Fuller Heavy Duty Transmissions TRSM0660 - …

1 Service ManualFuller Heavy duty TransmissionsTRSM0660 October 2007 RTLO-14613 BRTLOF-14613 BTABLE OF CONTENTSFOREWORD..MODEL DESIGNATIONS ANDLUBRICATION..OPERATION..POWER FLOW..TIMING..* ..SPECIFICATIONS.. TORQUE RECOMMENDATIONS ..TOOL REFERENCE ..PREVENTIVE MAINTENANCE..PRECAUTIONSDISASSEMBLY..INS PECTION.. mm.. m ..CHANGING INPUT SHAFT..AIR SYSTEMRANGE 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.

2 REASSEMBLY FRONT SECTION..INSTALLATION CLUTCH HOUSING, AUXILIARY SECTION AND OUTPUT YOKE ..INSTALLATION SHIFTING CONTROLS ..SHIMMING CHART..1 FOREWORDThis manual is designed to provide detailed informationnecessary to service and repair the Fuller Transmissionslisted on the outlined in the Table of Contents, the manual isdivided into 3 main sections:a. Technical information and referenceb. Removal, disassembly, reassembly andinstallationc. OptionsThe format of the manual is designed to be followed in itsentirety if complete disassembly and reassembly of thetransmission is necessary. But if only one component of thetransmission needs to be repaired, refer to the Table ofContents for the page numbers showing that example, if you need to work on the Shifting Controls,you will find instructions for removal, disassembly andreassembly on page 32. Instructions for installation are onpage 116.

3 Service Manuals, Illustrated Parts Lists, DriversInstructions, and other forms of product service informationfor these and other Fuller Transmissions are available uponrequest. A Technical Literature Order Form maybe found inthe back of this manual. You may also obtain ServiceBulletins, detailing information on product improvements,repair procedures and other service-related subjects bywriting to the following address:EATON CORPORATIONTRANSMISSION DIVISIONT echnical Service Box 4013 Kalamazoo, Michigan 49003(61 6) 342-3344 Every effort has been made to ensure the accuracy of all information in this , Eaton Transmission Divisionmakes no expressed or implied warranty or representation based on the enclosed information. Any errors or omissions maybe reported to Training and Publications, Eaton Transmission Division, PO. Box 4013, Kalamazoo, Ml DESIGNATIONSAND SPECIFICATIONSN omenclature:RTLO-14613 IMPORTANT: All Fuller Transmissions are identified bymodel and serial number.

4 This information is stamped onthe transmission identification tag and affixed to the NOT REMOVE OR DESTROY THE TRANSMISSIONIDENTIFICATION Transmissions (On/Off Highway):Relative Speed123 Gear Ratios:PTO GearLengthWeightOil Input St2nd3rd4th5th6th7th8thReverseRightBotto m(mm)(Kgs.)(Liters) ( )( )( ) measured from face of clutch housing to front bottoming surface of companion flange or - Listed weights are with clutch housing* and include standard controls, which consist of gear shift lever housingand gear shift lever. Weight of standard controls is approximately 10 lbs. ( kg.). All weights are Capacities are approximate, depending on inclination of engine and transmission. Always fill transmission with propergrade and type of lubricant to level of filler opening. See LUBRICATION.*For information on available clutch housings refer to Publication FUL-140 Clutch Housing Chart.

5 3 LUBRICATIONP roperLubrication ..Fahrenheit(Celsius)AmbientTemperaturet he 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 Fuller Transmissions are designedso that the internal parts operate in a bath ofoil circulated by the motion of gears and , ail parts will be amply lubricated ifthese procedures are closely followed:1. Maintain oil level. Inspect Change oil Use the correct grade and type of Buy from a reputable Change and InspectionEaton roadranger CD50 Transmission FluidHIGHWAY USE Heavy duty and Mid-RangeFirst 3,000 to 5,000 milesFactory fill(4827 to 8045 Km)Inltlal drainEvery 10,000 milesCheck fluid level(16090 Km)Check for leaksHeavy duty Highway Change IntervalEvery 250,000 milesChange transmission(402336 Km) fluid ,Mid-Range Highway Change IntervalEvery 100,000 miles (160,000 Km)Change transmissionor every 3 years whichever occurs USEF irst 30 hoursFactory fill Initial drain,Every 40 hoursInspect fluid level Check for leaksIEvery 500 hoursChange transmission fluid wheresevere dirt conditions 1,000 hoursChange transmission fluid (Normal off-highway use)

6 , Heavy duty Engine Lubricant orMineral Gear LubricantIHIGHWAY USEIF irst 3,000 to 5,000 milesFactory fill(4827 to 8045 Km)Initial 10,000 milesInspect Iubricant level,(16090 Km)Check for leaks,IEvery 50,000 milesChange transmission(80450 Km)lubricant,IOFF-HIGHWAY USE First 30 hoursChange transmission lubricant on new units Every 40 hoursInspect Iubricant level Check for leaksEvery 500 hoursChange transmission Iubricant wheresevere dirt conditions 1,000 hoursChange transmission Iubricant(Normal off-highway use),Change the oil filter when fluid or lubricant is LubricantsGradeType(SAE)Eaton roadranger CD50 TransmissionFluid50 AllHeavy duty Engine 011MI L-L-2104B C or D or50 Above 10oF(-12oC.)API-SF or API-CD40 Above 10oF(-12oC.)(Previous API designations 30 Below 10oF(-12oC.)acceptable)Mineral Gear 011 with rust90 Above 10oF(-12oC.)

7 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 temperatures areabove 230 F (110oC). Many of these gear oils,particularly 85W140, break down above 230 Fand coat seals, bearings and gears with de-posits that may cause premature failures. Ifthese deposits are observed (especially a coat-ing on seal areas causing oil leakage), changeto Eaton roadranger CD50 transmission fluid , Heavy duty engine oil or mineral gear oil toassure maximum component life and to main-tain your warranty with Eaton. (Also see Operating Temperatures .)Additives and friction modifiers are not recom-mended for use in Eaton 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 level. One 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 adding oil, types and brands of oilshould not be mixed because of possible in-4compatibility., ..LUBRICATIONO perating Temperatures With Eaton roadranger CD50 Transmission FluidHeavy duty Engine Oiland Mineral OilThe transmission should not be operated con-sistently at temperatures above 250oF (120oC).

9 However, intermittent operating temperaturesto 300oF (149oC) 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 lbs.

10 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 230 F (110). In addi-tion, transmission oil coolers are not recom-mended with these gear oils since the oilcooler materials may be attacked by thesegear oils. The lower temperature limit and oilcooler restriction with these gear oils gener-ally limit their success to milder Lubrication Levelsas Related to TransmissionInstallation AnglesIf the transmission operating angle is morethan 12 degrees, improper lubrication can oc-cur. 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.