Fuller Heavy Duty Transmissions TRSM0600 - Road Ranger

1 Service ManualFuller Heavy Duty TransmissionsTRSM0600 October 2007 TABLE OF CONTENTSFOREWARD..2 MODEL DESIGNATIONS AND SPECIFICATIONS..3 LUBRICATION..4 OPERATION..6 POWER FLOW..8 TIMING..11 TORQUE RECOMMENDATIONS ..12 TOOL REFERENCE..14 PREVENTIVE MAINTENANCE..15 PRECAUTIONSDISASSEMBLY..17 INSPECTION..17 REASSEMBLY..18 AIR SYSTEMOPERATION AND TROUBLESHOOTING ..19 WITH 3-POSITION SELECTOR VALVE..24 WITH A-5015 ROADRANGER VALVE..27AI R SYSTEM SCHEMATICS..30 DISASSEMBLY SHIFTING CONTROLSAI R SYSTEM..36 GEARSHIFT LEVER HOUSING ..42 SHIFT BAR HOUSING ASSEMBLY..44 DISASSEMBLY - COMPANION FLANGE AND CLUTCH HOUSING..47 DISASSEMBLY - AUXILIARY REAR HOUSING..DISASSEMBLY - AUXILIARY INTERMEDIATE HOUSINGDISASSEMBLY - FRONT SECTION ..REASSEMBLY - FRONT SECTION..REASSEMBLY - AUXILIARY INTERMEDIATE - AUXILIARY REAR HOUSING..REASSEMBLY - COMPANION FLANGE AND CLUTCH HOUSING.

2 101 REASSEMBLY - SHIFTING CONTROLSSHIFT BAR HOUSING ..102 GEAR SHIFT LEVER HOUSING ..105 AIR SYSTEM..1061 FOREWORDThis manual is designed to provide detailed informa-tion necessary to service and repair the Fuller @Transmission listed on the outlined in the Table of Contents, the manual isdivided into 3 main sections:a. Technical information and referenceb. Removal, disassembly, reassembly and instal-lationc. OptionsThe format of the manual is designed to be fol-lowed in its entirety if complete disassembly andreassembly of the transmission is necessary. But ifonly one component of the transmission needs to berepaired, refer to the Table of Contents for the pagenumbers showing that component. For example, ifyou need to work on the Shift Bar Housing, you willfind instructions for removal, disassembly and reas-sembly on page 19.

3 instructions for installation areon page 55. Service Manuals, Illustrated Parts Lists,Drivers instructions , and other forms of productservice information for these and other Fuller Trans-missions are available upon request. A Technical Lit-erature Order Form may be found in the back of thismanual. You may also obtain Service Bulletins, detail-ing information on product improvements, repair pro-cedures and other service-related subjects by writingto the following address:EATON CORPORATIONTRANSMISSION DIVISIONT echnical Service Box 4013 Kalamazoo, MI 49003(61 6) 342-3344 Everyeffort has been made to ensure the accuracy of all information in this brochure,However, Eaton Transmission Division makes no expressedor implied warranty or representation based on the enclosed errors or omissions may be reported to Training and Publications,Eaton Transmission Division, Box 4013, Kalamazoo, Ml DESIGNATIONSAND SPECIFICATIONSL etter DesignationsRoadrangerTwin CountershaftOverdriveNomenclature:RTO-66 13 Specifications:Number DesignationsForward SpeedsMulti-Mesh Gearingx 100 =Nominal TorqueCapacityIMPORTANT.

4 All Fuller Transmissions are identi-fied by model and serial number. This informationis stamped on the transmission identification tagand affixed to the NOT REMOVE OR DESTROY THE TRANS-MISSION IDENTIFICATION Ratios(Note 1)(Note 2)(Note 2)(Note 3)LowIntermediateHighRelative SpeedPTO GearLengthWeightOil Input St2nd3rd4th5th6th7th8th9th10th11th 10,968, ,288302528 See Chart Gears- 6613 Series Transmissions have a 33-tooth PTO gear, both right side and bottom. All modelshave 6/8 pitch PTO Listed lengths are installation dimensions from face of clutch housing to front of bottoming sur-face of companion flange or Listed weights arewithoutclutch housing*.Weights include standard controls, which consist ofgear shift lever housing, gear shift lever, range controls and attaching lines.

5 Weight of standard controls isapproximately 10 lbs. ( kg). All weights are Capacity- Oil capacities are approximate, depending on inclination of transmission. Always fill trans-mission to level of filler opening. Refer to Publication Form 121- Lubrication Recommendations forfurther information.*For information on available clutch housings refer to Publication FUL-140- Clutch Housing Chart .ProperLubrication ..the Key to longtransmission lifeProper lubrication procedures are the key to agood all-around maintenance program. If theoil is not doing its job, or if the oil level isignored, all the maintenance procedures in theworld are not going to keep the transmissionrunning or assure long transmission Transmissions are designed so thatthe internal parts operate in a bath of oil cir-culated by the motion of gears and , all parts will be amply lubricated ifthese procedures are closely followed:1.

6 Maintain oil level. Inspect Change oil Use the correct grade and type of Buy from a reputable Change and InspectionHIGHWAY USEF irst 3,000 toChange transmission5,000 miles (4827 to 8045 Km)oil on new unitsEvery 10,000 miles (16090 Km)Inspect oil for 50,000 milesChange transmission(80,450 Km) USEF irst 30 hoursChange transmissionoil on new 40 hoursInspect oil level. Check for 500 hoursChange transmission oil wheresevere dirt conditions 1,000 hoursChange transmission oil(Normal off-highway use).Oil filter should be changed at each oil change on unitsequipped with optional external oil filter.\Recommended LubricantsIFahrenheit(Celsius)GradeAmbie ntType(SAE)TemperatureHeavy Duty Engine OilMIL-L-2104B, C or D or50 Above 10oF(-12oC.)API-SF or API-CD40 Above 10oF(-12oC.)(Previous API designations 30 Below 10oF(-12oC.))

7 Acceptable)Mineral Gear Oil with rust 90 Above 10oF(-12oC.)and oxidation inhibitor80 WBelow 10oF(-12oC.)API-GL-1 The use of mild EP gear oil or multi= pur-pose gear oil is not recommended, but ifthese gear oils are used, be sure to adhere tothe following limitations:Do not use mild EP gear oil or multi-pur-pose gear oil when operating temperaturesare above 230oF (110oC). Many of these gearoils, particularly 85W140, break down above230 F and coat seals, bearings and gears withdeposits that may cause premature failures. Ifthese deposits are observed (especially acoating on seal areas causing oil leakage),change to Heavy duty engine oil or mineralgear oil to assure maximum component lifeand to maintain your warranty with Eaton.(Also see Operating Temperatures .)Additives and friction modifiers are notrecommended for use in Fuller Oil LevelMake sure oil is level with filler opening.

8 Be-cause you can reach oil with your finger doesnot mean oil is at proper inch of oillevel is about one gallon of OilDrain transmission while oil is warm. To drainoil remove the drain plug at bottom of the drain plug before case around filler plug and remove plugfrom side of case. Fill transmission to thelevel of the filler opening. If transmission hastwo filler openings, fill to level of both exact amount of oil will depend on thetransmission inclination and model. Do notover fill - this will cause oil to be forced outof the case through front bearing adding oil, types and brands of oilshould not be intermixed because of Temperatures With Heavy Duty Engine Oiland Mineral OilThe transmission should not be operated con-sistently at temperatures above 250 F (120oC).

9 However, intermittent operating temperaturesto 300oF (149 C) will not harm the transmis-sion. Operating temperatures above 250oFincrease the lubricant s rate of oxidation andshorten its effective life. When the averageoperating temperature is above 250oF, thetransmission may require more frequent oilchanges or external following conditions in any combina-tion can cause operating temperatures of over250oF: (1) operating consistently at slowspeeds, (2) high ambient temperatures, (3) re-stricted air flow around transmission, (4) ex-haust system too close to transmission, (5)high horsepower, overdrive oil coolers are available to reduceoperating temperatures when the above condi-tions are Oil Coolers are:Recommended-With engines of 350 and abovewith overdrive transmissionsRequired-With engines 399 and above withoverdrive Transmissions and GCW Sover 90,000 With engines 399 and above and1400 or greater torque- With engines 450 and above- With EP or Multipurpose Gear OilMild EP gear oil and multipurpose gear oil arenot recommended when lubricant operatingtemperatures are above 230oF (110o).

10 In addi-tion, transmission oil coolers are not recom-mended with these gear oils since the oilcooler materials may be attacked by thesegear lower temperature limit and oilcooler restriction with these gear oils genen-ally limit their success to milder Lubrication Levelsas Related to Operating AnglesIf the transmission operating angle is morethan 12 degrees, improper lubrication canoccur. The operating angle is the transmissionmounting angle in the chassis plus the per-cent of upgrade (expressed in degrees).The chart below illustrates the safe percentof upgrade on which the transmission can beused with various chassis mounting example: if you have a 4 degree transmis-sion mounting angle, then 8 degrees (or 14percent of grade) is equal to the limit of 12degrees. If you have a O degree mountingangle, the transmission can be operated on a12 degree (21 percent) the transmission operating angleof 12 degrees is exceeded for an extendedperiod of time the transmission should beequipped with an oil pump or cooler kit toinsure proper on the chart the effect low oil levelscan have on safe operating angles.