speed generally above 1400 RPM f necessary see Double Clutching Procedure page 12 Transmission Operation Procedure SEEN Neutral Lever Only Shift RNN Used for skipping a full gear ratio when the vehicle is lightly loaded or bobtail Upshift With the shift button rearward 1st to 3rd 3rd to 5th 5th to 7th and 7 to 9th With the shift button forward 2nd to 4th 4th to 6th 6th to 8th and 8th to 10th Accelerate through the current gear when the next gear is desired Break torque by releasing the throttle and depressing the clutch pedal then using normal Double Clutching techniques move the shift lever to the next desired gear position Remem2. 5 Let up onthe clutch pedal and apply accelerator Engaging the clutch with the shift lever in the neutral position connects the transmission input gearing to the engine This allows the operator to speed up or slow down the transmission input gearing to properly match the desired gear speed to the current road speed Transmission Operation Typical Transmission Shift Points for a Super 10 in An On Highway Application Vehicle Speed vs Engine Speed amp Gear 6th 7th 8th 9th 1600 4 oth s A ff E 1 Oth n 4th 65 MPH at tc 1566 RPM m 1400 J 3rd 44 4 _ pe ff eTa e ond Shift Points a n 1st 1000 rpm It 2nd 1300 rpm z 1200 TOR ENEE 3rd 1400 rom amp 4th 1500 rpm 5th 1600 rpm P LAM mcum T 6th 1700 rpm 7th 1700 rpm 8th 1700 rpm 9th 1700 rpm 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 Vehicle Speed MPH The example is based on a 1800 rpm governed engine RTLO 14610B transmission 3 90 1 rear axle ratio and 275 80R24 5 tires Note The transmission is shifted at less than the 1800 governed rpm Also progressive shifting is used in the lower gears to promote quicker transmis sion shifting and improved vehicle performance 13 Transmission Operation Reverse Operation The Super 10 has two useable reverse gear ratios These two reverse ratios
3. are selected by moving the shift button rearward Low Reverse or forward High Reverse when the gear shift lever is in the reverse position For maximum vehicle control Low Reverse is recommended for normal vehicle backing For a faster vehicle speed when bobtail high reverse can be used Although shifting between reverse ratios can be accomplished when the vehicle is moving it is recommended that the vehicle be stopped when changing reverse ratios Range Shift The auxiliary range shift automatically occurs between the center rail and the right rail See illustration This shift may be audible to the driver Important To avoid unnecessary wear and possible damage to the transmis sion the shift lever should not be moved to the center or left rail position when the vehicle speed is greater than 40 MPH Left Center Right OSENUN Range shift triggered Neutral 4 automatically at this location Transmission Operation Most heavy duty trucks are equipped with a clutch brake Occasionally a countershaft brake system will be used Clutch Brake A clutch brake stops the rotation of the clutch discs and transmission input gearing It prevents the clashing or grinding of the gears when the vehicle is stationary and the driver is shifting from neutral into the starting gear A properly adjusted clutch brake will be activated when the driver fully depresses the clutch pedal On a normal shift or when the vehicle is in motion t
4. with the engine the driver can successfully manage the powertrain package to achieve the best vehicle performance and fuel economy In a Super 10 this means that a driver should remember to shift at a lower RPM and allow enough time for the engine speed to decrease sufficiently for the next higher gear By shifting with the proper technique the driver can fully appreciate the ease and simplicity the Super 10 offers Transmission Operation Definitions Glossary of Terms The following terms are used in describing the transmission operating procedures Break Torque Releasing engine power or load from the transmission and drivetrain by releasing throttle or depressing clutch pedal Double Clutch The clutching procedure used when moving the shift lever to the next lever position See page 12 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 is 35 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 Transmission Operation Shift Pattern Shift Knob Shift Button Rearward Gears 1 3 5 7 9 when butt
5. Eaton Fuller Heavy Duty Transmissions Gana ETN RTLO 10 Top 2 Models m One Great Drivetrain from Two Great Companies Driver Instructions TRDR 0550 August 1996 For the most current information visit the Roadranger web site at www roadranger com A WARNING Read the entire driver instructions before operating this transmission Before starting a vehicle always be seated in the driv er s seat move the shift lever to neutral and set the parking brakes 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 When parking the vehicle or leaving the cab always place the shift lever in neutral and set the parking brakes TOWING To avoid damage to the transmission during towing place the transmission in neutral and lift the drive wheels off the ground or disconnect the driveline Every effort has been made to ensure the accuracy of all information in this brochure However Eaton Truck Components makes no expressed or implied warranty or representation based on the enclosed information Any errors or omissions may be reported to Technical Communications Eaton Truck Components P O Box 4013 Kalamazoo MI 49003 Table of Contents Introduction 4 Transmission Operation Definitions Glossary of Terms 5 Shift Pattern 6 Shift Knob 6 Initial Start Up 7 Types of Super 10 Shifts 8 Procedures Button Only Shi
6. ber Lever Only shifts skip an entire gear ratio and will require the engine RPM to decrease twice the amount of a normal shift Downshift With the shift button rearward 9th to 7th 7th to 5th 5th to 3rd and 3rd to 1st With the shift button forward 10th to 8th 8th to 6th 6th to 4th 4th to 2nd As the vehicle decelerates and a downshift is required Break torque by releasing the throttle and depressing the clutch pedal then using normal Double Clutching techniques move the shift lever to the next desired gear position Do not attempt a lever only downshift at too high of an engine speed generally above 1000 RPM f necessary see Double Clutching Procedure page 12 11 Transmission Operation Double Clutching Procedure Purpose 1 To break torque to allow the transmission to come out of gear and 2 To disengage the engine from the transmission when shifting into gear The Procedure 1 Release accelerator 2 Depress clutch pedal slightly to break torque enough to move the shift lever to neutral NOTE Avoid depressing the clutch pedal too far and contacting the clutch brake 3 When the shift lever is in neutral let up on clutch pedal a For upshifts allow engine RPM to decrease to match road speed b For downshifts increase engine RPM to match road speed 4 Atthe correct engine RPM depress the clutch pedal slightly and at the same time move the shift lever into the desired gear
7. esh Gearing This x 100 Nominal Torque Capacity O Overdrive 19 Service and Maintenance Vehicle Towing To avoid damage to the transmission during towing place the transmission in neutral and lift the drive wheels off the ground or disconnect the driveline Identification Tag Transmission model designation and other transmission identification information are stamped on the transmission tag To identify the transmis sion model designation and serial number locate the tag on the transmission and then locate the numbers as shown DO NOT REMOVE OR DESTROY THE TRANSMISSION IDENTIFICATION TAG PIO Code Eaton Fuller Transmissions The blank spaces provided below are for recording transmission identification data Have these reference numbers handy when ordering replacement parts or requesting service information Transmission Model Transmission Serial Number 20 Service and Maintenance Proper Lubrication the Key to long transmission life Proper lubrication procedures are the key to a good all around maintenance program If the oil is not doing its job or if the oil level is ignored all the maintenance procedures in the world are not going to keep the transmission running or assure long transmission life Eaton Fuller Transmissions are designed so that the internal parts operate in an oil circulating bath created by the motion of the gears and shafts Thus all parts are amply lubrica
8. ft 9 Combination Button and Lever Shift 10 Lever Only Shift 11 Double Clutching Procedure 12 Vehicle Speed and Engine Speed Shift Points 13 Reverse Operation 14 Range Shift 14 Clutch Brake 15 Countershaft Brake 15 How to get the most from your Super 10 16 Transmission Do s and Don ts 17 Gear Ratios 18 Service and Maintenance Model Designation 19 Vehicle Towing 20 Identification Tag 20 Lubrication 21 Maintenance Interval Chart 22 Preventive Maintenance 24 Operating Temperatures with Oil Coolers 26 Appendix Super 10 Top 2 Basic Operation and Overview 27 Upshift Procedure 28 Downshift Procedure 28 Driving Tips 29 Definitions 30 System Problem 31 Introduction Congratulations on your purchase of a Super 10 Transmission This new generation transmission may be different from any other transmission you have operated In the Super 10 half of the ten speed ratios are shifted with the shift lever while the other half are shifted by moving the shift button Button shifts require the driver to raise or lower the engine RPM the same amount as a lever shift To successfully operate this or any transmission the driver must be aware of the characteristics of today s diesel engines Today s engines e Produce horsepower and torque at a lower RPM e Operate at a lower RPM e Are governed at a lower RPM e Decelerate slower By understanding these engine characteristics and knowing that the trans mission works as a partner
9. g during lever shifts and breaking torque during button shifts Step 2 When the engine has reached the shift point use the normal double clutching procedure and move the shift lever into 9th gear NOTE The position of the shift button does not matter when moving the lever into the AUTO position It is recommended to leave the shift button in the forward position so it is ready when you want to make a downshift into 8th gear Step 3 When the engine has reached the shift point the transmission will automatically shift into 10th gear Downshift Procedure Step 1 To downshift from 10th to 9th gear Once the engine has reached the shift point the transmission will automatically downshift Step 2 To downshift from 9th gear to 8th gear a While in 9th gear make sure the shift button is in the forward position b Once the engine has reached the shift point move the lever to the next lower lever position while double clutching Step 3 Continue downshifting through the shift pattern double clutching during lever shifts and breaking torque during button shifts 28 Appendix Driving Tips To activate Top 2 mode the transmission must be shifted from 8th to 9th once the engine has reached the normal shift point If the operator moves the shift lever into the AUTO lever position below the engines normal shift point the transmission will be in normal Super 10 mode Once the engine reaches the normal shift point Top 2 mode wil
10. g in 2nd gear rather than 1st Use the vehicle tachometer Because newer vehicles and engines are quieter it is harder to shift by sound Use the vehicle tachometer to determine when a shift completes Transmission Operation Transmission Do s and Don ts Do s e Do use normal Double Clutching procedures when making lever shifts e Do preselect the shift button just prior to starting a shift e Do allow for the shift to complete by waiting for the engine speed to decelerate to the proper speed for the next desired gear Don ts e Don t slam or jerk the shift lever into gear e Don t coast with the shift lever in the neutral position e Don t move the gear shift lever to the center or left rail position when the vehicle speed is greater than 40 mph 17 Transmission Operation Gear Ratios RTLO 14610A RTLO XX610B Rao Step Ratio Step 32 46 1 14 1 9th 1 00 35 1 00 8th 1 35 32 1 35 7th 1 78 32 1 82 6th 2 36 32 2 46 5th 3 12 35 3 32 4th 4 20 32 4 49 3rd 5 57 34 6 06 2nd 32 1st Reverse Low Reverse High Service and Maintenance Important Safety Notes 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 Model Designation RTL 0 146104A wd L Ratio Set Twin Countershaft Forward Speeds Low Inertia 6 Multi M
11. ger The Roadranger System is an unbeatable combination of the best products from Eaton and Dana partnering to provide you the most advanced most trouble free drivetrain in the industry And it s backed by the Roadrangers the most experienced most expert most accessible drivetrain consultants in the business For spec ing or service assistance call 1 800 826 HELP 4357 24 hours a day 7 days a week Mexico 001 800 826 HELP 4357 for more time on the road Or visit our web site at www roadranger com TRDR 0550 08 96 POD Printed in USA
12. he driver must avoid activating the clutch brake to prevent transmis sion hard shifting and or damage to the clutch brake Countershaft Brake A countershaft brake also stops the rotation of the clutch discs and transmis sion input gearing It prevents the clashing or grinding of the gears when the vehicle is stationary and the driver is shifting from neutral into the starting gear A countershaft brake is usually activated by a small button mounted onto the shift lever The driver depresses this button when shifting from neutral to the initial starting gear The clutch pedal must be depressed Damage can occur to the countershaft brake and the transmission if the button is depressed with the vehicle in motion or the clutch pedal not depressed 15 Transmission Operation How to get the most from your Super 10 Button only upshifts BE PAT ENT The transmission will only complete a shift when the engine RPM decreases to the level required for the next higher gear 1st to 2nd upshift Perform the button shift to 2nd gear just after the vehicle has started in motion This shift from 1st to 2nd gear can be accom plished at approximately 1000 RPM even if fully loaded 3rd to 4th Button only shift on tight right turns Because of vehicle resistance created during the turn either stay in 3rd gear through the turn or shift into 4th before the turn Select the best starting gear If on level ground or lightly loaded try startin
13. is causes oil to be forced out of the case through the front bearing cover Proper Oil Level Improper Oil Level When adding oil types and brands of oil should not be mixed because of possible incompatibility 23 Service and Maintenance Preventive Maintenance The following maintenance items are necessary to prevent costly transmis sion failures which may not be covered by warranty Transmission Oil Check transmission daily for oil leaks Repair promptly to prevent oil loss and subsequent transmission failure Check transmission oil level at every engine oil change interval Add transmission oil as necessary Drain and replace transmission oil as recommended by the schedule in this book Air System Drain moisture from vehicle air system daily Listen for air leaks daily repair promptly If the vehicle is equipped with an air dryer confirm that the air dryer system is working properly Repair as necessary Service the vehicle air compressor as required to prevent oil from entering the vehicle air system Master Clutch System 24 Lubricate clutch release pedal shaft bushings at every chassis lubrica tion interval There should be one grease fitting on each side of the transmission clutch housing Have the clutch checked and adjusted if any of the following occurs Clutch does not disengage completely Clutch brake does not function Clutch pedal free play is less than 1 2 Service and Main
14. l become active Throttle position determines the upshift point Less throttle will lower the shift point Zero throttle down hill push will raise the up shift point To reset the shift points the engine must drop below it s normal shift point With the engine brake active the up and down shift points will be raised A feature of Top 2 is ANTI HUNT mode This is built in to avoid constant up and down shifts When the shift lever is in the AUTO position and the transmission has just completed an up shift the down shift point will be lower than normal If the transmission has just completed a down shift the up shift point will now be higher than normal 29 Appendix Definitions Auto Position Break Torque Double Clutch Shift Button Synchronous Top 2 Mode 30 When the shift lever is in the position labeled AUTO This position is where 9th and 10th gears are located Releasing engine power or load from transmission and drivetrain 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 accelerate or decelerate engine to obtain synchronous depress clutch pedal again and move lever into gear The button on the side of the shift knob used to change gears The point at which the input gearing speed engine matches output gearing speed road speed and a shift can occur without grinding The
15. ly loaded Note Button Only shifts and Combination Button Lever shifts are both full gear changes Lever only shifts skip a gear Transmission Operation Procedure TNN Neutral Button Only Shift RNE Upshift Used for gear changes 1st to 2nd 3rd to 4th 5th to 6th 7th to 8th and 9th to 10th Accelerate through the current gear when the next gear is desired Preselect by moving the shift button forward immediately break torque by releasing the throttle or depressing the clutch pedal allow the engine RPM to decrease to provide synchronous for the next desired gear The shift will complete when the engine RPM has decreased to the proper speed Tip Use the tachometer to determine when the shift completes Downshift Used for gear changes 10th to 9th 8th to 7th 6th to 5th 4th to 3rd and 2nd to 1st As the vehicle decelerates and a downshift is required With the throttle still applied preselect by moving the shift button rearward immediately break torque by releasing the throttle or depressing the clutch pedal increase engine RPM to provide synchro nous for the desired gear The shift will complete when the engine RPM has increased to the proper speed Do not attempt a downshift at too high of an engine speed generally above 1400 RPM Transmission Operation Procedure Combination Button and Lever Shift Upshift Used for gear changes 2nd to 3rd 4th to 5th 6th to 7th and 8th to 9th
16. on is rearward RIES Neutral BEEN Shift Button Forward Gears 2 4 6 8 10 when button is forward Shift Button Transmission Operation Initial Start Up Before starting a vehicle always be seated in the A WARNING driver s seat move the shift lever to neutral and set the parking brakes 1 Make sure the lever is in neutral and the parking brakes are set 2 Depress the clutch pedal turn on the key switch and start the engine Allow the vehicle air pressure to build to the proper operating pressure 90 120 PSI Refer to your Operator or Service Manual supplied with the truck Depress the brake pedal Depress the clutch pedal to the floor to contact the clutch brake Move the shift lever to the desired starting gear Release the parking brakes on the vehicle Slowly let up on the clutch pedal fo go So or le When the clutch is fully engaged apply the accelerator Transmission Operation Types of Super 10 Shifts There are three different types of shifts used with the Super 10 transmission Button Only Shift This is a gear ratio change that occurs by moving the shift button Combination Button Lever Shift This is a gear ratio change that occurs by moving both the shift button and shift lever Lever Only Shift This shift occurs when the shift lever is moved without moving the shift button It results in a skip of a full gear ratio and should only be used when the vehicle is bobtail or light
17. r 250 F 1 operating consistently at slow speeds 2 high ambient temperatures 3 restricted air flow around transmission 4 exhaust system too close to transmission 5 high horsepower overdrive operation External oil coolers are available to reduce operating temperatures when the above conditions are encountered Transmission Oil Coolers are Recommended e With engines of 350 H P and above Required e With engines 399 H P and above and GCW s over 90 000 Ibs e With engines 399 H P and above and 1400 Lb ft or greater torque e With engines 450 H P and above 26 Super 10 Top 2 Basic Operation and Overview The Super 10 Top 2 transmission operates like a normal Super 10 in gears 1 through 8 The transmission shifts automatically between 9th and 10th gear based on engine speed and load When the transmission is in the Top 2 Mode the system will a Shift the transmission between 9th and 10th gear automatically b Increase or decrease engine speed during a Top 2 shift c Momentarily interrupt cruise control or engine brake during the shift then resume SHIFT PATTERN Button Button Rearward Forward CN uller Transmissions t ller Transmissions Shift 1 3 5 7 Shift 2 4 6 8 when button is When button is rearward forward 27 Appendix Appendix Upshift Procedure Step 1 Upshift the transmission through the shift pattern to 8th gear Double clutchin
18. r follow maintenance intervals above Heavy Duty Engine Lubricant or Mineral Gear Lubricant HIGHWAY USE First3 000 to 5 000 miles Factory fill 4827 to 8045 Km initialdrain Every 10 000 miles Inspectlubricantlevel 16090Km Check forleaks Every 50 000 miles Changetransmission 80450Km ubricant OFF HIGHWAY USE First30hours Changetransmission lubricanton new units Every 40 hours Inspectlubricantlevel Checkfor leaks Changetransmission lubricant where Every 500 hours severedirtconditions exist Changetransmissionlubricant Every 1 000 hours Normal off highway use If your vehicle has a transmission oil filter you must change the filter when fluid or lubricant is changed For a list of Eaton Approved Synthetic Lubricants call 1 800 826 HELP 4357 22 Service and Maintenance Make sure oil is level with the filler opening Because you can reach oil with your finger does not mean oil is at the proper level One inch of oil level is about one gallon of oil Proper Oil Level Draining Oil Drain transmission while oil is warm To drain oil remove the drain plug at case bottom Clean the drain plug before re installing Refilling Clean case around filler plug and remove plug from case side Fill the transmission to the level of the filler opening RTLO 10 Oil Capacity The exact amount of oil depends on the transmission inclination and model Do not over fill th
19. state where the transmission automatically shifts between 9th and 10th gears Appendix System Problem If the system malfunctions the transmission will typically default to Super 10 mode For some malfunctions the system will detect a failure that the operator must allow the Top 2 to time out This will take 9 seconds During the 9 seconds the Top 2 will try to complete the shift Once the Top 2 has timed out the operator must place the transmission in neutral to obtain manual Super 10 mode The Top 2 function will be inactive until the vehicle is stopped and the key is turned off In some situations the system can be reset at a stop by leaving the key off for 10 seconds and then restarting the engine If this does not clear the problem verify air pressure and check the fuse to the Top 2 To help assure operation of the Super 10 Top 2 advise your maintenance personnel of any oil leaks above normal operating temperatures unusual noises fault codes or if the transmission is not operating right 31 Copyright Eaton and Dana Corporation 2002 EATON AND National Institute for DANA CORPORATION hereby AUTOMOTIVE grants its customers vendors or XR KE NCE distributors permission to freely copy reproduce and or distribute Jte this document in printed format THIS INFORMATION IS NOT INTENDED FOR SALE OR RE SALE AND THIS NOTICE MUST REMAIN ON ALL COPIES One Great Drivetrain from Two Great Companies Roadran
20. ted if these procedures are closely followed Maintain oil level Follow maintenance interval chart Use only recommended lubrication Buy lubricant from a reputable dealer amp wh Recommended Lubricant Fahrenheit Grade Ambient Type SAE Temperature Eaton Approved Synthetic Lubricant 50 Heavy Duty Engine Oil Above 10 F MIL L 2104D API CD Above 10 F or Cat TO 4 Below 10 F Automotive Gear Above 10 F Oil API MT 1 Below 10 F Additives and friction modifiers must not be introduced Never mix engine oils amp gear oils in the same transmission Fora list of Eaton Approved Synthetic Lubricants call 1 800 826 HELP 4357 21 Service and Maintenance Maintenance Interval Chart Eaton Approved Synthetic Transmission Oil HIGHWAY USE Heavy Duty and Mid Range Initial Fill with Eaton Approved Synthetic Transmission Oil Every 10 000 miles Check fluid level 16090Km Check for leaks Every 250 000 miles Changetransmission 402336Km fluid OFF HIGHWAY USE Every 40 hours Inspectlubricantlevel Checkforleaks Every 1 000 hours Changetransmission fluid where severe dirtconditions exist Every 2 000 hours Changetransmissionfluid Normaloff highway use HIGHWAY USE Heavy Duty and Mid Range Initial Fill with Other Recommended Oil First3 000to 5 000 miles Factoryfillinitial drain 4827 to 8045 Km Refill with Eaton Approved Synthetic Transmission Oil thereafte
21. tenance e When replacing the clutch use a high quality spring damped replace ment unit Drivetrain e Inspect the driveshaft for loose or worn U joints weekly Repair promptly to prevent excessive driveline vibration e Have the driveline checked by a repair facility if unusual noise or vibration is detected Overall Inspection e Inspect the transmission at the chassis lubrication interval for loose or missing capscrews and fasteners Pay particular attention to the capscrews that attach the transmission to the engine Grease Fitting On Each Side To l Range Actuator Shift Lubricate Clutch Valve Tower Pedal Shaft N Air Filter Regulator d c or YS Sea os w m USD Main Plu Section Case g Oil Clutch Inspection Drain Cover Plug 25 Service and Maintenance 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 temperature 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 ove
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