RTLO-18918B-AS
Table of contents
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Service Manual
Fuller Automated Transmissions
TRSM0050
October 2007
RTAO-11710B-AC
RTAO-11710C-AC
RTAO-12710B-AC
RTAO-12710C-AC
RTAO-13710B-AC
RTAO-13710C-AC
RTAO-14710B-AC
RTAO-14710B-AS
RTAO-14710C-AC
RTAO-14710C-AS
RTAO-15710B-AC
RTAO-15710C-AC
RTAO-16710B-AC
RTAO-16710B-AS
RTAO-16710C-AC
RTAO-16710C-AS
RTLO-14918B-AS
RTLO-16918B-AS
RTLO-18918B-AS
RTLO-20918B-AS
For parts or service call us
Pro Gear & Transmission, Inc.
1 (877) 776-4600
(407) 872-1901
parts@eprogear.com
906 W. Gore St.
Orlando, FL 32805
Introduction
Warnings and Cautions
WARNING: Follow the specified procedures in the indicated order to avoid personal injury
CAUTION: Follow the specified procedures in the indicated order to avoid equipment malfunction or damage.
Note: Additional relevant information not covered in the service procedure.
WARNING: Before starting a vehicle:
• Sit in the driver's seat
• Place shift lever in neutral
• Set the parking brake
WARNING: Before working on a vehicle or leaving the cab with engine running:
• Place shift lever in neutral
• Set the parking brake
• Block the wheels
WARNING: When parking the vehicle or leaving the cab:
• Place shift lever in neutral
• Set the parking brake
CAUTION: Do not release the parking brake or attempt to select a gear until the air pressure is at the correct level.
CAUTION: To avoid damage to the transmission during towing:
• Place shift lever in neutral
• Lift the drive wheels off of the ground or disconnect the driveline
CAUTION: Do not operate vehicle if alternator lamp is lit or if gauges indicate low voltage.
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 Services, Eaton Truck Component Operations, P.O. Box 4013, Kalamazoo, MI 49003.
Copyright Eaton Corporation, 2001. All rights reserved.
1
Introduction
Purpose .......................................................................1
Identification Tag ........................................................ 2
Model Designations .................................................... 3
Lubrication Information .............................................. 4
Maintenance/Lubricant Change Intervals ....................5
Preventive Maintenance Overview ............................... 7
Repair Warnings .......................................................10
Service Procedures
Reverse Ball Switch - Overview ................................. 12
How to Remove the Reverse Ball Switch ................... 13
How to Install the Reverse Ball Switch ...................... 15
Rail Select Sensor - Overview ................................... 18
How to Remove the Rail Select Sensor ..................... 19
How to Install the Rail Select Sensor ........................ 21
Gear Select Sensor - Overview .................................. 24
How to Remove the Gear Select Sensor .................... 25
How to Install the Gear Select Sensor ....................... 27
Input/Main Shaft Speed Sensors - Overview ............. 30
How to Remove the Input/Main Shaft
Speed Sensors .................................................. 31
How to Install the Input/Main Shaft
Speed Sensor ..................................................... 33
Output Shaft Speed Sensor - Overview ..................... 36
How to Remove the Output Shaft Speed Sensor ....... 37
How to Install the Output Shaft Speed Sensor .......... 39
Range Valve - Overview ............................................ 42
How to Remove the Range Valve ..............................43
How to Install the Range Valve ..................................45
Splitter Valve - Overview ........................................... 48
How to Remove the Splitter Valve .............................49
How to Install the Splitter Valve ................................ 51
Air Filter/Regulator - Overview ..................................54
How to Remove the Air Filter/Regulator .................... 55
How to Install the Air Filter/Regulator ....................... 57
Inertia Brake Solenoid - Overview ............................. 60
How to Remove the Inertia Brake Solenoid ............... 61
How to Install the Inertia Brake Solenoid .................. 63
Inertia Brake - Overview ............................................ 66
How to Remove the Inertia Brake .............................. 67
How to Install the Inertia Brake ................................. 69
Power Module - Overview ......................................... 72
How to Remove the Power Module ........................... 73
How to Install the Power Module .............................. 75
Electric Shifter - Overview ......................................... 78
How to Remove the Electric Shifter ........................... 79
How to Install the Electric Shifter .............................. 81
Table of Contents
Transmission ECU - Overview ...................................84
How to Remove the Transmission ECU .....................85
How to Install the Transmission ECU .........................87
Transmission Harness - Overview .............................90
How to Remove the Transmission Harness ...............91
How to Install the Transmission Harness ..................93
Shift Lever - Overview ...............................................96
How to Remove the Shift Lever .................................97
How to Install the Shift Lever .....................................99
Power Relay - Overview ...........................................102
How to Remove the Power Relay .............................103
How to Install the Power Relay ................................105
System Manager - Overview ....................................108
How to Remove the System Manager ......................109
How to Install the System Manager .........................111
Tower Harness - Overview .......................................114
How to Remove the Tower Harness .........................115
How to Install the Tower Harness ............................117
Gear Display - Overview ...........................................120
How to Remove the Gear Display ............................121
How to Install the Gear Display ................................123
Table of Contents
Introduction
Purpose
This manual is designed to provide detailed information necessary to service and repair the Automation of Eaton® Fuller® transmissions listed on the front.
How to Use This Manual
The service procedures in this manual are for transmission automation components only. To locate the information you need,
simply locate the procedure in the table of contents, turn to the page specified, and follow the procedure.
To service the mechanical portion of the transmission system, refer to the model specific transmission service manual.
1
Introduction
Identification Tag
PTO Code
Eaton Fuller
Transmissions
Model
Eaton Corporation
Transmission Div
Kalamazoo, MI 49003
All Eaton® Fuller® Transmissions are identified by the 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.
Have reference numbers handy when ordering replacement parts or requesting service repairs.
Made
In
Serial
Introduction
2
Model Designations
AutoSelect Nomenclature
RTA O -14710B-AC
Introduction
Roadranger
Twin Countershaft
Automated
Overdrive
AutoShift Nomenclature
RTA O -14710B-AS
Roadranger
Twin Countershaft
Automated
Overdrive
RTL O -20918B-AS
Roadranger
Twin Countershaft
Low-Inertia
O = Overdrive w/Direct Shift Pattern
AutoSelect
Gear Ratio
Forward Speeds
Design Level
This (x) 100 = Nominal Torque Capacity
AutoShift
Gear Ratio
Forward Speeds
Design Level
This (x) 100 = Nominal Torque Capacity
AutoSelect
Ratio Set
Forward Speeds
9 = Improved Seal System
This (x) 100 = Nominal Torque Capacity
3
Introduction
Lubrication Information
Recommended Lubricants
Where transmissions are concerned, lubrication is possibly the most important part of keeping a vehicle operating.
Lubricants which meet the Eaton (PS-164) specification are required in AutoSelect/AutoShift transmissions. Lubricants must be
approved by Eaton Corporation to qualify for the 5/750,000 warranty. For a list of Eaton® Roadranger® approved lubricants,
order item number TCMT-0021.
Type Grade (SAE) Ambient Temperature Drain Interval Note
Eaton® Roadranger®
CD-50 E500 (PS-164)
*The first lube change may be extended to 500,000 miles (800,000 km) when a new transmission has been factory filled with
a lube that is Eaton approved for 500,000 miles (800,000 km) (E-500, PS-164).
50 All 250,000*
(400,000)/1000 Hrs
Approved for
Oil Coolers
Introduction
4
Introduction
Maintenance/Lubricant Change Intervals
Transmission inspections and lubricant changes depend on the type of lubricant used and whether the vehicle is used On- or OffHighway.
On-Highway Lubricant - Vehicles operated on paved roads, interstate highways, and turnpikes are designated as onhighway vehicles. Lubricant change and inspection intervals are the most generous for on-highway vehicles using synthetic
lubricants.
Off-Highway Lubricant - When operating vehicles with AutoSelect/AutoShift transmissions in off-highway applications such as
coal trucks or mining vehicles, it is more important to use time rather than mileage to keep the transmission within its proper
preventive maintenance schedule. Off-highway applications are divided into two categories, severe and normal. 'Severe off-highway' is the designation used when there is excessive dust and dirt. 'Normal off-highway' is for applications where dust and dirt
are minimal.
PM Interval - The PM interval in off-highway vehicles with AutoSelect or AutoShift transmissions is every 40 hours.
Lubricant Change Interval - The lubricant must be changed in AutoSelect/AutoShift transmissions in off-highway vehicles every
500 hours in severe applications, and every 1000 hours for vehicles in normal applications.
Type Grade (SAE) Ambient Temperature Drain Interval Note
Eaton® Roadranger®
CD-50 E500 cm
(PS-164)
*The first lube change may be extended to 500,000 miles (800,000 km) when a new transmission has been factory filled with
a lube that is Eaton approved for 500,000 miles (800,000 km) (E-500, PS-164).
50 All 250,000*
(400,000)/1000 Hrs
Approved for
Oil Coolers
5
Introduction
Oil Level
Hole
When checking the transmission lubricant there are two important points to know: where to check the lubricant and what the
proper lubricant level is. Always be cautious when checking the transmission lubricant as it may be hot.
• Checking Location - Check the lubricant at the lubricant fill plug located on the left side of the main transmission case.
• Proper Lubricant Level - The lubricant is at the proper level when it is even with the bottom of the fill hole. When you
remove the plug to check the lubricant level, lubricant should actually seep out. Do not use your finger to feel for the
lubricant. Even if you can touch the lubricant, it may not be at the proper level. In a transmission one inch of lubricant
level equals about one gallon of lubricant.
Proper Oil Level
Hole
Improper Oil Level
Recommended Lubricant
Eaton requires the use of Eaton approved lubes meeting the E-500 performance requirements (PS-164) for these transmissions.
A current list of approved lubes is available from Eaton Roadranger Field Marketing, call 1-800-826-4357. Failure to use a
required lube may affect AutoSelect/AutoShift performance and warranty coverage.
Introduction
Buy from a reputable dealer
For a complete list of approved and reputable dealers, write to:
Eaton Corporation
Truck Components Operations
Global Marketing Services
P.O. Box 4013
Kalamazoo, MI 49003
http://truck.eaton.com/na/service_products/lubricant_requirements/
6
Introduction
Preventive Maintenance Overview
To keep a vehicle running properly, it is important to perform preventive maintenance on the vehicle components. This insures
the vehicle and its subassemblies will operate properly throughout their useful life. To cover preventive maintenance completely,
you must review the following subjects in detail.
• Inspecting the Transmission
• Changing the Fluid
• Vehicle System Effects
Transmission Inspections
When performing preventive maintenance (PM) inspections, several items must be checked. It is important to perform every
step to ensure the transmission meets its life expectancy. Proper PM consists of the following steps:
• Check the transmission oil level
• Inspect under the vehicle for loose/missing bolts
• Check the transmission for air leaks
• Check the transmission for lubricant leaks
Loose or Missing Bolts
While you are under the vehicle checking the lubricant, make a quick check for loose or missing bolts. Check all bolts on the back
box, PTO covers, shift bar housing, clutch housing and transmission controller. Replace any missing or broken bolt with the
proper bolt as called out in the illustrated parts listing. Follow the procedure defined in the manual transmission service manual
when tightening any bolts.
Air Leaks
While you are under the vehicle, check for air leaks as well. The two steps when checking for an air leak are inspection and repair.
• Audible Inspection for Leaks - To find air leaks, make sure the vehicle air system has at least 90 PSI air pressure. Then,
listen for leaks, making sure a vehicle leak is not mistaken for a transmission air leak.
• Refer to Troubleshooting Procedures for Repair - Once you find an air leak, use the troubleshooting guide to isolate
the air leak to the faulty component.
Lubricant Leaks
Oil leak repair is very important. An lubricant leak could cause a catastrophic transmission failure. Check for leaks first at the gasket surfaces, the rear seal, and the transmission cooler.
Visual Check for Leaks at Gaskets
A visual check at each gasket to ensure that no leak is present. Typically a moist spot is acceptable; however drips or larger wet
areas are not. Check for leaks at the rear housing, PTO, shift bar housing, shift tower, and clutch housing gasket surfaces. It is
also Important to ensure that the leak is indeed coming from the transmission. Make sure the lubricant is not being blown back
from the engine or another vehicle component.
7
Introduction
Check for Leaks Around the Input Shaft
Check for leaks around the input shaft. Leaks in this area could be caused by a faulty gasket, the input shaft, or pressurization of
the main transmission case by the air system. If you find a leak at the input shaft, make sure the air system is not leaking into the
case before looking for leaking gaskets.
Rear Seal
The rear seal is very important in maintaining lubricant in the transmission. If the seal is improperly installed or has failed, the
transmission may experience a catastrophic failure. Check the rear seal by performing the following steps:
• Visual Check For Leak - Visually inspect the rear seal for a leak. If a rear seal leak is suspected, proper isolation is nec-
essary.
• Verify the Leak Path - Other leaks may give the impression the rear seal is leaking. One possible cause is the vehicle
speed sensor. Any lubricant leak above and in front of the rear seal could cause lubricant to collect around the seal.
Wipe the seal with a clean rag, operate the vehicle, and recheck to verify the leak path. More information can be found in
the rear seal maintenance guide (TRSM-0912).
Transmission Cooler Leaks
If the vehicle is equipped with a transmission lubricant cooler, make sure there are no leaks at the lubricant cooler, hoses, and fitting of the cooler circuit. Repair any cooler leaks as necessary.
Introduction
Transmission Fluid Change
When it is time to change the transmission lubricant, there are only a few steps to follow: draining and filling the transmission,
draining and filling the cooler (if equipped), and changing the oil filter (if equipped). Remember to be careful when changing the
transmission lubricant, as it may be hot.
• Transmission Drain - Draining the transmission consists of removing the drain plug located on the bottom of the trans-
mission case. Put a drain pan in place under the drain plug before removing it. Once the oil has finished draining, install
the drain plug and torque to 45-55 Lb f ·ft. No sealant is required on the drain plug.
• Cooler Drain - If the vehicle is equipped with a transmission cooler, you must drain the cooler as well. To drain the
cooler, remove both cooler lines at the transmission and pressurize one line with 30 PSI of air pressure. This will force
the oil out of the cooler. Once the cooler has drained, reconnect the coolant lines to the transmission, making sure the
lines are not crossed.
• Transmission Fill - Remove the transmission fill plug and fill the transmission with the desired approved oil. The trans-
mission is full once oil starts flowing out of the fill hole. Replace the fill plug and torque to 60-70 Lb f ·ft.
• Cooler Fill - If the transmission is equipped with a cooler, the best way to fill the cooler is to place the transmission in
neutral, start the vehicle, then release the clutch pedal so the input shaft of the transmission can rotate. This allows the
pump to fill the cooler. Once the vehicle has run for about one minute, shut it off and recheck the transmission oil level.
• Filter Change - If the transmission is equipped with a spin-on oil filter, remove and replace the filter as you would any
spin-on filter. It is also necessary to remove the filter when draining the oil from the cooler. As you unscrew the filter,
catch the oil that seeps out between the filter opening and the "spin-on" casting.
8
Introduction
Vehicle System Effects
Some vehicle systems can affect transmission operation and possibly cause a failure. The major system that can affect AutoSelect or AutoShift is the air system.
Air System
If the air system is not given recommended preventive maintenance, it can cause transmission system problems. Although the
transmission has an air filter regulator it cannot protect the transmission from contaminants indefinitely. This is why it is important to follow OEM recommendations for air system PM. It is important to regularly drain the air tanks and insure that oil is not
being pumped by the air compressor into the vehicle air system. If moisture enters the transmission system, it may cause corrosion. Also, in cold climates it may freeze, preventing the shift mechanisms from operating. If allowed into the system, oil could fill
the air system components causing them to lose valuable air volume, slowing or preventing movement.
9
Introduction
Repair Warnings
When disassembling various assemblies, lay all parts on a clean bench in the same sequence as removed to simplify assembly
and reduce the possibility of losing parts.
Provide a clean work area. Make sure no dirt or foreign material enter the unit during repair and assembly.
Disconnect the vehicle's battery before removing or installing electronic parts.
Since the cost of a new part is generally a small fraction of the total cost of downtime and labor, avoid reusing a questionable part
that could lead to additional repairs and expense.
Use of other than recommended tools, parts, and instructions listed in this manual may place the safety of the service technician
or vehicle driver in jeopardy.
The location of some components may vary with each O.E.M.
The removal and installation procedure described for each component may vary for your vehicle.
Always use genuine Eaton replacement parts. For a complete list of approved and reputable dealers, write to:
Eaton Corporation
Truck Components Operations
Global Marketing Services
P.O. Box 4013
Kalamazoo, MI 49003
http://truck.eaton.com/na/service_products/lubricant_requirements/
Introduction
10
Introduction
11
Reverse Ball Switch - Overview
Service Procedure
Special Instructions
None.
Required Tools
• Torque Wrench with 25 lb.ft. capacity.
Essential Steps
Install a new fiber washer.
Service Procedure
Reverse Ball Switch
12
Service Procedure
How to Remove the Reverse Ball Switch
Procedure-
1. Disconnect the Transmission Harness from the Reverse
Ball Switch.
2. Using a 7/8" wrench, Loosen the Reverse Ball Switch.
3. Remove the Reverse Ball Switch and Fiber Washer from
the Shift Bar Housing.
13
1
Disconnect
Transmission Harness
from Reverse Ball Switch
Service Procedure
2
3
Remove Reverse Ball
Switch and Fiber Washer
Transmission Harness
Reverse Ball Switch
Loosen Reverse
Ball Switch
Reverse Ball Switch
Service Procedure
7/8" Wrench
Fiber Washer
Reverse Ball Switch Removal
Reverse Ball Switch
14
Service Procedure
How to Install the Reverse Ball Switch
Procedure-
1. Install a new fiber washer (included in the Reverse Ball
Switch service kit) on the Reverse Ball Switch.
2. Using a 7/8" wrench, install and tighten the Reverse Ball
Switch to 20-25 lbs. ft. (27.1-33.9 N•m).
3. Connect the Transmission Harness to the Reverse Ball
Switch.
Final Check
Verify Harness is locked.
15
1
Install reverse ball
Switch and Fiber Washer
Fiber Washer
Service Procedure
2
Tighten Reverse
Ball Switch
Reverse Ball Switch
3
Connect
Transmission Harness to
Reverse Ball Switch
Reverse Ball Switch
Service Procedure
7/8" Wrench
Transmission Harness
Reverse Ball Switch
Reverse Ball Switch Installation
16
Service Procedure
Solo Heavy Duty Clutch - Install, Con’t
17
Rail Select Sensor - Overview
Service Procedure
Special Instructions
Install the sensor with the connector on top.
While removing or installing the capscrews, hold the sensor
in place. Don't allow it to snap out of position.
Required Tools
• Basic Hand Tools
Essential Steps
The shifter module must be calibrated before the vehicle is
placed into operation.
Service Procedure
Rail Select Sensor
18
Service Procedure
How to Remove the Rail Select Sensor
Procedure-
1. Disconnect the Transmission Harness from the Rail
Select Sensor.
2. Using a 5/16" wrench, remove the two (2) sensor capscrews.
3. Carefully allow the sensor to rotate (not snap) to a
relaxed position. Then remove the sensor, steel sleeves
and O-rings from the housing.
4. Insert your finger into the sensor bore and push the arm
slightly.
19
g
1
Disconnect
Transmission Harness
from Sensor
Service Procedure
2
Remove Mounting
Capscrews
Select Sensor
Remove Rail
Select Sensor
Sensor Connector
Service Procedure
3
Sleeve O-Rin
Sensor O-Ring
Rail Select Sensor Removal
Select
Sensor
Sleeve
Capscrew
20
Service Procedure
How to Install the Rail Select Sensor
Procedure-
1. Align the sensor's tab with the slot in the shifter housing.
Then position the Sensor O-ring and insert the Rail Sensor into its mounting location.
2. Insert the new sleeve O-rings, new steel sleeves and capscrews into the sensor mounting holes.
3. Using a 5/16" wrench, install and tighten the capscrews
to 21-27 lbs. in. (2.4-3.1 N•m).
4. Reconnect the Transmission Harness to the Rail Select
Sensor.
Final Check
Make sure that the capscrews are tightened to specification.
Make sure that the sensor connections are secure.
Calibration
To operate properly, the system must be calibrated as follows:
a. Turn the ignition switch to ON and allow the trans-
mission to power up.
b. Turn the ignition switch to OFF and wait two minutes.
IMPORTANT: The shifter module must be calibrated before
the vehicle is placed into operation.
21
g
1
Insert Rail
Select Sensor
Sensor O-Ring
Sensor
Select
Sleeve
Service Procedure
Sleeve O-Rin
Capscrew
2
Attach Mounting
Capscrews
3
Reconnect Transmission
Harness to Sensor
Select Sensor
2
Service Procedure
5/16" Wrench
Mounting Capscrew
Sensor Connector
Rail Select Sensor Installation
22
Service Procedure
Solo Heavy Duty Clutch - Install, Con’t
23
Gear Select Sensor - Overview
Service Procedure
Special Instructions
Install the sensor with the connector on top.
While removing the capscrews, hold the sensor in place.
Don't allow it to snap out of position.
Required Tools
• Basic Hand Tools.
Essential Steps
The shifter module must be calibrated before the vehicle is
placed into operation.
Service Procedure
Gear Select Sensor
24
Service Procedure
How to Remove the Gear Select Sensor
Procedure-
1. Remove nylon cable ties from motor wires.
2. Disconnect the Transmission Harness from the Gear
Select Sensor and Rail Select Sensor.
3. Disconnect the Gear Select Motor and Rail Select Motor
from the Transmission ECU.
4. Using a 5/16" wrench, remove the four (4) Electric Shifter
capscrews.
5. Remove the Electric Shifter and gasket.
6. Turn the shifter over (upsidedown).
7. Using a 5/16" wrench, remove the two (2) Gear Select
Sensor capscrews.
8. Carefully allow the sensor to rotate (not snap) to a
relaxed position, then remove the sensor, steel sleeves
and O-ring from the housing.
9. Insert your finger into the sensor bore and push the arm
slightly.
25
Service Procedure
1
9/16" Wrench
Disconnect
Transmission Harness
from Rail and Gear
Select Sensor
Sensor Connectors
3
Remove Mounting
Capscrews
2
Disconnect Rail Motor
and Gear Motor from
Transmission ECU
Motor Connectors
4
Remove Electric
Shifter and Gasket
Electric Shifter
T
Service Procedure
5
Remove Gear
Select Sensor
Gear Select Sensor Removal
Capscrew
Sleeve
Sleeve
O-Ring
Gasket
Position
Sensor
Sensor
O-Ring
26
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