18 Speed Gearbox
Contents
1. Fuller Heavy Duty Transmissions Roadranger More time on the road 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 Driver Instructions Fuller Heavy Duty Transmissions TRDRO800 September 2007 RTLO 14718B RTLOF 16918B T2 RTLO 14918B RTLOF 18718B RTLO 14918B T2 RTLOF 18918B RTLO 16718B RTLOF 18918B T2 RTLO 16918B RTLOF 20918B RTLO 16918B T2 RTLOF 20918B T2 RTLO 18718B RTLOF 22918B RTLO 18718B T2 RTLO 18918B RTLO 18918B T2 RTLO 20918B RTLO 20918B T2 RTLO 22918B RTLOF 14718B RTLOF 14918B RTLOF 14918B T2 RTLOF 16718B RTLOF 16918B Introduction 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 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 veh2. 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 INFORMATION IS NOT INTENDED FOR SALE OR RESALE AND THIS NOTICE MUST REMAIN ON ALL COPIES Roadranger E T N 2007 Eaton Corporation and Dana Corporation All rights reserved Printed in USA For spec ing or service assistance call 1 800 826 HELP 4357 24 hours a day 7 days a week Mexico 001 800 826 4357 for more time on the road Or visit our web site at www roadranger com Roadranger Eaton Dana and other trusted partners providing the best products and services in the industry ensuring more time on the road
3. 4 To downshift from top gear Once the engine has reached the shift point the transmission will automatically downshift 5 To downshift from AUTO position to 7th H While AUTO position make sure the splitter selector 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 6 Continue downshifting through the shift pattern double clutching during lever shifts and breaking torque during button shifts Driving Operation Top 2 Driving Tips To activate Top 2 mode the transmission must be shifted from 7th H to AUTO 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 mode Once the engine reaches the normal shift point Top 2 mode will 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 When 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 upshifts and downshifts When the shift lever is in the AUTO position and the transmission has just completed an upshift the downshift point will be lower than normal If the
4. L LO to 1st L 3 Pre select just before making an upshift by moving the button rear ward while maintaining accelerator position 4 Movethe shift lever double clutching to the 1st speed gear position If the splitter control button is not moved the transmission will be in 1st H once the final clutch engagement is made CAUTION Never move the splitter control button or the range lever with the shift lever in neutral while the vehicle is moving 5 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 Driving Operation Combination Lever shift and Splitter shift LO Range H to HI Range L 4th H to 5th L Range shift 6 Pre select just before making an upshift by moving the button rear ward while maintaining accelerator position 7 Pullup the Range Lever move the shift lever double clutching to the 5th speed gear position If the splitter control button is not moved the transmission will be in 5th H once the final clutch engagement is made CAUTION Never move the splitter button or the range lever with the shift lever in neutral while the vehicle is moving 8 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 Splitter shift HI Range L to HI Range H 5th L to 5th H
5. clutching to the next lower gear position If the splitter control button is not moved the transmission will be in 4th L once the final clutch engagement is made 21 Continue downshifting through LO range Double clutching during lever shifts single clutch during split shifts while the shift lever is in the same position Splitter shift LO Range H to LO Range L 4th H to 4th L 22 Pre select just before making a downshift by moving the button rear ward while maintaining accelerator position 23 Then immediately release the accelerator depress the clutch pedal once to break torque release the pedal to reengage the clutch accel erate the engine until the shift is complete Continue driving or down shifting The transmission shifts from H to L when synchronous is reached Combination Lever shift and Splitter shift LO Range L to LO Range H 4th L to 3rd H 24 Pre select just before making a downshift by moving the button for ward while maintaining accelerator position 25 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 3rd L once the final clutch engagement is made 26 Continue downshifting through LO range Double clutching during lever shifts single clutch during split shifts while the shift lever is in the same position Driving Operation Top 2 Basic Operation and Overview The Sup
6. 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 in the LO Range position for LO And Splitter Control Range Button Rearward Depress the clutch pedal to the floor Move the shift lever to desired initial gear Release the parking brakes on the vehicle Slowly release the clutch pedal and apply accelerator COND Driving Operation Upshift 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 CAUTION Never move the range lever or the splitter control button with the shift lever in neutral while the vehicle is moving Splitter shift LO Range L to LO Range LO L to LO H 1 Pre select just before making an upshift by moving the button for ward while maintaining accelerator position 2 Then immediately release the accelerator depress the clutch pedal once to break torque release the pedal to reengage the clutch allow the engine to decelerate until the shift is complete Continue driving or upshifting The transmission shifts from L to H when synchro nous is reached Combination Lever shift and Splitter shift LO Range H to LO Range
7. 9 Pre select just before making an upshift by moving the button for ward while maintaining accelerator position 10 Then immediately release the accelerator depress the clutch pedal once to break torque release the pedal to reengage the clutch allow the engine to decelerate until the shift is complete Continue driving or upshifting The transmission shifts from L to H when synchro nous is reached Combination Lever shift and Splitter shift HI Range H to HI Range L 5th H to 6th L 11 Move the splitter control button into the rearward position 12 Move the shift lever double clutching to the 6th speed gear posi tion If the splitter control button is not moved the transmission will be in 6th H once the final clutch engagement is made CAUTION Never move the splitter button or the range lever with the shift lever in neutral while the vehicle is moving Driving Operation 18 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 CAUTION Never move the range lever or the splitter c
8. er 18 Top 2 transmission operates like a normal Super 18 in positions LO through 7th H The transmission shifts automatically in the AUTO posi tion based on engine speed and load When the transmission is in the Top 2 Mode the system will a Shiftthe transmission between top 2 gears automatically b Increase or decrease engine speed during a Top 2 shift c Momentarily interrupt cruise control or engine brake during the shift Splitter Range Splitter Range 5 Seta 5 Selector ES 15 LO Range LO Range Shift LOL 1st L 2nd L 3rd L 4th L Shift LO H 1st H 2nd H 3rd H 4th Splitter Range Splitter Range Selector Seleno TEE Selector 4 HI Range HI Range Shift 5th L 6th L 7th L Driving Operation 1 Upshift the transmission through the shift pattern to 7th H position Double clutching during lever shifts and breaking torque during but ton shifts 2 When the engine has reached the shift point use the normal double clutching procedure and move the shift lever into AUTO position Upshift Procedure Note The position of the splitter selector does not matter when moving the lever into the AUTO position It is recommended to leave the splitter selector in the forward position so it is ready when you want to make a downshift into 7th H position 3 When the engine has reached the shift point the transmission will automatically shift into top gear Downshift Procedure
9. icle 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 effort has been made to ensure the accuracy of all information in this manual However Eaton Truck Component Operations makes no expressed or implied warranty or representation based on the enclosed information Any errors or omissions may be reported to Marketing Ser vices Eaton Truck Component Operations P O Box 4013 Kalamazoo MI 49003 Copyright Eaton Corporation 2001 All rights reserved Table of Contents Introduction Warnings and Cautions oo ccccececccsescescsesceeeecesecsseeneeeeesesaeeeeesanasaeees Model Designation 1 Identification Tag essere 2 Driving Operation General Intormation u c citi rente 3 Shift Pattern Diagram onte e nee om ope epa 4 Shift Controls esee ade e a e Ee e EAR 5 Transmission Features sessssssssssee eene nene 6 Driving Tips zai rode rrt rte redes 8 Double Clutching Procedure 9 Initial Statt UP cette ete e he et pee p re pt ee ands 10 Upshitt Procedure oi e Ro E DD XS 11 Top 2 Basic Operation and 15 Upshift Procedure poi e Be edt ie
10. ing 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 20 Overview Operating Temperatures with Oil Coolers Operating at temperatures above 250 F 120 C causes loaded gear tooth temperatures to exceed 350 F 177 C which will ultimately destroy the heat treatment of the gears Temperatures above 250 F 120 C should be regarded as a warning of inadequate cooling If the elevated temperature is associated with unusual operating conditions that will reoccur a cooler should be added or the capacity of the existing cooling system increased 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 available to reduce operating temperatures when the above conditions are encountered Oil Cooler Chart 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 Ibs With engines 399 H P and above and 1400 lbs ft or greater torque With engines 450 H P and above 21 Ove
11. lutch 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 Note 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 8 Forupshifts allow engine RPM to decrease to match road speed b Fordownshifts 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 5 Letupon the clutch pedal and apply accelerator Driving Operation Initial Start Up Special Instructions WARNING Before starting a vehicle always be seated in the driver s A seat move the shift lever to neutral and set the parking brakes CAUTION Before moving a vehicle make sure you understand your A shift pattern configuration A shift label should be in your vehicle s cab If not refer to General Information to order one 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
12. o 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 All 18 Speed Models Eaton Fuller 18 SPEED Transmissions SPLITTER SELECTOR 5 ALL GEAR SHIFT LEVER POSITIONS PRE SELECT ALL RANGE SHIFTS move RANGE SELECTOR BEFORE MOVING SHIFT LEVER UPSHIFTING HER RANGE SELECTOR DOWN FT sors 4 RAISE RANGE SELECTOR SHIFTING HIFT 8 7 5 MOVE RANGE SELECTOR DOWN SHIFT 432 110 DO NOT CHANGE RANGE WHILE MOVING IN REVERSE PUT TRANSMISSION IN NEUTRAL AAWARNIN Driving Operation Shift Controls Roadranger Valve A 5013 Rearward for L Up for HI Range Splitter Control Button Range Lever Forward for Down for LO Range Rearward for L Splitter Control Down for LO Range Button Forward for Driving Operation 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 sequence Preselect IMPORTANT Always preselect all range shifts when upshifting or downshift ing 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 gea
13. oS ORE REO 16 Top 2 Driving T DS rd e otio ty 17 Top 2 System Problem sssssseseeeeeeeeennens 18 Overview Lubrication Procedures 19 Preventive Maintenance ssssssseeeneemeeenenne 22 Glossary Definitions for Top 2 Transmissions ss 24 Overview Model Designation RTLOF 16 7 18 T2 Top 2 Roadranger MT Multi Torque Twin Countershaft Ratio Set Low Inertia Forward Speeds O Overdrive 7 Helical Auxilary Gearing and Multi Mesh Front Section Geari F Forward Mounted Shift Tower 9 Improved Seal System This x 100 Nominal Torque Capacity Overview Transmission Tag and Location Identification Tag 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 Introduction General Information This manual is designed to provide detailed information necessary for the proper driving techniques of the Eaton Fuller transmissions listed on the cover Introduction Driver instructions are divided into two sec
14. ontrol button with the shift lever in neutral while the vehicle is moving Splitter shift HI Range H to HI Range L 8th H to 8th L 14 Pre select just before making a downshift by moving the button rear ward while maintaining accelerator position 15 Then immediately release the accelerator depress the clutch pedal once to break torque release the pedal to reengage the clutch accel erate the engine until the shift is complete Continue driving or down shifting The transmission shifts from H to L when synchronous is reached Combination Lever shift and Splitter shift HI Range L to HI Range H 7th L to 6th H 16 Pre select just before making a downshift by moving the button for ward while maintaining accelerator position 17 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 6th L once the final clutch engagement is made 18 Continue downshifting through HI range Double clutching during lever shifts single clutch during split shifts while the shift lever is in the same position Driving Operation Combination Lever shift and Splitter shift HI Range L to LO Range H 5th L to 4th H Range Shift 19 Pre select just before making a downshift by moving the button for ward while maintaining accelerator position 20 Push the range lever down immediately move the shift lever dou ble
15. r Preselecting all range shifts prevents damage to the transmission and provides for smoother shifts Splitter Shift When in LO or HI range the ratios can be split by using the splitter control but ton The LO range L rearward position provides for LO through 4th speeds the LO range H forward position splits each of those speeds providing 10 ratios in LO range The HI range L rearward position provides for 5th through 8th speeds the HI range H forward position splits each of those speeds providing 8 ratios in range 18 progressive ratios can be obtained Driving Operation Optional Equipment For easier and faster engagement while the vehicle is standing still some Eaton Fuller amp 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 do
16. rview Preventive Maintenance Grease Fitting On Each Side To Lubricate Clutch Pedal Shaft Range Slave Valve Air Filter Regulator Output EC Seal X Y Auxilliary Main Plug Cil Section Clutch Inspection Case B Cover ug The following maintenance items are necessary to prevent costly transmission failures which may not be covered by warranty Transmission Oil e Check transmission daily for oil leaks Repair promptly to prevent oil loss and subsequent transmission failure e 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 22 Overview Air System e Drain moisture from vehicle air system daily Listen for air leaks daily repair promptly e If the vehicle is equipped with an air dryer confirm that the air dryer system is working properly Repair as necessary e Service the vehicle air compressor as required to prevent oil from entering the vehicle air system Master Clutch System e Lubricate clutch release pedal shaft bushings at every chassis lubri cation interval There should be one grease fitting on each side of the transmission clutch housing e 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 les
17. s than 1 2 When replacing the clutch use a high quality spring damped replacement unit Drivetrain e inspect the driveshaft for loose or worn U joints weekly Repair promptly to prevent excessive driveline vibration Havethe driveline checked by a repair facility if unusual noise or vibration is detected Overall Inspection 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 23 Definitions for Top 2 Transmissions Auto Position When the shift lever is in the position labeled AUTO This position is where the Top 2 gears are located Break Torque Releasing engine power or load from transmission and drivetrain Double Clutch The shifting technique used when moving the shift lever to the next lever position Procedures Depress clutch move lever to neutral let up clutch accelerate or decelerate engine to obtain synchronous depress clutch pedal again and move lever into gear Splitter Selector The button on the side of the shift knob used to change gears Synchronous The point at which the input gearing speed engine matches output gearing speed road speed and a shift can occur without grinding Top 2 Mode The state where the transmission automatically shifts between the top two gears 24 Copyright Eaton and Dana Corporation
18. tions Transmission Operation and Service and Maintenance Transmission 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 18 Speed Models Models in this series provide eighteen forward speeds and four reverse con sisting of a five speed front section and a 4 speed auxiliary section The auxil iary section contains LO and HI range ratios plus a splitter gear The LO position in the front section is used only as a starting gear it is never used when the transmission is in HI range The other four ratios are used once in LO range and once again in HI range However each of the five ratios LO 1 2 3 4 in LO range and each of the four ratios 5 6 7 8 in HI range can be split with the splitter gear After shifting out of the LO position you use the easy Roadranger repeat H shift pattern LO range and HI range are selected with the range lever It is used once during the upshift sequence and once during the downshift sequence Always preselect the range shift After preselection the transmission automat ically makes the synchronizer range shift as the shift lever passes through neutral Driving Operation Shift Pattern Diagram A shift pattern diagram should be in your vehicle If it has been lost a replace ment may be obtained by writing t
19. transmission has just completed a downshift the upshift point will now be higher than normal Driving Operation Top 2 System Problem If the system malfunctions the transmission will typically default to Super 18 mode For some malfunctions the system will detect a failure that the opera tor 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 18 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 electrical connections to the Top 2 To help assure operation of the Super 18 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 correctly These instructions assume the driver is currently familiar with the operation of anormal Super 18 transmission Overview Lubrication Procedures Proper lubrication procedures are the key to a good all around maintenance program Eaton Fuller Transmissions are designed so that the internal parts operate in an oil circulating bath created by the motion of the gears and shaf
20. ts All parts will be properly lubricated if these procedures are closely followed Maintain oil level Inspect regularly Follow maintenance interval chart Use the correct grade and type of oil Buy from a reputable dealer Boc 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 Proper Oil Level Hole gt Improper Oil Level Hole gt For additional lubrication information see TCM T 0021 If your vehicle has a transmission oil filter you must change the filter when fluid or lubricant is changed Additives and friction modifiers must not be introduced Never mix engine oils amp gear oils in the same transmission 19 Overview The use of lubricants not meeting these requirements will affect warranty cov erage For alist of Eaton Approved Synthetic Lubricants see TCMT 0020 or call 1 800 826 HELP 4357 Buy from a reputable dealer For acomplete 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 Transmission Operating Angles If the transmission operating angle is more than 12 degrees improper lubrica tion will occur The operat
21. wn 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 only for initial gear engagement when the vehicle is standing still Driving Operation e Always select an initial starting gear that provides sufficient reduc tion for the load and terrain Always use normal double clutching procedures when making lever shifts Never slam or jerk the shift lever to complete gear engagements 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 Never make a range shift while moving in reverse e 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 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 Do not lug engine below peak torque 1200 r p m Driving Tips Driving Operation Double Clutching Procedure Special Instructions Purpose 8 To break torque to allow the transmission to come out of gear and b To disengage the engine from the transmission when shifting into gear Procedure 1 Release accelerator 2 Depress c
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