Fuller 10 and 15 Speed Transmission Service Manual

Service Manual

Fuller Heavy Duty Transmissions

TRSM0525

October 2007

TABLE OF CONTENTS

FOREWORD

MODEL DESIGNATIONS AND SPECIFICATIONS

LUBRICATION

OPERATION

10-SPEED MODELS

15-SPEED MODELS

POWER FLOW

TIMING

TORQUE RECOMMENDATIONS

TOOL REFERENCE

PREVENTIVE MAINTENANCE

PRECAUTIONS

DISASSEMBLY

INSPECTION

REASSEMBLY

CHANGING INPUT SHAFT

AIR SYSTEM

RANGE SHIFT AIR SYSTEM: ALL MODELS

DEEP REDUCTION AIR SYSTEM: 15-SPEED MODELS

AIR SYSTEM SCHEMATICS

DISASSEMBLY AND REASSEMBLY-SHIFTING CONTROLS

AIR SYSTEM

GEAR SHIFT LEVER HOUSING ASSEMBLY

SHIFT BAR HOUSING ASSEMBLY

REMOVAL-COMPANION FLANGE, AUXILIARY SECTION AND CLUTCH HOUSI NG

DISASSEMBLY-AUXILIARY SECTION (10-SPEED MODELS)

REASSEMBLY-AUXILIARY SECTION (10-SPEED MODELS)

DISASSEMBLY-AUXILIARY SECTION (15-SPEED MODELS)

REASSEMBLY-AUXILIARY SECTION (15-SPEED MODELS)

DISASSEMBLY-FRONT SECTION

REASSEMBLY-FRONT SECTION

INSTALLATION-COMPANION FLANGE, AUXILIARY SECTION A N D C L U T C H H O U S I N G

INSTALLATION-SHIFTING CONTROLS

SHIFT BAR HOUSING ASSEMBLY

GEAR SHIFT LEVER HOUSING ASSEMBLY

AIR SYSTEM

FOREWORD

This manual is designed to provide detailed information necessary to service and repair the Fuller?

Transmissions listed on the cover.

As outlined in the Table of Contents, the manual

is divided into 3 main sections:

a. Technical information and reference

b. Removal, disassembly, reassembly and

installation

c. Options

The format of the manual is designed to be

followed in its entirety if complete disassembly and

reassembly of the transmission is necessary. But if

only one component of the transmission needs to

be repaired, refer to the Table of Contents for the

page numbers showing that component. For example, if you need to work on the Shift Bar Housing,

you will find instructions for removal, disassembly

and reassembly on page 44. Instructions for installation are on page 125. Service Manuals, Illustrated

Parts Lists, Drivers Instructions, Driver Training

I

Programs and other forms of product service information for these and other Fuller Transmissions are

available upon request. A Technical Literature Order

Form may be found in the back of this manual. You

may also obtain Service Bulletins, detailing information on product improvements, repair procedures

and other service-related subjects by writing to the

following address:

EATON CORPORATION

TRANSMISSION DIVISION

Technical Service Department

P.O. Box 4013

Kalamazoo, Michigan 49003

(616) 342-3344

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, P.O. Box 4013, Kalamazoo, Ml 49003.

I

MODEL DESIGNATIONS

AND SPECIFICATIONS

Nomenclature:

RTOF-11610

.

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.

10-Speed Transmissions (On-Highway):

Relative Speed

Gear Ratios

Models

PTO Gear

To Input R. PM.

Right

Bottom

1

Length

In

2

Weight

Lbs.

Oil Cap

Pints

.696

28.9

620

26

885

885

28.9

620

26

2.76/9.84

696

.696

28.9

685

26

78

2.16/7.73

885

885

289

685

26

1,27

100

2.76/9.84

.696

696

29.5

697

26

1 00

78

2.16/7.73

885

885

29.5

697

26

1

Length

In,

2

Weight

Lbs.

Oil Cap.

Pints

No

Spds

1 St

2nd

3rd

4th

5th

6th

7th

8th

9th

10th

Reverse

10

996

763

590

4.54

357

279

214

1 65

1.27

1 00

2.76/9.84

696

10

783

6.00

463

357

280

219

1.68

1 30

1.00

78

2.16/7.73

10

996

763

590

454

3.57

2.79

2.14

1 65

1,27

1 00

10

7.83

6.00

463

357

280

219

1 68

1 30

1,00

10

996

763

590

.,54

357

279

214

165

10

783

6.00

463

357

280

2.19

1 68

1 30

RT-11610

(F)

RTO-11610

(F) (X)

RT-12610

(F) (X)

RTO-12610

(F) (X)

RT-14610

(F)

RTO-14610

See Chart Notes.

15-Speed Transmissions

(On/Off-Highway):

Gear Ratios

Models

RT-11615

(F)

RTO-11615

(F) (X)

RT-14615

(F) (X)

RTO-14615

(F) (X)

RT-15615

No

Spds.

15

15

15

15

15

(F) (X)

RTO-15615

(F) (X)

15

1 St

2nd

3rd

4th

5th

6th

7th

8th

9th

10th

Reverse

9.96

14.88

783

1169

9.96

1552

7.83

1220

996

1552

7.83

12.20

7.63

1140

600

896

7,63

11.89

600

9.35

7.63

11.89

6.00

9.35

590

881

463

692

590

919

4.63

722

590

919

463

7.22

4.54

678

3.57

533

4.54

7.08

357

556

454

708

357

5.56

357

533

280

4,19

3.57

5.56

2.80

4.37

357

556

2.80

4,37

2.79

214

1 65

1.27

1 00

219

1 68

1 30

100

78

279

2.14

1 65

1.27

1.00

2.19

1.68

1.30

1 00

.78

279

214

1 65

1 27

1 00

2.19

1.68

1.30

1 00

.78

2.76/9 84

1469

2.16/7 73

11.54

2,76/9 84

15.33

2.16/7.73

12,04

2.76/!3.84

1533

2.16/7.73

1204

Relative Speed

PTO Gear

To Input R. PM.

Right

Bottom

.696

696

32.1

670

28

.885

885

321

670

28

696

696

33.6

779

30

.885

885

33.6

779

30

696

.696

336

792

30

885

.885

33.6

792

30

CHART NOTES:

Lengths measured from face of clutch housing to front bottoming surface of companion flange or yoke.

Weights include SAE No. 1 cast iron clutch housing and standard controls (control valve, gear shift lever and

housing assembly, and air lines), less clutch release parts. For information on available clutch housings, refer to Publication FUL-140¨C¡± Clutch Housing Chart.¡± All weights are approximate.

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.

LUBRICATION

Proper

Lubrication . . .

the Key to long

transmission life

Recommended Lubricants

Type

?

Eaton Roadranger

CD50 Transmission

Fluid

Mineral Gear 011 with rust

and oxidation Inhibitor

API-GL-1

Eaton? Roadranger ? CD50 Transmission Fluid

HIGHWAY USE¡ªHeavy Duty and Mid-Range

Factory fill

Inltlal drain

Every 10,000 miles

(16090 Km)

Check fluid level

Check for leaks

Heavy Duty Highway Change Interval

Every 250,000 miles

(402336 Km)

All

50

40

30

Above 10 F(-12 C.)

o

o

Above 10 F(-12 C.)

o

o

Below 10 F(-12 C.)

90

80W

Above 10 F(-12 C.)

o

o

Below 10 F(-12 C.)

o

o

o

o

The use of mild EP gear oil or multi-purpose gear oil is not recommended, but if

these gear oils are used, be sure to adhere to

the following limitations:

Do not use mild EP gear oil or multi-purpose gear oil when operating temperatures are

above 230¡ãF (110oC). Many of these gear oils,

particularly 85W140, break down above 230¡ãF

and coat seals, bearings and gears with deposits that may cause premature failures. If

these deposits are observed (especially a coating on seal areas causing oil leakage), change

to Eaton Roadranger CD50 transmission fluid,

heavy duty engine oil or mineral gear oil to

assure maximum component life and to maintain your warranty with Eaton. (Also see

¡°Operating Temperatures¡±.)

Lubrication Change and Inspection

First 3,000 to 5,000 miles

(4827 to 8045 Km)

50

?

Heavy Duty Engine 011

MI L-L-2104B C or D or

API-SF or API-CD

(Previous API designations

acceptable)

Proper lubrication procedures are the key to a

good all-around maintenance program. If the

oil is not doing its job, or if the oil level is

ignored, all the maintenance procedures in the

world are not going to keep the transmission

running or assure long transmission life.

Eaton? Fuller ? Transmissions are designed

so that the internal parts operate in a bath of

oil circulated by the motion of gears and shafts.

Thus, ail parts will be amply lubricated if

these procedures are closely followed:

1. Maintain oil level. Inspect regularly.

2. Change oil regularly.

3. Use the correct grade and type of oil.

4. Buy from a reputable dealer.

Grade

(SAE)

Fahrenheit

(Celsius)

Ambient

Temperature

Additives and friction modifiers are not recommended for use in Eaton Fuller transmissions.

Change transmission

fluid,

Mid-Range Highway Change Interval

Every 100,000 miles (160,000 Km)

or every 3 years whichever occurs first

I

OFF-HIGHWAY USE

First 30 hours

Factory fill Initial drain,

Every 40 hours

I

I

Change transmission

fluid.

Proper Oil Level

Inspect fluid level Check for leaks

Every 500 hours

Make sure oil is level with filler opening. Because you can reach oil with your finger does

not mean oil is at proper level. One inch of oil

level is about one gallon of oil.

Change transmission fluid where

severe dirt conditions exist.

Every 1,000 hours

Change transmission fluid

(Normal off-highway use),

Draining Oil

Heavy Duty Engine Lubricant or

Mineral Gear Lubricant

I

I

I

I

Drain transmission while oil is warm. To drain

oil remove the drain plug at bottom of case.

Clean the drain plug before re-installing.

HIGHWAY USE

First 3,000 to 5,000 miles

(4827 to 8045 Km)

Factory fill

Initial drain.

Every 10,000 miles

(16090 Km)

Inspect Iubricant level,

Check for leaks,

Every 50,000 miles

(80450 Km)

Change transmission

lubricant,

I

Refilling

OFF-HIGHWAY USE

First 30 hours

Every 40 hours

Every 500 hours

Every 1,000 hours

Change transmission lubricant on new units

Inspect Iubricant level Check for leaks

Change transmission Iubricant where

severe dirt conditions exist.

Change transmission Iubricant

(Normal off-highway use),

Change the oil filter when fluid or lubricant is changed.

4

Clean case around filler plug and remove plug

from side of case. Fill transmission to the

level of the filler opening. If transmission has

two filler openings, fill to level of both openings.

The exact amount of oil will depend on the

transmission inclination and model. Do not

over fill¡ªthis will cause oil to be forced out

of the transmission.

When adding oil, types and brands of oil

should not be mixed because of possible incompatibility.

,

.. .. . .

 ................
................

In order to avoid copyright disputes, this page is only a partial summary.

Google Online Preview   Download