Eaton Fuller FTS-112L Series Installation and operation manual

Eaton®Fuller®
Heavy Duty Transmissions
Driver Instructions
SynchroShiftTM Fuller Heavy Duty
Synchronized Transmissions
FTS-XX112L
November 2009

2
Read the entire driver instructions before operating this transmission.
Set the parking brakes before starting a vehicle, always be seated in the driver’s seat, move
the shift lever to neutral, and depress the master clutch.
If the engine cranks in any gear other than neutral or without the master clutch depressed,
service your vehicle neutral safety start circuit immediately.
Before working on vehicle or when leaving the cab with the engine running, place the
transmission in neutral, set the parking brakes, and block the wheels.
Do not release the parking brake or attempt to select a gear until the air pressure is at the
correct level.
When parking the vehicle or leaving the cab, always place the shift lever in neutral and set
the parking brakes.
If your vehicle is equipped with a remote throttle, before operation, the transmission must
be in neutral.
TOWING: To avoid damage to the transmission during towing, disconnect the driveline.

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Identification Tag 4
Model Designation 5
Shift Lever Positions 6
Shift Controls 7
General Information 8
Transmission Features 10
Operations
Driving Tips 11
Initial Start Up 12
Upshifting 14
Downshifting 15
Lubrication 16
Preventive Maintenance 19
Table of Contents
Every effort has been made to ensure the accuracy of all information in this brochure.
However, Eaton Corporation makes no expressed or implied warranty or representation
based on the enclosed information. Any errors or omissions may be reported to Technical
Service. Phone: [phone].

4
Transmission model designation and other transmission identification information are
stamped on the transmission tag. To identify the transmission model designation and serial
number, locate the tag on the transmission and then locate the numbers as shown.
DO NOT REMOVE OR DESTROY THE TRANSMISSION IDENTIFICATION TAG.
Record transmission identification data. Have these reference numbers handy when
ordering replacement parts or requesting service information.
Transmission Model _________________________________
Transmission Serial Number _________________________________
Identification Tag
FTS
-
16112L

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Nomenclature:
Model Designation

6
Shift Lever Positions
Shift Lever Positions

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Master Control Valve
(A-6815)
Shift Controls

8
Models in this series provide 12 forward speeds, one reduced (LO) and three reverse,
consisting of a 5-speed front section and a 3-speed auxiliary section. The auxiliary section
contains Deep and LO range ratios.
LO gear lever position is used only as a starting gear in severe conditions. The other four
ratios are used once in Deep range, once again in LO range and then in HI range. The
Range Selector is used once during the upshift sequence and once during the downshift
sequence.
Shifting is simple and easy with the repeat "H" shift pattern. The gear shift lever position
for 9
th
HI range is the same as 5
th
in Lo range and 1
st
in Deep range, 10
th
Hi range is the
same as 6
th
in Lo range and 2
nd
in Deep range, 11
th
Hi range is the same as 7
th
Lo range and
3
rd
in Deep range, and 12
th
Hi range is the same as 8
th
in Lo range and 4
th
in Deep range.
High Speed Downshift Protection System
The SynchroShift
TM
control module is equipped with advanced diagnostic features to
evaluate the integrity of the system and provide operator feedback of a system fault. In
addition, if the fault shall result in a condition that will compromise the reliability of the
transmission or result in a safety risk, the system logic will compensate and default to a safe
mode. The diagnostic capability of the control module includes identification of component
failures. The service light used for identification of a component failure is on for 2 seconds
upon vehicle start up to allow for identification of a malfunctioning service light.
Prevent Deep Reduction when Hi range is selected
To prevent transmission damage and operator confusion, the system is designed to avoid
deep reduction when high range is selected. This is prevented by using a mechanical
interlock in the master control valve. However, there are electrical and pneumatic failure
modes that can result in a Hi range to deep reduction shift. The control module is equipped
with logic to recognize this and automatically hold the transmission to high range.
General Information

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Optional Equipment:
By-pass System
When in downshift protection, the transmission will engage high range at the first
opportunity and will keep it in Hi range until the source of the failure is gone. By-pass
mode will allow the operator to drive the vehicle – only in low range – to a place where the
repair can be done. To turn on the by-pass system the driver must stop the vehicle, use the
parking brake and turn on the by-pass control (inside the vehicle cabin).
Shift Pattern Diagram
A shift pattern diagram should be in your vehicle. If it has been lost, a replacement may be
obtained by writing to:
Eaton Corporation
Truck Components
Rua Clark, 2061, Bairro Macuco – CEP 13279-400.
Valinhos - São Paulo - Brasil.
Phone: [phone].
Please specify shifting controls used and transmission model number when making request.
General Information

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Range Shift
The Range Selector lever is used to select Deep, LO or HI range. It is used once during an
upshift sequence and once during a downshift sequence.
Pre-select
IMPORTANT: Always pre-select all range shifts when upshifting or downshifting. Pre-
selection requires that the Range Selector lever is moved to the needed position before
starting the lever shift.
Pre-selected range shifts are completed automatically as the lever is moved through neutral
and into the next gear position. Pre-selecting all range shifts prevents damage to the
transmission range synchronizers and provides for smoother shifts.
Transmission Features

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Driving Tips
•Always select an initial starting gear that provides sufficient reduction for the load
and terrain.
•Never slam or jerk the shift lever to complete gear engagements.
•Never coast with the shift lever in the neutral position.
•Never move the shift lever to the Deep speed gear position while operating in LO or
HI range.
•Never move the range selection lever with the shift lever in neutral while the vehicle
is moving.
•Never make a range shift while moving in reverse.
•Avoid downshifting at high speed, because these damage the synchronizer elements.
Operation

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Initial Start Up
Special Instructions
Before starting a vehicle always be seated in the driver’s seat, move the shift lever to
neutral, and set the parking brakes.
Before moving a vehicle, make sure you understand your shift pattern configuration. A
shift label should be in your vehicle’s cab. If not, refer to General Information section to
order.
Procedure
1. Make sure the shift lever is in neutral and the parking brakes are set.
2. Turn on the key switch, start the engine.
3. Allow the vehicle air pressure to build to the correct level. Refer to your “Operator
and Service Manual” supplied with the truck.
4. Apply the service brakes.
5. Make sure the range selection is in the Deep range position.
Range Lever MUST be in the Deep
Range position to start the
movement
.
Operation

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Operation
6. To move the vehicle in adverse conditions, when is needed: make sure to operate in
the Deep range position.
7. Press the clutch all the way down.
8. Move the shift lever to start gear position initial that provides sufficient reduction for
the load and terrain.
9. Disengage the park brake.
10. Disengage the clutch while simultaneously pushing on the accelerator pedal to move
the vehicle.
Operation

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In the instructions below, is assumed that the driver is familiarized with the operation of
Heavy Duty trucks - Towing - can control the shift lever and the clutch to obtain exact
and smooth shifts, in upshifting and downshifting sequences.
Upshifting
Range Change –Deep Reduction to LO Range
1. When all Deep range gears have been achieved, pre-select the deep reduction
selector button rearward to select the LO range and move the shift lever as the
diagram shows. When the shift lever passes neutral, the transmission will
automatically change from Deep Reduction to LO range.
Range Change –LO to HI Range
2. When all LO range gears have been achieved, pre-select the range selection lever up
(HI) to select the HI range and move the shift lever as the diagram shows. When the
shift lever passes neutral, the transmission will automatically change from LO to HI
range.
Warning: Never move the shift lever to Deep gear position after lo range (LO) or
high range (HI) was pre-selected, or during the operation in the lo range (LO) or high
range.
Operation

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Downshifting
.
1. Disengage the accelerator and press the clutch half-way, to stop torque to the
transmission then move the shift lever to the next desired gear position and re-
engage the clutch. Continue driving the vehicle, downshifting when it’s
necessary.
Range Change – HI Range to LO Range
2. With the transmission in high range and ready to start downshifting, pre-select
the range selection lever to the down position.
3. Disengage the clutch half-way and move the shift lever to the next position
wanted in the low system (LO). When the shift lever passes the neutral position,
the transmission range will change automatically from HI range to LO range.
4. Continue to downshifting to desired next position wanted in the LO range.
Range Change –LO Range to Deep Reduction
5. With the transmission in LO range and ready to start downshifting, pre-select
the deep reduction button forward.
6. Disengage the clutch half-way and move the shift lever to the next position
wanted in the Deep system (Deep Reduction). When the shift lever passes the
neutral position, the transmission range will change automatically from LO
range to Deep reduction.
7. Continue to downshifting to desired next position wanted in the Deep reduction.
Operation

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Proper Lubrication...
the Key to long transmission life
Proper lubrication procedures are the key to a good all-around maintenance program. If the
improper lubricant is used or if the lubricant level is ignored, general maintenance will not
keep the transmission running properly 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, all 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.
Lubrication

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* To obtain a reputable lubricate dealers list, write to:
Eaton Corporation
Truck Components
Rua Clark, 2061, Bairro Macuco – CEP 13279-400.
Valinhos - São Paulo - Brasil.
Phone: [phone].
.
Additives and friction modifiers are not recommended for use in Eaton Fuller
transmissions.
Never mix engine oil with gear oil in a transmission.
Lubrication
Product Type of Lubricate Specification Lubrication change Lubrication change
HIGHWAY USE OFF-HIGHWAY USE
Mineral MIL-PRF-2104H 62500 miles 31250 miles
(SAE 50) or 1 year or 1 year
CAT TO-4 62500 miles 31250 miles
FTS-16108LL Mineral (SAE 40 or SAE 50) or 1 year or 1 year
Mineral API CF-4 62500 miles 31250 miles
(SAE 40 or SAE 50) or 1 year or 1 year

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Proper Oil level
Make sure Oil is level with filler opening. Because you can reach oil with you fingers does
not mean oil is at proper level. One inch of oil level is about one gallon of oil. Make sure
vehicle is parked on level surface when checking for proper oil level.
Draining Oil
Drain transmission while oil is warm. To drain oil removes the drain plug at bottom of
case. Clean the drain plug before re-installing and torque the drain plug to proper
specification.
Refilling
Clean case around filler plug and remove plug from side of case. Fill the transmission to the
level of the filler opening, as shown below. Reinstall the fill plug and torque to the proper
specification.
The exact amount of oil will depend on the transmission inclination and model. Do not over
fill-this will cause oil to be forced out of the transmission.
The oil level of the transmission FTS-16112L is around 4.5 gallons.
When adding oil, types and brands of oil should not be mixed because of possible
incompability.
Lubrication
Incorrect Oil Level Correct Oil Level
Hole
Hole

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The maintenance items below must be observed to prevent fails in transmission, resulting
in unnecessary repairs that are not covered for warranty.
1. Air System and Connections
•Check daily for air leaks, worn hoses and air lines; repair immediately.
•If the vehicle has air dehumidification equipment installed check to ensure the
system is working correctly. Repair as needed.
•Check and repair air compressor as is needed. The vehicles air compressor can
allow oil to enter in the air system if not working properly.
2. Clutch Housing Mounting
•Check all capscrews of clutch housing for looseness.
3. Clutch Release Bearing (Not Shown)
•Remove hand hole cover and check radial and axial clearance in release bearing.
•Check relative position of thrust surface of release bearing with thrust sleeve on
push-type clutches.
4. Clutch Pedal Shaft and Bores
•Pry upward on shafts to check wear.
•If excessive movement is found, remove clutch release mechanism and check the
bushing and bore and shafts for wear.
5. Lubricant
•Change at specified service intervals.
•Use only the types and grades of oils recommended.
Preventive Maintenance

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6. Filler and Drain Plugs
•Remove filler plugs and check level of lubricant at specified intervals. Tighten
fill and drain plugs to proper torque specification.
7. Capscrews and Gaskets
•Check all capscrews, especially those on PTO covers and rear bearing covers for
looseness which could cause oil leakage.
8. Gear Shift Lever Housing
•Remove air lines at air valve. Remove the gear shift lever housing assembly
from the transmission.
•Check the tension spring and washer for set and wear.
•Check the gear shift lever spade pin and slot for wear.
•Check bottom end of gear shift lever for wear and check slot of yokes and
blocks in shift bar housing for wear at contact points with shift lever.
General Inspection
During the lubricate intervals specified by the vehicle chassis manufacturer, check for
missing or loose transmission mounting capscrews that attach the transmission to the
engine.
Preventive Maintenance