Eaton FO-6406A-ASX Installation and operation manual

More time on the road ®
Fuller® Automated Transmissions
Driver Instructions
Fuller Automated Transmissions
TRDR0062
September 2007
Video Instruction Available
Instructional videos are available for download at no
charge at roadranger.com
Videos are also available in DVD format for $20. To
order, call 1-888-386-4636. Ask for item # RRSD0002
FO-6406A-ASX
FO-8406A-ASX
RT-14910B-AS2
RTLO-14918A-AS2
RTLO-16918A-AS2
RTLO-18918A-AS2
RTLO-20918A-AS2
RTLO-22918A-AS2
RTO-10710B-AS2
RTO-10910B-AS2
RTO-12710B-AS2
RTO-12910B-AS2
RTO-14710B-AS2
RTO-14710C-AS2
RTO-14910B-AS2
RTO-14910C-AS2
RTO-16710C-AS2
RTO-16910B-AS2
RTO-16910C-AS2
RTO-18910B-AS2

Warnings & Cautions
Warnings & Cautions
Read the entire driver instructions before operating this transmission.
Before starting a vehicle always be seated in the driver's seat, select “N”
on the shift control, and set the parking brakes.
If engine cranks in any gear other than neutral, service your vehicle imme-
diately!
Before working on a vehicle, parking the vehicle, or leaving the cab with
the engine running, place the transmission in neutral, set the parking
brakes, and block the wheels.
For safety reasons, always engage the service brakes prior to selecting
gear positions from "N".
Do not release the parking brake or attempt to select a gear until the air
pressure is at the correct level.
Before operating the PTO, refer to “Transmission Power Take Off Opera-
tion”.
Battery (+) and (-) must be disconnected prior to any type of welding on any
AutoShift™ equipped vehicle.
It is a requirement that the driver of a commercial vehicle specified under
paragraph A sections 1-6 of FMCSA regulation 392.10 need only cross rail-
road grade crossings in a gear that permits the vehicle to complete the
crossing without a change of gears.
This can only be achieved by utilizing the Manual “M” mode. Please refer
to pages 2 and 9 for correct manual mode operation.
WARNING
CAUTION
IMPORTANT

Table of Contents
Operation
Shift Console Positions ......................................................................... 1
Gear Display.......................................................................................... 2
Start-up and Power Down..................................................................... 3
Driving Tips........................................................................................... 4
Reverse Mode ....................................................................................... 5
Drive Mode............................................................................................ 6
MANUAL Mode ..................................................................................... 7
LOW Mode ............................................................................................ 9
Transmission Power Take Off ............................................................. 10
Service & Maintenance
General Model Information ................................................................. 11
Troubleshooting.................................................................................. 12
Proper Lubrication .............................................................................. 14
Vehicle Towing.................................................................................... 16
Extended Warranty Form...................................................................... 17

1
Operation
Shift Console Positions
AutoShift™ initiates upshifts from “MANUAL” and “LOW” for engine over
speed protection. Some engines do not use the Eaton engine overspeed
protection.
R Selects Reverse gear once vehicle speed is less than 2 mph.
N Selects Neutral
D Selects the default starting gear and automatically selects
gears between the starting gear and top gear.
MANUAL Allows the driver to hold current gear and manually select the
appropriate gear for road conditions using the up/down but-
tons. MANUAL mode should be used whenever the driver
wants to select the shifts instead of letting UltraShift select
them automatically. For example, when the driver is moving
around the yard, over railroad tracks, or on steep grades.
(See the “Manual Mode” section for more details.)
LOW Transmission downshifts at the earliest opportunity for maxi-
mum engine braking.
Up / Down
Buttons
Used in the MANUAL mode to select upshifts and downshifts.
PTO Power Take Off is activated and transmission is ready for PTO
operation. (See “Transmission Countershaft Power Take Off”
section for more details.)
R - Reverse
N - Neutral
D - Drive
MANUAL
LOW
- Upshift
- Downshift
SERVICE
SHIFT
MANUAL
EATON FULLER
TRANSMISSIONS
LOW
D
N
R
Service Indicator
PTO
PTO
WARNING

2
Operation
Gear Display
The Gear Display shows the current gear position of the transmission. The
Gear Display will flash the target gear position of the transmission when in
neutral during a shift.
Down arrows on the Gear Display indicate the transmission is waiting to verify
decreased input shaft speed, before a gear engagement from Neutral can be
completed.
The “DASH” indicates the transmission may be torque locked in gear (see Ser-
vice and Maintenance Locked in Gear).
5
Satisfactory
engagement
in 5th gear
Out of gear waiting
for engine/trans rpm
to reach synchronous
Satisfactory
engagement
in 6th gear
SOLID FLASHING SOLID
6
6
2

3
Operation
Start-up and Power Down
Start-up
1. Turn the ignition key to “ON” and allow the AutoShift to power-up.
2. Depress the clutch pedal.
• Engine cranking is delayed until the transmission power-up is
complete and the gear display shows a solid “N”.
3. Start the engine.
4. Apply service brake.
5. Release the clutch pedal to register proper input shaft speed.
6. Depress clutch pedal.
7. Select the desired mode and starting gear, on the shift console.
8. Release the vehicle parking brakes.
9. Release service brake.
10. Release the clutch pedal to begin vehicle movement.
Power Down
1. Select Neutral on the shift control.
• If gear display does not show solid “N”, neutral has not yet been
obtained.
2. Set the vehicle parking brakes.
3. Turn off the ignition key and allow the engine to shut down.

4
Operation
Driving Tips
Proper Starting Gear
Choose a starting gear appropriate for the load and grade conditions, while at
a stop in Drive and MANUAL modes by using the up/down buttons. Refer to
Drive Mode for detailed information.
Skip Shifting
Performed in MANUAL by pressing the shift button more than once. Refer to
MANUAL mode section for detailed information.
Optimal Engine Braking
The LOW mode can be selected while moving. This initiates downshifts as
soon as possible. Refer to Low mode section for detailed information.
Skid Conditions
If a skid or Antilock brake conditon occurs, disengage the clutch. The Auto-
Shift senses sthe vehicle speed dropping rapidly and will limit downshift gear
selections until the skid condition is complete.
Cruise Control
The AutoShift is totally compatible with cruise control. If a shift is required
while cruise control is active, cruise is temporarily interrupted while the shift
is performed and then automatically resumed after the shift.
Load Based Shifting
In Drive, the AutoShift will adapt to the changing conditions of the vehicle.
Right after power-up or after changing loads, AutoShift needs to learn the new
conditions. While learning, it may hold a gear instead of upshifting. Simply
push the Up button to start the upshift. It may take three or four shifts for the
AutoShift to learn the new conditions. After that it will handle upshifts and
downshift automatically.
Coast Mode
When coasting to a stop in lower gears, AutoShift may not finish downshifting
until the driver gets back on the throttle. This is normal for the AutoShift.

5
Operation
Reverse Mode
The vehicle speed must be less than 2 mph before Reverse is permitted. If the
driver requests Reverse above 2 mph, the shift is not performed until the
speed has dropped below 2 mph.
Depending on the transmission model, there may be a number of reverse
gears available. Each time Reverse is selected from Neutral, the default
reverse gear is engaged.
While the vehicle is stopped in Reverse, the up/down buttons are used to
change the reverse gear. This selection is used only until another mode is
selected.
There is a speed limit on the reverse engagements, yet the driver can effec-
tively rock the vehicle by moving the shift control from reverse to drive and
drive to reverse.
R
R
1R
1R
1H
1H H
H
18-Speed
10-Speed
LO Range HI Range
HI Range
HI Split
HI Range
LO Split
LO Range
LO Split LO Range
HI Split

6
Operation
Drive Mode
Depending on the transmission model and Shift Control configuration, there
may be alternate forward starting gears available. While the vehicle is stopped
in Drive, the up/down buttons are used to change the starting gear. This selec-
tion is used until it is changed again, or the AutoShift is powered down.
In Drive mode, all upshifts and downshifts are performed automatically based
on vehicle and transmission conditions.
The driver can advance a shift (by about 75 rpm) by pressing the proper up/
down button (up for upshifts, down for downshifts) when the transmission is
within 75 rpm of the load based shift point.
The Gear Display shows the status of the shift:
• The current gear is displayed solid.
• At the start of the shift, the current gear is displayed solid until the
transmission is pulled to the neutral position.
• While the transmission is in neutral and synchronizing for the target
gear, the target gear is flashed.
• When the shift is complete, the new current gear is displayed solid.

7
Operation
MANUAL Mode
Manual mode should be used whenever you want to select the shifts instead
of letting AutoShift select them for you. For example, when you are moving
around the yard and on some grade conditions.
Selecting from Neutral:
• As described above for Drive Mode, the starting gear can be changed
in exactly the same way in Manual mode.
• If Manual mode is selected from a stop, the starting gear is main
tained- no shifts are performed, except for condition noted below.
• The driver can request shifts using the proper shift button (up for
upshifts, down for downshifts). The upshift or downshift is per-
formed by the AutoShift provided the result in engine speed is not
outside of defined limits. For upshifts, the resulting engine speed
must be greater than 800 RPM; for downshift, the resulting engine
speed must be less than engine rated speed. By pressing the button
twice, the driver can request a skip shift.
Selecting Manual from Drive or Low while Moving:
• If Manual mode is selected while moving, the current gear is main-
tained- no shifts are performed, except for conditions noted below.
• As described above, the driver can request shifts using the proper
shift button (up for upshifts, down for downshifts) within the same
limits described.

8
Operation
Some engines do not use the Eaton overspeed protection.
Transmission Manual Override:
• If the vehicle is being back driven and the engine is approaching a
higher than normal level (approximately 300 RPM above rated
speed), the AutoShift overrides the Manual position and performs an
upshift to prevent engine damage.
• If the gear being maintained is higher than starting gear, and the
vehicle come to a stop, the AutoShift overrides the Manual mode and
performs a shift into starting gear.
WARNING

9
Operation
LOW Mode
LOW mode should be used any time you want to maximize engine braking and
minimize the use of the brake pedal. For example, when driving down long
grades or when coming to a stop.
Selecting LOW from Neutral:
• If LOW mode is selected from Neutral while stopped, the starting
gear is always 1st gear. The starting gear cannot be changed in LOW
mode.
• If LOW mode is selected from Neutral while stopped, 1st gear is
maintained - no shifts are performed, except for conditions noted
below.
Selecting LOW from Drive or MANUAL while moving:
• If LOW mode is selected while moving, no upshifts are performed,
except for override conditions noted below.
• Downshifts are performed at higher RPM’s than normal to enhance
engine braking. The downshift point is chosen so engine speed after
the shift is about 50 rpm below engine rated speed.
Some engines do not use the Eaton overspeed protection.
Transmission LOW Override:
• If the vehicle is being back driven and the engine is approaching a
higher than normal level (approximately 300 rpm above rated
speed), the AutoShift overrides the LOW position and performs an
upshift to prevent engine damage.
• If the gear being maintained is higher than the starting gear, and the
driver depresses the pedal, the AutoShift system will override the
LOW mode and shift to the best available gear if the engine lugs
excessively.
WARNING

10
Operation
Transmission Power Take Off
Stationary PTO Operation
The transmission countershaft PTO is used in this application.
To engage the PTO for stationary operation perform the following steps:
1. Apply the parking brake.
2. Select “D” on the Shift Control (this stops countershaft rotation for
PTO engagement).
3. Select the transmission PTO switch.
4. Select “N” on the Shift Control.
5. Raise engine speed up to specified minimum speed required to
engage clutch and operate PTO.
Mobile PTO operation
The Transmission countershaft PTO is used in this application, and provides
limited mobile operation in the starting gears.
To engage the PTO for mobile operation perform the following steps:
1. Depress the service brake.
2. Release the parking brake.
3. Select “MANUAL” on the Shift Control (this stops countershaft rota-
tion for PTO engagement).
4. Select the transmission PTO switch.
5. Select “MANUAL”, “Neutral” or, “Reverse”, as required for vehicle
movement.
6. Release the service brake.
7. Raise the engine speed up to specified minimum speed required to
engage clutch and move vehicle/operate PTO.
Split shaft PTO Operation (stationary only)
To engage the transmission for split shaft operation perform the following
steps:
1. Select “D” on the Shift Control.
2. Select PTO switch.

11
Service & Maintenance
General Model Information
Nomeclature
Tag Location
The blank spaces provided below are for recording transmission identification
data and part numbers of maintenance items. All Eaton® Fuller® Transmis-
sions 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.
The blank spaces provided below are for recording transmission identification
data. Have these reference numbers handy when ordering replacement parts
or requesting service information:
Transmission Model ________________________________
Transmission Serial Number _______________________________
Roadranger
Twin Countershaft
Low-Inertia
Overdrive
Torque x 100
R T L O - 18 9 18 B-AS2
2- AutoShift II (Second Generation)
AutoShift
Gear Ratio
Forward Speeds
Design Level
Model
Serial
Eaton
Transmissions
R
Made In
RTLO-18918-AS2
Eaton Corporation
Transmission Div.
Kalamazoo, MI. 49003
Fuller
R

12
Service & Maintenance
Troubleshooting
Diagnostics
In the event there is a problem with the AutoShift, there are three primary
tasks the driver should perform:
1. Note the driving condition under which the problem occurred.
2. Note the condition of the AutoShift under which the problem
occurred (i.e. operation mode (Drive, MANUAL, LOW), current gear,
engine speed, etc).
3. Reset the system.
Transmission Reset Procedure
In some cases, proper transmission operation can be restored by “resetting”
the transmission Electronic Control Unit (ECU). Use the following procedure
to reset the ECU:
1. When it is safe to do so, stop the vehicle.
2. Place the transmission shift lever in Neutral and turn the ignition key
to the “off” position.
3. Wait at least 2 minutes.
4. Restart the engine.
5. If the problem continues, contact a service facility to have the vehicle
and transmission system evaluated.

13
Service & Maintenance
Locked In Gear
If the truck is shut down or stalls in gear, the AutoShift may become locked in
gear. The transmission will attempt to get to Neutral during the next power up
if the shifter is in Neutral. If Neutral is achieved, a solid “N” appears on the
Gear Display. If Neutral cannot be achieved, a “DASH” will appear on the dis-
play and the engine will not start. If a dash appears during power up and the
lever is in Neutral try the following:
6. Turn the key OFF and let the transmission power down for a least 2
minutes.
7. Depress the brake pedal.
8. Release the parking brake.
9. Depress the clutch, but do not push in all the way to the floor or you
will make contact with the clutch brake.
10. Make sure the shifter is in Neutral.
11. Turn the key to the ON position.
12. AutoShift will attempt to shift into Neutral once you turn the key ON,
but you may have to slightly release the brake pedal to help let the
torque off the driveline.
13. Once it reaches Neutral a solid “N” will appear on the Gear Display
and the truck will start. If a dash still appears after this procedure,
get the vehicle to a service center.

14
Service & Maintenance
Proper Lubrication
Proper lubrication procedures are key to a good all-around maintenance pro-
gram. If the lubricant is not doing its job or if the lubricant level is ignored, all
the maintenance procedures in the world are not going to keep the transmis-
sion running or assure long transmission life.
Eaton® Fuller® Transmissions are designed so the internal parts operate in
an oil bath circulated by the motion of the gears and shafts.
Thus, all parts are amply lubricated if these procedures are closely followed:
1. Maintain lubricant level and inspect regularly.
2. Follow maintenance interval chart.
3. Use the correct grade and type of lubricant.
4. Buy lubricant from an approved dealer.
Mixing of Oil Types
Never mix engine oils & gear oils in the same transmission.
Engine oils and gear oils may not be compatible; mixing can cause breakdown
of the lubricant and affect component performance. When switching between
types of lubricants, all areas of each affected component must be thoroughly
flushed.
Note: For a list of Eaton approved synthetic lubricants, see TCMT-0021 or call
1-800-826-HELP (4357).
Note: Additives and friction modifiers must not be introduced.
CAUTION

15
Service & Maintenance
Proper Transmission Lubrication Level
Make sure the transmission lubricant is level with the bottom of the fill open-
ing. Being able to reach the lubricant with your finger does not mean the lubri-
cant is at the proper level. (On heavy duty transmissions, one inch of lubricant
level equals about one gallon of lubricant.)
If the transmission operating angle is more than 12 degrees, improper lubrica-
tion can occur. The operating angle is the transmission mounting angle in the
chassis plus the grade (expressed in degrees).
Any time the transmission operating angle of 12 degrees is exceeded for an
extended period of time, the transmission must be equipped with an oil pump
or cooler kit to insure proper lubrication.
Lube Change Intervals
Lubricant changes should be based on a combination of the intervals shown
in TCMT-0021, the Roadranger Products Lubrication Manual, and user judge-
ment based on the application and operating environment. Extending drain
intervals beyond those shown in the tables is not recommended and will put
warranties at risk.
Note: The first lube change for a Line-Haul vehicle 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).
Note: Vocational service applications are those which require components to
be consistently operated at heavy loads, in contaminated environments
or on steep grades. For these applications, the Vocational Service sec-
tion should be used.
ImproperOil Level
Hole
Pro
p
erOil Level
Hole

16
Service & Maintence
Vehicle Towing
When towing the vehicle, the output shaft of the transmission must not be
allowed to spin or turn. If the vehicle is towed with the drive wheels still in
contact with the road surface, the vehicle axle shafts or driveline must be
removed or disconnected.
Serious internal transmission damage can result from improper vehicle
towing.
CAUTION
Correct
WRONG

17
Warranty
Extended Warranty Form
Before signing below, please read this section carefully !
I/we understand the terms of this warranty and acknowledge the following:
This warranty is only valid if the vehicle is used in the vocation/application selected.
This warranty is only valid if the clutch and/or transmission are properly maintained. This includes
maintaining proper adjustment, the use of required lubricants, adhering to prescribed lubricant change
schedules and keeping lubricant at prescribed levels at all times.
I may be required to provide proof that lubricants have been changed at the required intervals.
This warranty is only valid for verifiable defects in material or workmanship.
This warranty does not cover failures due to operator error or abuse, improper maintenance or adjustments,
driveline vibration or torsional activity, improper driveline angles, unauthorized alterations to the warranted
product or failures caused by other components.
This warranty might be subject to other requirements, limits and exclusions.
Date: _______
OWNER Signature: ________________________________
DEALER Contact Signature:
United States
Check #: ______________
Check Date: ___________
Check Amt.:
______________ USD/
CAN Funds
IMPORTANT: To ensure this warranty registration can be processed, please provide complete and accurate
answers to ALL information requested below. Failure to do so will cause delays in registering the vehicle.
Required Registration Information
OWNER __________________________________ DEALER _________________________________
Address _________________________________ Address ________________________________
City ____________________ State/Prov. _____ City ____________________ State/Prov. _____
Postal Code __________________ Postal Code __________________
Phone __________________________ Phone ___________________________
Email: __________________________________ Email: __________________________________
Vehicle & Component Information
Ch
NOTE: Not all Vocations are eligible for Extended Warranty Coverage.
assis VIN (17 characters): __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __
Vehicle Vocation: City Delivery Heavy Haul Line Haul
(Check one) Logging Oil Field Refuse
Other ____________________________________________
OEM: ___________________ Current Mileage: ________________
Transmission Model: _________________________ Trans Serial No. _______________
Clutch Mfg. : Model _______________
Eaton Corporation
Attn: Warranty Registration
P.O. Box 93531
Chicago, IL 60673-3531
For extended warranty pricing and coverages, please visit our website at www.Roadranger.com or reference these
warranty documents:
See TCWY-0900 for purchased warranty requirements, limitations, exclusions, and pricing.
See TCWY-0600 for general warranty information, claim processing procedures, and part requirements.
- Vehicles registered from the 13th month through the 24th month of service require payment of a $100.00 USD/
$120 CAN fee plus the extended warranty coverage price.
.
- Vehicles registered from the 25th month through the 36th month of service require payment of a $300.00 USD/
$350 CAN fee plus the extended warranty coverage price.
Remittance Instructions
08/0
5
TCWY-0750
Purchased Warranty Registration Form
DEALER Contact Phone:
www.Roadranger.com
__________________________
__________________________
__________________________________
Construction
Mining
DEALER (Printed:)
Checks should be made in U.S. or CAN funds and made payable to Eaton Corporation. Checks may be written
by the dealer or the owner. Checks and registration forms should be mailed to the appropriate address listed below:
_________________________
Truck In-Service Date:
________________
Eaton Corporation
Attn: Warranty Registration
P.O. Box 2473, Station A
Toronto, Ontario, M5W2K6
Canada