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Eaton Fuller Heavy-Duty Transmissions Service Manual

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Eaton Fuller Heavy-Duty Transmissions Service Manual Service Manual Fuller Heavy-Duty Transmissions TRSM0890 EN-US October 2007 RTLO-14618A RTLO-16618A RTLOF-14618A RTLOF-16618A TABLE OF CONTENTS FOREWORD . ...* . MODEL DESIGNATIONS AND SPECIFICATIONS . LUBRICATION . OPERATION . POWER FLOW . TIMING . ■ ✎✎✌✎ ✎ ✎ ✎ ✎ ✎ ✎ ✎ ✎ ✎ ✎ ✎ ✎ ✎ ✎ ✎ ✎ ✎ ✎ ✎ ✎ ✎ ✎ ✎ ✎ ✎ ✎ ✎ ✎ ✎ ✎ ✎ ✎ ✎ TORQUE RECOMMENDATIONS . TOOL REFERENCE . PREVENTIVE MAINTENANCE . PRECAUTIONS DISASSEMBLY . INSPECTION . REASSEMBLY .. mm. m.. m . CHANGING INPUT SHAFT . AIR SYSTEM RANGE SHIFT AIR SYSTEM . SPLITTER SHIFT AIR SYSTEM . AIR SYSTEM SCHEMATICS . DISASSEMBLY SHIFTING CONTROLS . DISASSEMBLY GEAR SHIFT LEVER ASSEMBLY . REASSEMBLY GEAR SHIFT LEVER ASSEMBLY . DISASSEMBLY AND REASSEMBLY SHIFT BAR HOUSING . ■ . REMOVAL – OUTPUT YOKE, AUXILIARY SECTION AND CLUTCH HOUSING . DISASSEMBLY – AUXILIARY SECTION . REASSEMBLY -AUXILIARY SECTION . DISASSEMBLY – FRONT SECTION . REASSEMBLY – FRONT SECTION . INSTALLATION – CLUTCH HOUSING, AUXILIARY SECTION AND OUTPUT YOKE . INSTALLATION – SHIFTING CONTROLS . SHIMMING CHART . 1 FOREWORD This manual is designed to provide detailed information page 116. Service Manuals, Illustrated Parts Lists, Drivers necessary to service and repair the Fuller’ Transmissions Instructions, and other forms of product service information listed on the cover. for these and other Fuller Transmissions are available upon As outlined in the Table of Contents, the manual is request. A Technical Literature Order Form maybe found in divided into 3 main sections: the back of this manual. You may also obtain Service a. Technical information and reference Bulletins, detailing information on product improvements, b. Removal, disassembly, reassembly and repair procedures and other service-related subjects by installation writing to the following address: c. Options The format of the manual is designed to be followed in its EATON CORPORATION entirety if complete disassembly and reassembly of the TRANSMISSION DIVISION transmission is necessary. But if only one component of the Technical Service Department transmission needs to be repaired, refer to the Table of P.O. Box 4013 Contents for the page numbers showing that component. Kalamazoo, Michigan 49003 For example, if you need to work on the Shifting Controls, (61 6) 342-3344 you will find instructions for removal, disassembly and reassembly on page 32. Instructions for installation are on Every effort has been made to ensure the accuracy of all information in this brochure. However, Eaton Transmission Division makes no expressed or implied warranty or representation based on the enclosed information. Any errors or omissions may be reported to Training and Publications, Eaton Transmission Division, PO. Box 4013, Kalamazoo, Ml 49003. 2 MODEL DESIGNATIONS AND SPECIFICATIONS Nomenclature: RTLO-16618 IMPORTANT: All Fuller Transmissions are identified by model and serial number. This information is stamped on the transmission identification tag and affixed to the case. DO NOT REMOVE OR DESTROY THE TRANSMISSION IDENTIFICATION TAG. 18-Speed Transmissions (On/Off Highway): Relative Speed 1 2 3 Gear Ratios: PTO Gear Length Weight Oil Cap. Model No To Input R.P.M. In. Lbs. Pints Spds. 1 st 2nd 3rd 4th 5th 6th 7th 8th 9th 10th Reverse Right Bottom (mm) (Kgs.) (Liters) 324 748 28 RTLO-14618 18 DIR 14.71 10.20 7.34 5.26 3.78 2.70 1.94 1.39 1.00 3.89/14.71 .696 .696 (823.5) (339.3) (13.25) 324 748 28 RTLO-16618 18 OD 12.44 8.62 6.21 4.45 3.20 2.28 1.64 1.18 .85 3.29/12.45 .788 .788 (823.5) (339.3) (13.25) CHART NOTES: 1. Lengths measured from face of clutch housing to front bottoming surface of companion flange or yoke. 2. Weight - Listed weights are with clutch housing* and include standard controls, which consist of gear shift lever housing and gear shift lever. Weight of standard controls is approximately 10 lbs. (4.5 kg.). All weights are approximate. 3. Oil Capacities are approximate, depending on inclination of engine and transmission. Always fill transmission with proper grade and type of lubricant to level of filler opening. See LUBRICATION. *For information on available clutch housings refer to Publication FUL-140 Ð ÒClutch Housing ChartÓ. 3 LUBRICATION Proper Recommended Lubricants Fahrenheit (Celsius) Grade Ambient Lubrication . Type (SAE) Temperature Eaton® Roadranger® the Key to long CD50 Transmission Fluid 50 All transmission life Heavy Duty Engine 011 MI L-L-2104B C or D or 50 Above 10oF(-12oC.) Proper lubrication procedures are the key to a o o API-SF or API-CD 40 Above 10 F(-12 C.) good all-around maintenance program. If the (Previous API designations 30 Below 10oF(-12oC.) oil is not doing its job, or if the oil level is acceptable) ignored, all the maintenance procedures in the Mineral Gear 011 with rust 90 Above 10oF(-12oC.) world are not going to keep the transmission and oxidation Inhibitor 80W Below 10oF(-12oC.) running or assure long transmission life. API-GL-1 Eaton® Fuller® Transmissions are designed so that the internal parts operate in a bath of The use of mild EP gear oil or multi-pur- oil circulated by the motion of gears and shafts. pose gear oil is not recommended, but if Thus, ail parts will be amply lubricated if these gear oils are used, be sure to adhere to these procedures are closely followed: the following limitations: 1. Maintain oil level. Inspect regularly. Do not use mild EP gear oil or multi-pur- 2. Change oil regularly. pose gear oil when operating temperatures are 3. Use the correct grade and type of oil. above 230°F (110oC). Many of these gear oils, 4. Buy from a reputable dealer. particularly 85W140, break down above 230°F and coat seals, bearings and gears with de- Lubrication Change and Inspection posits that may cause premature failures. If Eaton® Roadranger ® CD50 Transmission Fluid these deposits are observed (especially a coat- ing on seal areas causing oil leakage), change HIGHWAY USE—Heavy Duty and Mid-Range to Eaton Roadranger CD50 transmission fluid, First 3,000 to 5,000 miles Factory fill heavy duty engine oil or mineral gear oil to (4827 to 8045 Km) Inltlal drain assure maximum component life and to main- Every 10,000 miles Check fluid level tain your warranty with Eaton. (Also see (16090 Km) Check for leaks “Operating Temperatures”.) Heavy Duty Highway Change Interval Additives and friction modifiers are not recom- Every 250,000 miles Change transmission (402336 Km) fluid, mended for use in Eaton Fuller transmissions. Mid-Range Highway Change Interval Every 100,000 miles (160,000 Km) Change transmission or every 3 years whichever occurs first fluid. I OFF-HIGHWAY USE First 30 hours Factory fill Initial drain, Every 40 hours Inspect fluid level Check for leaks Proper Oil Level Every 500 hours Change transmission fluid where Make sure oil is level with filler opening. Be- I severe dirt conditions exist. cause you can reach oil with your finger does Every 1,000 hours Change transmission fluid not mean oil is at proper level. One inch of oil I (Normal off-highway use), level is about one gallon of oil. Heavy Duty Engine Lubricant or Draining Oil Mineral Gear Lubricant Drain transmission while oil is warm. To drain I HIGHWAY USE oil remove the drain plug at bottom of case. First 3,000 to 5,000 miles Factory fill Clean the drain plug before re-installing. (4827 to 8045 Km) Initial drain. I Refilling Every 10,000 miles Inspect Iubricant level, I (16090 Km) Check for leaks, Clean case around filler plug and remove plug Every 50,000 miles Change transmission from side of case. Fill transmission to the I (80450 Km) lubricant, level of the filler opening. If transmission has I OFF-HIGHWAY USE two filler openings, fill to level of both open- ings. First 30 hours Change transmission lubricant on new units The exact amount of oil will depend on the Every 40 hours Inspect Iubricant level Check for leaks transmission inclination and model. Do not Every 500 hours Change transmission Iubricant where over fill—this will cause oil to be forced out severe dirt conditions exist. of the transmission. Every 1,000 hours Change transmission Iubricant When adding oil, types and brands of oil (Normal off-highway use), should not be mixed because of possible in- Change the oil filter when fluid or lubricant is changed. 4 compatibility. , . .. LUBRICATION Operating Temperatures Proper Lubrication Levels —With Eaton® Roadranger ® as Related to Transmission CD50 Transmission Fluid Installation Angles Heavy Duty Engine Oil If the transmission operating angle is more and Mineral Oil than 12 degrees, improper lubrication can oc- cur. The operating angle is the transmission The transmission should not be operated con- mounting angle in the chassis plus the per- sistently at temperatures above 250oF (120oC). cent of upgrade (expressed in degrees). However, intermittent operating temperatures The chart below illustrates the safe percent to 300oF (149oC) will not harm the transmis- of upgrade on which the transmission can be o used with various chassis mounting angles. sion. Operating temperatures above 250 F For example: if you have a 4 degree transmis- increase the lubricant’s rate of oxidation and sion mounting angle, then 8 degrees (or 14 shorten its effective life. When the average percent of grade) is equal to the limit of 12 operating temperature is above 250oF, the degrees. If you have a O degree mounting transmission may require more frequent oil angle, the transmission can be operated on a changes or external cooling. 12 degree (21 percent) grade. Anytime the transmission operating angle of The following conditions in any combina- 12 degrees is exceeded for an extended tion can cause operating temperatures of over period of time the transmission should be 250oF: (1) operating consistently at slow equipped with an oil pump or cooler kit to speeds, (2) high ambient temperatures, (3) re- insure proper lubrication. stricted air flow around transmission, (4) ex- Note on the chart the effect low oil levels can have on safe operating angles.
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