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Roadranger Lubrication Manual - CCC Parts Company

1. vehicle in Neutral and start the engine The Heavy Duty HD chart includes the following prefixes 2 Allow the input shaft of the transmission to rotate AT FR FRO FRLO RT RTAO RTL RTLO RTLOM RTO 4 by releasing the clutch pedal The oil pump will fill RTOM RTOO RTX T TO and TX S tie cooler HD Model Number Pints Liters 3 3 After one minute shut off the engine recheck the 1056AA 29 14 A transmission oil level and top off lubricant Repeat this process until proper lubricant level is achieved 10710 AC AS AS2 26 12 10910 AS3 DM2 DM3 26 12 1110 25 12 11109 AT 88 42 11210 23 5 11 11509 25 12 1157DL 27 13 1157DLL 29 14 11605 22 10 11606 26 12 11607 ASX 36 17 11607L 28 13 11607LL 31 15 11608 26 12 11608LL 29 14 11609 27 13 11610 26 12 RTLO 11610 28 13 11610 T2 31 15 11613 29 14 11615 28 13 11707 DLL LL 28 13 11708LL 28 13 11709 27 13 Transmission HD Model Number Pints Liters HD Model Number Pints Liters 11709ALL 28 13 RTL 13710 28 13 11710 26 12 13710 AS 89 42 RTL 11710 T2 28 13 13813 29 14 11710 AS 89 42 13909ALL 28 13 11715 28 13 14109 AT Ceemat 88 42 11813 29 14 14210 23 5 11 11908LL 28 13 14607 ASX
2. Benefits of Using Approved Lubricants Lubricants must meet rigorous test criteria set by the component manufacturer to ensure performance and long life Approved lubricants are designed to work with the specific component When improper or unapproved lubricant is used several problems can occur Benefits of using approved lubricants e Oil formulation is tested per component manufacturer s specifications e Reduced wear on components such as gears and bearings e Longer life by reducing operating temperatures e Prevention of corrosion especially when copper coolers are used e Excellent cold temperature performance e Maintain extended warranty coverage Risks from not using approved lubricants are e Shortened bearing life e Seal leakage e Reduced fuel economy e Shortened copper cooler life e Loss of warranty coverage hea E r n a Transmission Sludge Seal Coking Copper Cooler Failure Transmission Roadranger SAE 50 Synthetic Transmission Lubricant Benefits Typical Properties This product is extended drain and severe service capable to protect the higher torgue manual and automated mechanical Characteristic Roadranger SAE 50 Test Method transmissions coupled with high horsepower engines SAE viscosity grade 50 SAE J306 Roadranger SAE 50 Synthetic Lubricant provides Kinematic Viscosity cSt ASTM D445 e Less friction and drag in transmission improves fuel 100 C
3. Note DO NOT apply lubricant grease or anti seize to the input shaft splines The disc must be free to slide Grease Zerk Input Shaft Clutch ef Brake 23 Eaton Clutch Lubrication and Service Interval List Use the chart below by selecting the Eaton Clutch product to service The application line haul and vocational definitions are located earlier in this manual DO NOT mix other thickener type greases It has been shown that certain Calcium Sulfonate Type greases are not compatible with Lithium Complex Type greases and cause premature bearing failures For more information about selecting the correct grease see What To Look For When Selecting Grease on page 21 Product NLGI Grade Thickener Type Performance Rating Grease Interval Grease Interval Line Haul see Vocational see Note 2 and 3 Note 2 and 3 Stamped Angle Spring NLGI 2 or 3 Lithium Complex NLGI GC LB 10 000 miles max 250 hours Medium Duty Solo 16 000 km or 1 month 365 mm see Note 1 No Lubricant Needed 395 mm see Note 1 EverTough NLGI 2 or 3 Lithium Complex NLGI GC LB 25 000 miles max 250 hours 40 000 km or 1 month Heavy Duty ECA NLGI 2 or 3 Lithium Complex NLGI GC LB 50 000 miles max 250 hours Clutch 80 000 km or 1 month Solo Advantage Easy Pedal Advan tage Value Clutch NLGI 2 or 3 Lithium Complex
4. Product Specification Manual Roadranger Lubricant Products TCMTOO21 EN US October 2013 Roadranger ring Business Worldwide TN E Te Powering B Table of Contents General Information Roadranger Lubrication Philosophy Benielit8i ne RR EG EE Gas ete ed 1 Genuine Product Label e ee ee ee ee ee ee ee ee ee 1 Unapproved Lubricants Things to Watch Out For 2 Benefits of Using Approved Lubricants ese ee 2 Transmission Roadranger SAE 50 Synthetic Transmission Lubricant Benefits RE eer cedar areata eal Ge EE Dee 3 APDrOVAlS EG RE EE BE GR DER ER DE ge ge ie aes 3 Typical Properties ee ee RR RR 3 Application Definitions Line Haul On Highway Service esse ee ee 4 Vocational Service anirnar 4 Stationaly EE ELKE EN DEE DR RENS SE 4 Severe Duty SeMVIC ee ee ee ee ee ee 4 Transmission Oil Filter ee ee ee ee ee ee ee ee ee ee ee ee 5 Operating Temperatures Cooling Requirements 5 Oil Cooler Usage cceecccseseescseseecseeceseeseeeeteesesenes 5 Eaton Extended Warranty Protection Plan Lubrication REQUIFEMENIS ses ee MAD Ge ede etn 5 Transmission Lubrication Procedures Transmission Oil Level Check e ee ee ee ee 6 Drain Transmission Oil e ee ee ee ee ee ee 6 Drain Transmission Oil Cooler if equipped 6 Fill Transmission Oil 0 0 0 0 ee ee ee ee ee ee ee ee 6 Fill Transmission Oil Cooler if equipped 6 Transmission Lubricant Ca
5. ck o Transmission Europe For a list of approved Extended Service Interval Lubricant Suppliers PS 164 rev7 visit www Roadranger com Lubricants to download TCMT0020 T a Servi Lubricant SAE Drain Interval ransmission ervice ubrican i Product ee Viscosit i Torque Interval Specification Grade Y Line Haul e Stationary Hybrid All Extended Eaton PS 164 SAE 50 800 000 Km 300 000 Km N A Rev 7 or 3 years Automated All Extended Eaton PS 164 SAE 50 800 000 Km 300 000 Km _ 2 000 hours UltraShift PLUS Rev 7 or 3 years or 5 years Manual lt 1 850 lb ft Extended Eaton PS 164 SAE 50 800 000 Km 300 000 Km 2 000 hours Transmission lt 2 500 Nem Rev 7 or 1 year or 5 years Standard Eaton PS 321 N A 120 000 Km 120 000 Km 600 hours or or 3 years 1 year MTF Gear Oil SAE 80W90 100 000 Km 100 000 Km 500 hours or API GL 4 SAE 75W90 See Note 1 or 1 year 1 year Engine Oil SAE 50 See Note 1 See Note 2 API CD SAE 40 MIL 2104H SAE 30 CAT TO 4 Manual gt 1 850 lb ft Extended Eaton PS 164 SAE 50 800 000 Km 300 000 Km 2 000 hours Transmission gt 2 500 Nem Rev 7 or 3 years or 5 years Note Standard service interval lubricants require an initial drain prior to regular drain intervals 1 On Highway applications shall have oil drained after first 5 000 to 10 000 Km 2 Off Highway applications shall have oil drained afte
6. NLGI Grade Appearance Consistency 000 Fluid Cooking oil 00 Fluid Applesauce 0 Very soft Brown mustard 1 Soft Tomato paste 2 Moderately soft Peanut butter 3 Semi fluid Vegetable shortening 4 Semi hard Frozen yogurt 5 Hard Smooth pate 6 Very hard Cheddar cheese spread Thickener Type Compatibility When greases of different thickener types are mixed undesired results may occur When the mixture of the greases changes the performance properties then the two greases are considered incompatible Greases are considered compatible when these parameters don t change when mixed e Grade Consistency e Lower Heat Resistance e Less Shear Stability e Decrease in Additive Performance The use of a grease that is not compatible with the Roadranger Grease EP 2 Lithium Complex grease can result in premature release bearing failures Note Calcium Sulfonate Type Greases have been shown to be incompatible with the Roadranger Grease EP 2 Lithium Complex Type Use of Calcium Sulfonate Type Grease will reduce the life of Eaton Clutch release bearings 21 Performance NLGI developed designations and performance descriptions for service grease categories These categories are defined per ASTM D4950 and include the lubrication of wheel bearings and chassis components An L designation includes such things as ball joints steering pivots universal joints and other chassis components and a G designatio
7. 27 13 S 16618 28 13 8609 12 6 5 16709 27 13 8709 26 12 A 16710 AC AS AS2 26 12 8908LL 28 13 S 16710 AS CEEMAT 89 42 905 22 10 16713 28 13 906 26 12 16713 T2 27 13 909 25 12 16718 28 13 910 25 12 16718 T2 27 13 913 27 13 16908LL 28 13 915 28 13 16909ALL 28 13 9508 25 12 16910 AS3 DM2 DM3 28 13 9509 25 12 16913 28 13 9513 21 13 16913L DM3 28 13 955AL 28 13 16915 28 13 955ALL 25 12 16918 AS2 AS3 28 13 958LL 28 13 17210 23 5 11 9710 26 12 17610 28 13 18210 23 5 11 HD Automated UltraShift PLUS 18610 28 13 use of the following suffixes 18710 CAS 26 12 LAS Linehaul 26 12 18718 28 13 VAS VCS VHP VMS VXP 28 13 Vocational 18910 AS2 AS3 26 12 18913 T2 28 13 18918 AS2 T2 AS3 28 13 Fuller Advantage Series 9 A 92 12 6 Automated FAOM 1X810S EC3 16 75 20913 28 13 Manual 16 75 FAO F FAOM F 1X810C 20918 AS2 AS3 28 13 Medium Duty Transmission Lubricant Capacities The Medium Duty MD model numbers include the following prefixes FS FSO Transmission MD Hybrid Model Number Pints Liters All Models 19 5 MD Model Number Pints Liters 4005 10 5 5 4205 12 5 6 5005 10 5 5 5106 18 9 5205 12 5 6 5306 18 9 5406 19 5 9 6005 19 9 6105 19 9 6106 19 9 6205 19 9 6206 18 9 6305 19 5 9 6306 19 5 9 6406 19 5 9 7206 20 9 8206 20 9 8406 19 5 9 The M
8. 36 17 11909ALL 28 13 14608 28 13 1202 11 5 14608LL 29 14 12210 23 5 11 14609 27 13 12509 25 12 14610 28 13 12510 25 12 14613 29 14 12513 27 13 RTLO 14613 28 13 12515 28 13 14615 30 14 12508LL 28 13 14618 28 13 12609 27 13 14708LL 29 14 12610 28 13 14709 27 13 12613 29 14 14709ALL 28 13 12709 27 13 14710 AC AS AS2 26 12 12709ALL 28 13 RTL 14710 28 13 12710 AC AS AS2 26 12 14710 AS CEEMAT 89 42 RTL 12710 28 13 14713 28 13 12713 28 13 14713 T2 27 13 12813 29 14 14715 28 13 12909ALL 28 13 14718 28 13 12910 AS3 DM2 DM3 28 13 14718 T2 27 13 12913 28 13 14813 29 14 13109 AT 88 42 14908LL 28 13 13210 23 5 11 14909ALL 28 13 13609 27 13 14910 AS3 DM2 DM3 28 13 13610 28 13 14913 28 13 13613 29 14 14915 28 13 13707 DLL MLL 28 13 14918 A2 AS3 28 13 13709 27 13 15210 23 5 11 13709ALL 28 13 15610 28 13 13710 26 12 15613 29 14 8 Transmission HD Model Number Pints Liters HD Model Number Pints Liters 15615 30 14 22918 AS2 AS3 28 13 15618 28 13 610 12 6 15709 27 13 613 16 8 15710 26 12 6609 12 6 15715 28 13 6610 12 6 15813 29 14 6613 16 8 15909ALL 28 13 7608LL 19 5 9 16210 23 5 11 8607 36 17 16610 28 13 8608L
9. Drain Interval Lists for Europe Australia Asia Pacific Africa and Middle East Updated images for Proper and Improper Fill Level with Fill Plug and added image of Proper Oil Level with Sight Glass July 2013 Updated Faton Clutch Lubrication and Service Interval List June 2013 New product specification manual for Roadranger Lubricant Products 26 Copyright Eaton 2013 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 and services in the industry ensuri
10. NLGI GC LB 20 000 miles max 250 hours Reman Solo Clutch 32 000 km or 1 month Reman Easy Pedal Clutch DM No Lubricant Needed Pedal Shaft Bushings NLGI 2 Lithium Complex NLGI GC LB At every chassis At every chassis lubrication lubrication Note 1 Grease the ECA Cross Shaft at vehicle chassis lubrication maintenance intervals 2 Frequent lubrication of the release bearing is required for severe duty cycles 3 If the vehicle has been out of service for an extended period of time lubrication of the clutch release bearing and clutch linkage is required prior to returning to service 24 Roadranger Synthetic Gear Axle Lubricants FE75W 90 75W 90 80W 140 Roadranger Synthetic Gear Lubricants are extreme pressure gear oil lubricants designed to promote longer gear life and better Operating economy thus improving fuel economy in heavy mid and light duty applications They are formulated using synthetic base stock which has a high viscosity index and an exceptionally low pour point Benefits e Longer Axle Component Life e Reduces Gear Wear e Less Maintenance e Less Oil Disposal e Increases Vehicle Uptime e Improves Protection In Extreme Conditions e Extended Drain and Extended Warranty Protection e Genuine OEM Equipment Approvals FE 75W 90 75W 90 80W 140 API GL 5 MT 1 API GL 5 MT 1 API GL 5 MT 1 MIL PRF 2105E MIL PRF 2105E MIL PRF 2105E ArvinMeri
11. TCMT0020 Cool Servi Lubricant SAE Drain Interval ooler ervice ubrican 3 Product GCW Viscosit i Used Interval Spec Grade Line Haut Y Onal Stationary Hybrid All No Extended Eaton PS 164 SAE 50 800 000 Km 300 000 Km N A Rev 7 or 3 years Automated All Yes No Extended Eaton PS 164 SAE 50 800 000 Km 300 000 Km 2 000 hours UltraShift Rev 7 or 3 years or 5 years PLUS Manual lt 50 Ton Yes No Extended Eaton PS 164 SAE 50 800 000 Km 300 000 Km 2 000 hours Transmission Rev 7 or 3 years or 5 years Standard Eaton PS 321 N A 120 000 Km 120 000 Km 600 hours or 1 year or 1 year MTF Gear Oil SAE 80W90 100 000 Km 100 000 Km 500 hours API GL 4 SAE 75W90 or 1 year or 1 year Engine Oil API SAE 50 CD SAE 40 MIL 2104H SAE 30 CAT TO 4 Manual gt 50 Ton Yes Extended Eaton PS 164 SAE 50 800 000 Km 300 000 Km 2 000 hours Transmission Rev 7 or 3 years or 5 years Standard Eaton PS 321 N A 120 000 Km 120 000 Km 600 hours or 1 year or 1 year MTF Gear Oil SAE 80W90 100 000 Km 100 000 Km 500 hours API GL 4 SAE 75W90 or 1 year or 1 year Engine Oil API SAE 50 CD SAE 40 MIL 2104H SAE 30 CAT TO 4 No Extended Eaton PS 164 SAE 50 400 000 Km 150 000 Km 1 000 hours Rev 7 or 2 year or 2 years Standard Eaton PS 321 N A 60 000 Km 60 000 Km 300 hours or 1 year or 1 year MTF Gear Oil SAE 80W90 50 000 Km 50 000 Km 250 hours API GL 4 SAE 75W90 or 6 months o
12. 17 5 economy 40 C 132 improve component protecion Brookfield Viscosity cP ASTM D2983 e Easier cold weather shiftin K 40 C 104 000 5 e Extend drain intervals 3 e All climate year round performance Viscosity index ine AOIM De 70 3 e Reduce maintenance Pour Point C F lt 45 lt 49 ASTM D97 a i e Minimize downtime Flash Point C F 221 430 ASTM D92 5 e Reduce component wear API gravity 15 6 C 33 0 ASTM D287 e Maintain warranty coverage Density 15 6 C g l 860 7 17 ASTM D1298 60 F Ibs gal Approvals Roadranger SAE 50 Synthetic Manual Transmission Lubricant is approved for the following specifications e Eaton PS 164 rev 7 e Mack Truck TO A Plus e International Truck TMS 6816 e Meritor 0 81 pending e ZF FreedomLine ZF AS Tronic e Volvo 97305 e API MT 1 Transmission Application Definitions Line Haul On Highway Service e Line Haul is moving different types of freight in high mileage operation e Operation on road surfaces of good to excellent concrete or asphalt e Distances are more than 30 miles 48 km between starting and stopping e Typical vehicle configurations are 4 x 2 6 x 2 and 6 x 4 tractor trailer combinations some straight trucks Typical Vehicle Uses Line Haul Recreational Rescue Fire Service Transit Coach Check fluid levels and inspect for leaks at regular PM maintenance intervals not to exceed 12 000 miles Voc
13. AE 50 Manual API CD SAE 40 Transmission MIL 2104H SAE 30 CAT TO 4 Recommended 20 000 Km service interval check oil level and inspect for leaks Note 1 Standard service interval lubricants require an initial drain prior to regular drain intervals On Highway applications shall have oil drained after first 5 000 to 10 000 km 2 Standard service interval lubricants require an initial drain prior to regular drain intervals Off Highway applications shall have oil drained after first 40 hours or 2 months 3 When ambient temperatures routinely exceed 45 C more than 100 days per year use Extended Drain Lubricants and a Reduce drain intervals to 250 000 Km b or perform oil sample analysis at every 60 000 Km to check for lubricant oxidation 16 Hydraulic Launch Assist Hydraulic Launch Assist HLA High Performance Hydraulic Fluid Benefits Formulated for excellent seal compatibility All temperature performance Excellent cold temperature operation High temperature protection Designed for long fluid life and system reliability An engineered fluid developed in conjunction with Eaton s HLA system resulting in optimal system performance including rust protection seal and bladder compatibility cleanliness and system durability Formulated with highly refined Group III base oils to maximize fluid life High viscosity index provides all season performance resulting in excellen
14. antage or 5 years or 3 years FRW Models Manual Above 1 850 lb ft Extended PS 164 Rev 7 SAE50 500 000 mi 180 000 mi 2 000 hours Transmission 2 500 Nm 800 000 km 288 000 km or 5 years Heavy Duty or 5 years or 3 years see Note 1 Below 1850 Ib ft Extended PS 164Rev7 SAE50 500 000mi 180 000 mi 500 hours 2 500 Nm 800 000 km 288 000 km or 1 year or 5 years or 3 years Standard PS 321 N A 75 000 mi 75 000 mi 500 hours 120 000 km 120 000 km or 1 year or 1 year or 1 year Heavy Duty Die SAE50 60 000 mi 60 000 mi 500 hours sel Engine Oil 96 500 km 96 500 km or 1 year MIL PRF 2104H or 1 year or 1 year CAT TO 4 SAE 40 SAE 50 Manual All Extended PS 164 Rev 7 SAE 50 500 000 mi 180 000 mi 2 000 hours Transmission 800 000 km 288 000 km or 5 years Medium Duty or 10 years or 3 years see Note 1 Standard PS 321 N A 75 000 mi 75 000mi 500 hours 120 000 km 120 000 km or 1 year or 1 year or 1 year Heavy Duty Die SAE 50 60 000 mi 60 000 mi 500 hours sel Engine Oil 96 500 km 96 500 km or 1 year MIL PRF 2104H or 1 year or 1 year CAT TO 4 SAE 40 SAE 50 ASW Clutch All Standard Dexron VI N A 150 000 mi 150 000 mi N A Module 250 000 km 250 000 km or 3 years or 3 years Note 1 Transmissions with Extended Warranties or Extended Protection Plans require the Extended Service Interval lubricant to maintain warranty agreements 11 D 5 7 5 7
15. ash off resistance e Performs in high and low temperatures e Excellent elastomer compatibility e Recommended operating temperatures between 40 C and 150 C Typical Properties Characteristic id Test Method NLGI Grade 2 ASTM D217 Thickener Type Lithium Complex Performance Rating NLGI GC LB ASTM D4950 Color Blue Visual Texture Smooth Dropping Point C 274 ASTM D2265 Base Oil Viscosity cSt ASTM D445 40 C 150 100 C 15 6 Timken OK Load kg 50 ASTM D2509 Four Ball EP ASTM D2596 Load Wear Index kgf 74 Weld Point kg 620 Four Ball Wear mm 0 41 ASTM D2266 Fretting Wear mg 5 1 ASTM D4170 Water Resistance at 3 9 ASTM D1264 80 C removed Eaton Clutch Lubrication Requirements Failure to properly lubricate the bearing bushing will result in bearing and bushing failures e Consult the appropriate Clutch Service Manual for detailed explanation of the lubrication techniques e Regular grease service intervals are required to purge the debris from the grease e f not properly maintained the debris can become hard and prevent the flow of grease when serviced Pictured are examples of failures due to incompatible greases Release Bearing Failure The photo below shows the release bearing where the majority of the grease has disappeared This is likely due to using grease with a lower operating temperature or using an incompatible greas
16. ational Service e Low mileage operation under 60 000 miles 96 500 km per year e Off highway or areas of unstable or loose unimproved road surfaces e Less than 30 miles 48 km between starting and stopping e Typical Vehicle Uses City Delivery Construction Heavy Haul Logging Mining Oil Field Refuse School Bus Intercity Bus Coach Agriculture Yard Tractor Check fluid levels and inspect for leaks every 50 hours Stationary e Transmissions not used for mobile applications e Check fluid levels and inspect for leaks every 50 hours Severe Duty Service e Consistent operation at or near maximum GCW or GVW ratings e Dirty or wet environments e Consistent operation on grades greater than 8 Transmission Transmission Oil Filters Transmission oil filters are required for all 2050 Ib ft and 2250 Ib ft rated transmission models Transmission filters should be changed during regular transmission lube change intervals Inspect the transmission filter for damage or corrosion during all preventative maintenance checks Replace as necessary Operating Temperatures Cooling Requirements Transmissions must not be operated at temperatures above 250 F 121 C Operation at temperatures above 250 F 121 C causes loaded gear teeth temperatures to exceed 350 F 177 C which will ultimately lead to premature gear failure If the elevated temperature is associated with an unus
17. e When the release bearing gets hot the grease melts and does not provide adequate lubrication 7 Grease Contaminated with Debris The photo below shows a release bearing with grease that is contaminated with debris It is very important to grease at regular service intervals to purge the debris from the bearing 20 Debris Close Up The photo below is a close up of the debris in the grease The debris contains hard particles is damaging to the bearing and will cause premature failures Grease Information Greases available to the trucking industry are not created egual and many are formulated for specific applications Just reading the information on the label on the container may not be enough to determine if the grease used by customers for maintenance is compatible with greases used in Eaton clutch products What To Look For When Selecting Grease Look for these 3 things 1 Grade Consistency 2 Thickener Type Compatibility 3 Performance Grade Consistency The NLGI grade of grease refers to its consistency It is measured by dropping a weighted cone into the grease per ASTM D217 The depth the cone penetrates into the grease is called the consistency The NLGI grade refers to a range of depths the cone penetrates into the grease The chart below is a helpful reference to understand the consistency and appearance of a grease based on the NLGI Grade
18. e RA 25 Typical Properts rocin ee RR Ge Re 25 General Information Roadranger Lubrication Philosophy In promoting component reliability and longevity proper lubrication is the key to a sound and effective maintenance program Without effective lubricants at proper levels and temperatures remaining maintenance procedures will not keep components functional Synthetic lubricants have proven to be superior to petroleum products and represent opportunities to promote superior maintenance and bottom line operating performance while significantly extending component service life and reliability Certain products and applications as noted in this manual require the use of approved synthetic lubricants A list of approved lubricants and suppliers can be found at Roadranger com in the approved Lubricant Supplier Manual TCMT0020 It is important to perform a daily pre trip inspection of drivetrain components for lubricant leaks Leaks should be brought to the attention of maintenance and immediate corrective action should be taken Benefits Extended Drain synthetic lubricants offer superior thermal and oxidative stability for extended product performance and reliability The superior performance characteristics of these lubricants enable component manufacturers to offer extended drain intervals and extended warranties Added benefits include a more efficient drivetrain that translates into proven fuel economy savings over mineral based lubr
19. edium Duty MD Automated model numbers including the following prefixes F and FO PLUS Model Humber PIE iter 5405B DM3 21 10 5406B DM3 21 10 5505B DM3 21 10 5506B DM3 21 10 6405B DM3 21 10 6406B DM3 21 10 6505B DM3 21 10 6506B DM3 21 10 10 Transmission Eaton Transmission Lubricant and Drain Interval Lists NAFTA For a list of approved Extended Service Interval Lubricant Suppliers PS 164 rev7 visit www Roadranger com Lubricants to download TCMT0020 Ad P SAE Drain Interval Transmission Service Lubricant 4 P t a Viscosit i roduc Torque Interval Specification CRES Line Haul a ha Stationary Hybrid All Extended PS 164 Rev 7 SAE50 500 000 mi 180 000 mi 2 000 hours see Note 1 800 000 km 288 000 km or 5 years or 10 years or 3 years Automated All Extended PS 164 Rev 7 SAE50 500 000 mi 180 000 mi 2 000 hours Heavy Duty 800 000 km 288 000 km or 5 years Uitrashift PLUS or 5 years or 3 years Fuller Advantage see Note 1 Automated All Extended PS 164 Rev 7 SAE50 500 000 mi 180 000 mi 2 000 hours Medium Duty 800 000 km 288 000 km or 5 years Uitrashift PLUS or 10 years or 3 years see Note 1 Manual All Extended PS 164 Rev 7 SAE 50 500 000 mi 180 000 mi 2 000 hours Transmission 800 000 km 288 000 km or 5 years Fuller Adv
20. ements e Approved extended drain lubricants are required to maintain Roadranger Extended Warranty Protection Plans e For specific details about Eaton extended warranty programs refer to the Roadranger Warranty Guide TCWY0900 or call 1 800 826 HELP 4357 e For a complete list of Roadranger Approved Lubricants see Roadranger com Lubricants TCMT0020 z D 5 7 3 7 o o Transmission Transmission Lubrication Procedures Each Transmission model has specific lubrication requirements Consult the appropriate Transmission Service Manual for detailed instructions Transmission Oil Level Check Note Before checking the oil level the engine must be idling Fill and the transmission in neutral for at least 2 minutes Hole Lubricant temperature must be between 60 F and 120 F 15 5 C and 48 8 C Inspect the transmission exterior for leaks Look around the oil filter and exterior seals for damage and replace as necessary Check fluid levels and inspect for leaks at regular intervals not to exceed 12 000 miles The lubricant level can be checked by the fill hole or the sight glass They are usually located on the driver s side of the transmission 1 Turn engine off Fill Hole 2 Remove fill hole plug or view oil level through the sight glass 3 Lubricant must be level with the hole Note For transmissions with dipsticks the proper level is between the cold ADD mark and
21. ent Maintenance Requirement Component Interval hours 2 400 12 000 Transfer Case Lubricant Change Roadranger FE 75W 90 x 1 9 gallons HLA System Fluid Lubricant Change Roadranger HLA High Performance Hydraulic Fluid X 21 gallons HLA System Filters Change System Oil Filter Part 6025270 001 Change Secondary Oil Filter Part 5994113 001 Reservoir Breather Change Breather Part 5998865 001 18 Roadranger Grease EP 2 Roadranger Grease EP 2 is a multi purpose high performance NLGI Grade 2 lithium complex grease for a variety of uses for both on and off road applications where the use of conventional lithium grease is limited Application It is recommended for lubrication of U joints tripods drive shafts release bearings in clutches and brakes with high temperature conditions Its excellent low temperature behavior makes it suitable for extreme climate conditions across the country Roadranger Grease EP 2 has excellent anti friction properties in order to reduce shudder It is also suitable for machinery in construction dredging forestry marine and mining where this type of grease is required Benefits e Meets NLGI GC LB Chassis and Wheel Bearing requirements e Approved for Roadranger clutch requirements e improved extreme pressure and rust protection e Copper and iron corrosion resistance e Extended bearing life e Low oil bleed e Provides greater w
22. icants Extended Drain synthetic lubricants are advantageous in all applications and Eaton highly recommends for severe duty applications and in cold climates It is important to use the lubricants that are approved for the current specifications set forth by each component manufacturer Look for the appropriate approval code on the container Use of lubricants meeting these specifications will ensure the highest performing lubricants for maximum performance To identify Genuine Roadranger Lubricants look for the Genuine Lubricants Label on the container to ensure you have Genuine Roadranger Lubricants Genuine Product Label Look for the Genuine product label on lubricant packaging to ensure the highest performing lubricants Roadranger Genuine Lubricants EF TeM Note Eaton discontinued the use of the E500 logo in 2006 Note Eaton and Dana Genuine Lubricants logo was discontinued in 2012 ep 17 17 o 5 i 3 et i 5 General Information Unapproved Lubricants Things to Watch Out For Roadranger recommends using genuine Roadranger approved lubricants Unfortunately the product labeling can be difficult to understand Here is some common jargon to look for when determining if a lubricant is approved Jargon to avoid e Product X meets and or exceeds the manufacturer s requirements of e Product X is recommended for use where What to look for e Approved for by
23. iled grease hoses will prevent grease from reaching the release bearing causing pre mature failure Release Fork Wear Pads The release fork has hardened steel pads where it contacts the release bearing housing Apply a small amount of grease to the surface of these pads Clutch Brake The clutch brake friction material is designed to operate with lubricant While lubricating the release bearing grease should purge from the Cross Shaft Bushings Input Shaft Release Splines Fork Pads Release Fork Release Bearing Housing housing and contact the clutch brake If desired a small amount of grease could be applied to both sides of the clutch brake Note Do not be concerned if excess grease gets onto the clutch brake friction surface or the LCIB friction surface It will not affect the brake s stopping ability Cross Shaft Bushings The cross shaft bushings are greased through a grease Zerk fitting on the side of the clutch housing or by a grease hose extension tube On some models the Zerk fittings are labeled CS Cross shaft on the clutch housing case Removal of the inspection cover is typically necessary to access the extension lube tube Apply grease until it can be seen at the cross shaft bushing weep hole bushings Clutch Control Linkage Refer to specific OEM requirements to lubricate the bell crank and pivot pins Pilot Bearing The pilot bearing inside the flywheel does not require lubrication
24. n includes wheel bearing greases Each class L and G prefix are further divided into categories based on service needs The most demanding service category is designated by defining both classes L and G and the highest alphabetical nomenclature for the class The GC LB service category defines multi purpose grease suitable for both chassis and bearing service applications The symbol below is provided from NLGI to designate the service performance quality of a grease It is not always found on the packaging Often a reference to the specification is found on the product datasheet NATIONAL LUBRICATING GREASE INSTITUTE NLGI AUTOMOTIVE WHEEL BEARING amp CHASSIS LUBRICANT G Designation is for bearings L Designation is for chassis components 22 Clutch Lubrication Procedure 1 Each Clutch model has specific lubrication requirements Consult the appropriate Clutch Service Manual for detailed instructions Clutches typically need service lubrication in the following areas Release Bearing The release bearing is greased through a grease Zerk fitting on the clutch housing or by a grease hose extension tube On some mod els the Zerk fittings are labeled RS release bearing on the clutch housing case Removal of the inspection cover is typically necessary to access the extension lube tube Apply grease until it purges from the release bearing housing and onto the transmission input shaft Note Fa
25. ng more time on the road Eaton Vehicle Group PO Box 4013 Kalamazoo MI 49003 USA 800 826 HELP 4357 www eaton com roadranger Printed in USA Roadranger E T N Powering Business Worldwide
26. pacities Heavy Duty Transmission Lubricant Gapaelti Sas RE se E Ee ee ee 7 Medium Duty Transmission Lubricant Capaciti S e ee ee ee ee Ge ee ee ek ee 10 Faton Transmission Lubricant and Drain Interval Lists NAETAE SE EE GENE JoeB eee 11 PUTOO EE ME EE ES ee ae ar 12 Australia oe Ee nna i 13 Asla PaellIE EE EA ee ee Re 14 India AE SE EE ee eis 15 Africa and Middle East ese ee ee ee ee ee ee 16 Hydraulic Launch Assist Hydraulic Launch Assist HLA High Performance Hydraulic Fluid Benefits eves EE Ot ei ein EES 17 ApprovalS sd Ee ER clea ete A ER GE ge 17 Typical Properti S ee ee ee RR RR Ge Re 17 Eaton Hydraulic Launch Assist Lubrication Requirements Lubricant Drain Interval List eee 18 Clutch Roadranger Grease EP 2 ee IE Ui N es 19 Penei EE EE nin ER RE ain Deed EE 19 Typical Properti S ee ee ee ee RR Ge 19 Eaton Clutch Lubrication Reguirements Release Bearing Failure ee ee Ge 20 Grease Contaminated with Debris 06 20 Debris Close Up ee ee se ee Be Ge AA Be ee ae 20 Grease Information What To Look For When Selecting Grease 21 Grade CONSISTENCY eek ek RR ee RR RR 21 Thickener Type Compatibility eee 21 Perf0imanees iss SERE oe SE GR ERGE GE 22 Clutch Lubrication Procedure ese see ee ee 23 Eaton Clutch Lubrication and Service Interval List 24 Axle Roadranger Synthetic Gear Axle Lubricants EE EE OE RE 25 ApprovalS ee ee ee ee RR ee Re R
27. r 6 months Engine Oil API SAE 50 CD SAE 40 MIL 2104H SAE 30 CAT TO 4 14 Transmission India For a list of approved Extended Service Interval Lubricant Suppliers PS 164 rev7 visit www Roadranger com Lubricants to download TCMT0020 Drain Interval T ieai Service Lubricant SAE Off High Product ransmission ae Viscosit Hi Highway Torque Interval Specification ep B On Highway Vocational Line Haul ae Mining Manual All Extended PS 164 Rev 7 SAE 50 300 000 Km 2 000 hours or Transmission 185 000 mi 3 years or 5 years All Standard PS 321 N A 120 000 Km 1 000 hours 75 000 mi or 1 year 3 or 1 year 3 Group II Mineral Oil SAE 80W90 100 000 Km 1 000 hours B using 7 wt of 60 000 mi or 1 year S Lubrizol Anglamol or 1 year 6097 Group II Mineral Oil SAE 80W90 80 000 Km 1 000 hours using 7 wt of 50 000 mi or 1 year Lubrizol Anglamol or 1 year 2026 see Note 1 Group II Mineral Oil using 3 75 wt of Afton HiTEC 381 and 0 3wt of Afton HITEC 382 See Note 1 Note 1 Oil samples should be taken from the center of the transmission with oil at operating temperature using a suitable syringe Note Oil sampling to take place at 20 000 30 000 Km Note DO NOT USE ADDITIVES OR FRICTION MODIFIERS Africa and Middle East Transmission For a list of approved Extended Service Interval Lubricant Suppliers PS 164 rev7 visi
28. r first 40 hours or 2 months 12 Transmission Australia For a list of approved Extended Service Interval Lubricant Suppliers PS 164 rev7 visit www Roadranger com Lubricants to download TCMT0020 Transmission Service Lubricant SAE Product Torque Interval Specification Viscosity Drain Interval Grade Hybrid All Extended Eaton PS 164 Rev 7 SAE 50 400 000 Km Automated All Extended Eaton PS 164 Rev 7 SAE 50 400 000 Km UltraShift PLUS Manual lt 1 850 lb ft Extended Eaton PS 164 Rev 7 SAE 50 400 000 Km ke A Transmission 2 500 Nem standard Eaton PS 321 N A 120 000 Km 5 MTF Gear Oil API GL 4 SAE 80W90 100 000 Km 5 SAE 75W90 a Engine Oil API CD SAE 50 S SAE 40 MIL 2104H SAE 30 CAT TO 4 Manual gt 1 850 lb ft Extended Eaton PS 164 Rev 7 SAE 50 400 000 Km Transmission gt 2 500 Nem Note Oil analysis is required to determine exact oil change interval which can vary depending on the application Note Oil Changes should be taken from the center of the transmission with oil at operating temperature using a suitable syringe Note Oil sampling to take place at 80 000 to 100 000 Km Note DO NOT USE ADDITIVES OR FRICTION MODIFIERS Asia Pacific Transmission For a list of approved Extended Service Interval Lubricant Suppliers PS 164 rev7 visit www Roadranger com Lubricants to download
29. t cold temperature Operation and high temperature protection Excellent shear stable viscosity modifier assures optimal viscometrics to protect equipment and minimize downtime Demonstrated proof of performance through field testing Product meets Eaton s performance specification for HLA system based on rigorous laboratory pump testing Approvals The HLA Hydraulic Fluid is specifically engineered to work in conjunction with the Eaton Hydraulic Launch Assist system Typical Properties Characteristic Roadranger Test Method HLA Fluid Flash Point C 173 ASTM D92 Density 60 F Ibs gal 7 10 ASTM D1298 Pour Point C 45 ASTM D97 Kinematic Viscosity cSt ASTM D445 40 C 42 8 100 C 8 1 Elemental Content Calcium 0 015 wt Nitrogen 0 030 wt Phosphorous 0 073 wt Sulfated Ash 0 19 wt Sulfur 0 20 wt Zinc 0 090 Yowt Water 0 030 wt max p lt a D o rm D ix e gt N N N pr Hydraulic Launch Assist Eaton Hydraulic Launch Assist Lubrication Requirements Regular maintenance is important for safe and reliable operation of the Eaton HLA system A preventative maintenance PM schedule should be used to ensure the longest performance Follow maintenance procedures as described in the HLA service manual TRSM1200 Lubricant Drain Interval List Maintenance Drain HLA System Compon
30. t www Roadranger com Lubricants to download TCMT0020 Transmis SAE i i i Drain Interval Product Sion Torque Service Lubricant Viscosity Interval Specification Grade Line Haul Vocational Bus Stationary Hybrid All Extended Eaton SAE 50 N A N A 300 000 Km N A PS 164 Rev 7 or 3 years Automated All Extended Eaton SAE50 480 000 Km 6 500 hours 300 000 Km 2 000 hours UltraShift PS 164 Rev 7 See Note 3 or 1 year or 3 years or 5 years PLUS Medium Duty All Extended Eaton SAE50 300 000 Km 6 500 hours 300 000 Km N A Manual PS 164 Rev 7 or 1 year or 2 years Transmission Heavy Duty All Extended Eaton SAE50 480 000 Km 6 500 hours 300 000 Km 2 000 hours Manual PS 164 Rev 7 See Note 3 or 1 year or 2 years or 5 years Transmission FR Models RT Models Heavy Duty All Extended Eaton SAE50 300 000 Km 6500 hours 200 000 Km 2 000 hours Manual PS 164 Rev 7 See Note 3 or 1 year or 2 years or 5 years Transmission FTS 10 S10 FTS 13 S13 Heavy Duty lt 1850 lb ft Standard Eaton N A 100 000 Km N A 100 000 Km 600 hours Manual PS 321 or 1 year or 1 year or 1 year Transmission 2500Nem FR Models RT Models Heavy Duty All Standard MTF Gear Oil SAE 80W90 60 000 Km N A 60 000 Km 500 hours Manual API GL 4 SAE 75W90 See Note 1 or 1 year or 1 year Transmission See Note 1 See Note 2 FTS 10 S10 FTS 13 S13 Medium Duty Engine Oil S
31. the cold FULL mark 2 3 Fill Hole 4 5 1 2 dere Oil Level with Sight Glass 3 S Improper Oil Level Drain Transmission Oil 1 Use a drain pan under the transmission drain plug to collect oil from the bottom of the transmission Make sure the oil temperature is cool Clean around drain plug and remove plug Allow transmission oil to drain out Clean drain plug and torque as required Drain Transmission Oil Cooler if equipped Remove both cooler lines at the transmission Pressurize one line with 30 PSI 0 2 MPa of air pressure to force the oil out Capture the oil in a oil drain pan from the other hose Reconnect the coolant lines to the transmission making sure lines are not crossed Transmission Fill Transmission Oil Transmission Lubricant Capacities ee EIS On SI DUG Note Capacity of transmissions eguipped with PTOS or 2 Make sure drain plug is properly installed Oil Coolers are greater than capacities listed These 3 Fill with approved oil until the oil starts flowing out values are approximate Always use the fill hole as the fill hole final reference 4 Clean install and properly and torque fill plug Heavy Duty Transmission Lubticant Capacities Fill Transmission Oil Cooler if equipped Capacities are sorted by model number only The prefixes are 1 After filling the transmission with oil place the included when necessary
32. tor 076 E 076 N ArvinMeritor 076 E 076 N ArvinMeritor 076 E 076 N DANA SHAES 256 Rev C DANA SHAES 256 Rev C DANA SHAES 429 Rev A International TMS 6816 International TMS 6816 International TMS 6816 Mack GO J Plus Mack GO J Plus Note Use of Roadranger Approved Lubricants is Required for Extended Warranty Protection Plans For a list of approved Roadranger Suppliers visit www Roadranger com Lubricants to download TCMT0020 Typical Properties Characteristic FE 75W 90 75W 90 80W 140 Test Method Part Number 2986 2984 2831 SAE Grade 75W 90 75W 90 80W 140 SAE J300 Kinematic Viscosity cSt ASTM D445 40 C 103 122 284 100 C 15 0 16 6 30 6 Brookfield Viscosity cP ASTM D2983 26 C 75 000 40 C 90 000 125 000 Pour Point C lt 45 lt 45 lt 40 ASTM D97 Flash Point C 215 204 200 ASTM D92 API Gravity 15 6 C 27 3 25 2 23 6 ASTM D287 Density 15 6 C g l 891 891 902 ASTM D1298 60 F Ibs gal 7 42 7 42 7 51 25 Change Control Log Change Control Log Date Description October 2013 Added Fuller Advantage Series to Transmission Lubrication Capacities and Eaton Transmission Lubricant and Drain Interval Lists for NAFTA Updated Eaton Transmission Lubricant and Drain Interval Lists for India Added Fuller SAE Viscosity Grade 75W90 under products with 80W90 to Eaton Transmission Lubri cant and
33. ual operating condition that will recur a transmission oil cooler must be added or the capacity of an existing cooling system increased The following conditions in any combination can cause operating temperatures of over 250 F 120 C e Operating consistently at high low speeds e High ambient temperatures e High horsepower operation e Restricted airflow around transmission e Excessive use of engine retarder e Exhaust system proximity to transmission e High power PTO operation for extensive periods while stationary e High engine RPM for extensive periods External oil coolers are available to reduce operating temperatures when the above conditions are encountered Eaton oil cooler systems must meet a minimum requirement of 3 4 water coolant lines and 8 GPM water coolant flow at 1500 RPM The end user is ultimately responsible for maintaining transmission lube temperatures below 250 F 121 C Transmission oil coolers must be used to reduce operating temperatures when the above conditions are encountered Oil Cooler Usage Transmission oil coolers are recommended for e Engines 350 hp and above Transmission oil coolers are required for e Engines 400 hp and above and 1 400 Ib ft 1498 Nm or greater torque e Engines 400 hp and above and a GVW GCW over 90 000 Ibs e Engines 450 hp and above e Engines 1500 Ib ft 2033 Nm and above Eaton Extended Warranty Protection Plan Lubrication Requir

Roadranger Lubrication Manual - CCC Parts Company

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