Eaton Fuller Roadranger Installation and operation manual

More time on the road ®
Fuller® Heavy Duty Transmissions
Driver Instructions
Fuller Heavy Duty Transmissions
TRDR0630
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

General Information
Warnings and Cautions
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 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 a 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 pres-
sure 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 trans-
mission must be in neutral.
TOWING: To avoid damage to the transmission during towing, disconnect the
driveline.
Every effort has been made to ensure the accuracy of all information in this manual. However,
Eaton Truck Component Operations makes no expressed or implied warranty or representation
based on the enclosed information. Any errors or omissions may be reported to Marketing Ser-
vices, Eaton Truck Component Operations, P.O. Box 4013, Kalamazoo, MI 49003.
Copyright Eaton Corporation, 2001. All rights reserved.

Table of Contents
General Information
How to Use This Manual .......................................................................1
Identification Tag .................................................................................. 2
Model Designation ................................................................................ 3
General Information .............................................................................. 4
Operation
Shift Pattern Diagram ............................................................................ 4
Shift Lever Positions ............................................................................. 5
Shift Controls ........................................................................................ 7
Transmission Features .......................................................................... 8
Range Shift ........................................................................................... 8
Preselect ............................................................................................... 8
Splitter Shift .......................................................................................... 8
Optional Equipment ............................................................................... 9
Driving Tips ......................................................................................... 10
Double-Clutching Procedure ............................................................... 11
Initial Start Up ..................................................................................... 12
Upshifting ........................................................................................... 13
Service & Maintenance
Lubrication.......................................................................................... 16
Maintain Proper Oil Level .................................................................... 16
Oil Filter............................................................................................... 17
Transmission Operating Angles .......................................................... 18
Operating Temperatures with Oil Coolers ............................................ 18
Oil Cooler Char.................................................................................... 19
Preventive Maintenance ...................................................................... 20
Reference
Definitions/Glossary of Terms for Transmission
Operation ..................................................................................... 22

1
General Information
Purpose
This manual is designed to provide detailed information necessary for the
proper driving techniques of the Eaton® Fuller® transmissions listed on the
cover.
How to Use This Manual
Driver instructions are divided into two sections: Transmission Operation and
Service and Maintenance. Transmission Operation contains information on
driving techniques along with shift patterns. Service and Maintenance con-
tains information items that deal with basic service and maintenance; such as,
identification tags and lubrication information.
The two sections are laid out with a general heading at the top outside edge of
each page followed by more specific headings labeling the information. To find
the information you need, refer to the Table of Contents or page through the
book section that covers what you need.

2
General Information
Identification Tag
Transmission Tag and Location
DO NOT REMOVE OR DESTROY THE TRANSMISSION IDENTIFICATION TAG.
Transmission model designation and other transmission identification infor-
mation 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 (example: RTLO-14610B).
Record transmission identification data. Have these reference numbers handy
when ordering replacement parts or requesting service information.

3
General Information
Model Designation
Nomenclature
RTOXF-14613A
Ratio Set
Forward Speeds
5 = Conventional Gearing
6 = "Multi-Mesh" Gearing
7 = Helical Auxiliary Gearing
This (x) 100 = Nominal
Torque Capacity
Roadranger
TwinCountershaft
Overdrive
DirectShiftPattern
ForwardShift
BarHousing

4
General Information
General Information
Models in this series provide thirteen forward speeds and two reverse, con-
sisting of a 5-speed front section and a 3-speed auxiliary section. The auxiliary
section contains LO and HI range ratios, plus an overdrive splitter gear.
The 1st position in the front section is used only as a starting gear. The other
four ratios are used once in LO range and once again in HI range. Each of the
four ratios, when used in HI range, can be split with the overdrive splitter gear.
After shifting out of the 1st position, you use the easy Roadranger repeat "H"
shift pattern. LO range and HI range are selected with the Range Knob/Range
Lever. It is used once during the upshift sequence and once during the down-
shift sequence.
Always preselect the range shift. After preselection, the transmission will
automatically make the synchronizer range shift as the shift lever passes
through neutral.
When in HI range the ratios can be split by using the Splitter Control Button.
The Direct/Rearward position gives the 5th, 6th, 7th, and 8th speed ratios: the
Overdrive/Forward position splits each of the HI range speed ratios. Therefore,
eight progressive HI range ratios can be obtained.
Shift Pattern Diagram
A shift pattern diagram should be in your vehicle. If it has been lost, a replace-
ment may be obtained by writing to:
Eaton Corporation
Truck Components
Global Marketing Services
P.O. Box 4013
Kalamazoo, MI 49003
www.roadranger.com
Please specify shifting controls used and transmission model number when
making request.

5
Operation
Shift Lever Positions
RT & RTF
RTO, RTOF, RTXO & RTXOF
RTOO & RTOOF

6
Operation
RT & RTF
RTO, RTOF, RTOX & RTOXF
RTOO & RTOOF
1
53 7
2
6
LO
4
8
Eaton Fuller Roadranger
¨
Transmissions
13 SPEED
(RT)
RANGE
SELECTOR
PRE-SELECT
ALL RANGE SHIFTS
SPLITTER SELECTOR
MAY BE SHIFTED
IN 5-6-7-8 ONLY
DO NOT RANGE SHIFT
WITH SPLITTER
SELECTOR IN OD
MOVE RANGE SELECTOR BEFORE MOVING SHIFT LEVER
START WITH RANGE SELECTOR DOWN
SHIFT LO-1-2-3-4 RAISE RANGE SELECTOR
SHIFT 5-6-7-8
SHIFT 8-7-6-5- MOVE RANGE SELECTOR DOWN
SHIFT 4-3-2-1-LO
HI
LO
UPSHIFTING
DOWNSHIFTING
DO NOT CHANGE RANGE WHILE MOVING IN REVERSE
Neutral
20160
WARNING
!
PUT TRANSMISSION IN NEUTRAL
BEFORE STARTING ENGINE
LO
R
HI
1
53 7
2
6
LO 4
8
Eaton
¨
Fuller
¨
Roadranger
¨
Transmissions
13 SPEED
(RTO & RTOX)
RANGE
SELECTOR
PRE-SELECT
ALL RANGE SHIFTS
SPLITTER SELECTOR
MAY BE SHIFTED
IN 5-6-7-8 ONLY
DO NOT RANGE SHIFT
WITH SPLITTER
SELECTOR IN OD
MOVE RANGE SELECTOR BEFORE MOVING SHIFT LEVER
START WITH RANGE SELECTOR DOWN
SHIFT LO-1-2-3-4 RAISE RANGE SELECTOR
SHIFT 5-6-7-8
SHIFT 8-7-6-5- MOVE RANGE SELECTOR DOWN
SHIFT 4-3-2-1-LO
HI
LO
UPSHIFTING
DOWNSHIFTING
DO NOT CHANGE RANGE WHILE MOVING IN REVERSE
Neutral
20161
WARNING
!
PUT TRANSMISSION IN NEUTRAL
BEFORE STARTING ENGINE
LO
R
HI
1
58
4
2
63 7
Eaton Fuller Roadranger
Transmissions
13 SPEED
(RTOO)
RANGE
SELECTOR
PRE-SELECT
DO NOT RANGE SHIFT
WITH SPLITTER
SELECTOR IN OD
ALL RANGE SHIFTS
DEEP REDUCTION
(MOVE RANGE SELECTOR BEFORE MOVING SHIFT LEVER)
START WITH RANGE SELECTOR DOWN
SHIFT 1-2-3-4-5 RAISE RANGE SELECTOR
SHIFT 6-7-8-9-10
SHIFT 10-9-8-7-6 MOVE RANGE SELECTOR DOWN
SHIFT 5-4-3-2-1
HI
LO
UPSHIFTING
DOWNSHIFTING
DO NOT CHANGE RANGE WHILE MOVING IN REVERSE
Neutral
20162
WARNING
!
PUT TRANSMISSION IN NEUTRAL
BEFORE STARTING ENGINE
HI
LO
R
LO

7
Operation
Shift Controls
Range Valve (A-3546) with Two-Position Selector Valve (A-4491/4494)
Roadranger Valve - A-4900
Up for HI Range
Down for LO Range
Range Lever
Rearward for Direct
Forward for Overdrive
Splitter Control
Button
Up for HI Range
Down for LO Range
Range Lever
Rearward for Direct
Forward for Overdrive
Splitter Control
Button

8
Operation
Transmission Features
Range Shift
The range lever selects LO or HI range. It is used once during an upshift
sequence and once during a downshift.
Preselect
IMPORTANT: Always preselect all range shifts when upshifting or downshift-
ing. Preselection requires that the range lever is moved to the needed position
before starting the shift.
Preselected range shifts are completed automatically as the lever is moved
through neutral and into the next gear. Preselecting all range shifts prevents
damage to the transmission and provides for smoother shifts.
Splitter Shift
The splitter control button selects HI range direct or HI range overdrive. It is
used in each HI range speed ratio.

9
Operation
Optional Equipment
For easier and faster gear engagement while the vehicle is standing still, some
Eaton® Fuller® transmissions may be equipped with either a Countershaft
Brake or a Clutch Brake.
Countershaft Brake
(Used with push-type clutches) - The control button is mounted on the shift
lever just below the shift knob. To operate, disengage the clutch, press down
the control button, and shift into LO or reverse. This is an air operated
mechanical brake which slows down the transmission gearing by forcing a
piston against the countershaft PTO gear. Never use the Countershaft Brake
when upshifting or downshifting. Use only for initial gear engagement when
the vehicle is standing still.
Clutch Brake
(Used with pull-type clutches) - The clutch brake is applied by fully depressing
the clutch pedal to the floor board. When applied the brake slows down and
can stop the transmission front box gearing. It is a disc-type brake incorpo-
rated into the clutch and transmission drive gear assemblies. Never use the
Clutch Brake when upshifting or downshifting. Use only for initial gear
engagement when the vehicle is standing still.

10
Operation
Driving Tips
• Always select an initial starting gear that provides sufficient reduc-
tion for the load and terrain.
• Always use normal double-clutching procedures when making lever
shifts.
• Never slam or jerk the shift lever to complete gear engagements.
• Never coast with the shift lever in the neutral position.
• Never move the range lever with the shift lever in neutral while the
vehicle is moving.
• Never make a range shift while moving in reverse.
• Never downshift at too high of a road speed.
• In most cases, depending on the engine and axle ratios, you can save
valuable fuel by operating the vehicle at less than governed RPM
while cruising in top gear.
• Never move the shift lever to the LO speed gear position while oper-
ating in HI range.
• Never make a splitter shift while moving in reverse.
• Do not lug engine below peak torque (1200 r.p.m.).

11
Operation
Double-Clutching Procedure
When ready to make a shift:
1. Depress the pedal to disengage the clutch.
2. Move the gear shift lever to neutral.
3. Release the pedal to engage the clutch.*
a. UPSHIFTS - Decelerate engine until engine RPM and road speed
match.
b. DOWNSHIFTS - Accelerate engine until engine RPM and road
speed match.
4. Quickly depress pedal to disengage clutch and move gear shift lever
to next gear speed position.
5. Release pedal to engage clutch.
*By engaging the clutch with the gear shift lever in the neutral position, the
operator is able to control the RPM of the mainshaft gears since they are reg-
ulated by engine RPM. This procedure enables the operator to match the RPM
of the mainshaft gears with those of the mainshaft driven by the vehicle’s rear
wheels.

12
Operation
Initial Start Up
Special Instructions
WARNING: Before starting a vehicle always be seated in the driver's
seat, move the shift lever to neutral, and set the parking brakes.
CAUTION: 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 to order one.
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 lever is down in the LO range position and the
splitter control button is rearward.
6. Depress the clutch pedal to the floor.
7. Move the shift lever to desired initial gear.
8. Release the parking brakes on the vehicle.
9. Slowly release the clutch pedal and apply accelerator.
Range Lever MUST be
in the LO Range
position for LO
Range. And Splitter Control
Button Rearward
Transmissions
Fuler
l
¨

13
Operation
Upshifting
In the following instructions, it is assumed that the driver is familiar with oper-
ating heavy-duty trucks and tractors, and can coordinate the movement of the
shift lever and clutch pedal to make smooth gear engagements while upshift-
ing or downshifting. Always double-clutch when making lever shifts.
CAUTION: Never move the range lever or the splitter control button
with the shift lever in neutral while the vehicle is moving.
1. Move the shift lever, double-clutching, to the next gear position in LO
range.
Range shift - LO to HI Range Direct (4th to 5th DIR)
2. When in last gear position for LO range and ready for the next
upshift, pull up the Range Lever and move the shift lever, double-
clutching, to the next higher speed position according to your shift
pattern. As the shift lever passes through neutral, the transmission
will automatically shift from LO to HI range.
CAUTION: Never move the shift lever to the LO speed gear position
after HI range preselection, or at anytime the transmission is in HI
range.
Splitter shift - HI Range Direct to HI Range Overdrive (5th DIR to 5th OD)
3. Move the splitter control button into the forward/overdrive position.
4. Then, immediately, release the accelerator, depress the clutch pedal
once to break torque, release the pedal to reengage clutch, and
accelerate the engine. The transmission shifts from direct to over-
drive when synchronous is reached.
Combination Range shift and Splitter shift - HI Range Overdrive to HI Range
Direct (5th OD to 6th DIR)
5. Start a normal shift, move the shift lever, double-clutching, to the 6th
speed gear position.

14
Operation
6. But, move the splitter control button into the rearward/direct position
just prior to completing final clutch engagement and accelerating the
engine. If the splitter control button is not moved, the transmission
will be in 6th overdrive once the final clutch engagement is made.
CAUTION: Never move the splitter control button or the range lever
with the shift lever in neutral while the vehicle is moving.
7. Continue upshifting through the shift pattern. Double-clutching dur-
ing lever shifts, single-clutch during split shifts while the shift lever is
in the same position.
Downshift Procedure
In the following instructions, it is assumed that the driver is familiar with oper-
ating heavy-duty trucks and tractors, and can coordinate the movement of the
shift lever and clutch pedal to make smooth gear engagements while upshift-
ing or downshifting. Always double-clutch when making lever shifts.
CAUTION: Never move the range lever or the splitter control button
with the shift lever in neutral while the vehicle is moving.
Splitter shift - HI Range Overdrive to HI Range Direct (8th OD to 8th DIR)
1. Move the splitter control button into the rearward/direct position.
2. Then, immediately, release the accelerator, depress the clutch pedal
once to break torque, release the pedal to reengage clutch, and
accelerate the engine. The transmission shifts from overdrive to
direct when synchronous is reached.
Combination Range shift and Splitter shift - HI Range Direct to HI Range
Overdrive (7th DIR to 6th OD)
3. Move the splitter control button into the forward/overdrive position.
4. Then, immediately move the shift lever, double-clutching, to the
next lower gear position. If the splitter control button is not moved,
the transmission will be in 7th direct once the final clutch engage-
ment is made.

15
Operation
5. Continue downshifting through HI range. Double-clutching during
lever shifts, single-clutch during split shifts while the shift lever is in
the same position.
Range shift from HI Range Direct to LO Range (5th DIR to 4th)
6. While in HI range direct and ready for the next downshift, preselect
LO range, push the range preselection lever down.
CAUTION: When downshifting from HI range to LO range, the splitter
control button must be in the rearward/direct position and the shift to
the direct position completed before making the range shift. The shift
to LO range cannot be make with the splitter control button in the for-
ward/overdrive position.
7. Continue moving the shift lever, double-clutching, to the next desired
gear position in LO range. As the shift lever passes through neutral,
the transmission automatically shifts from HI range to LO range.
8. Continue downshifting, double-clutching, to the next desired gear
position in LO range.

16
Service and Maintenance
Lubrication
Proper lubrication procedures are the key to a good all-around maintenance
program.
Eaton® Fuller® Transmissions are designed so that the internal parts operate
in an oil circulating bath created by the motion of the gears and shafts.
All parts will be properly lubricated if these procedures are closely followed:
• Maintain oil level. Inspect regularly.
• Follow maintenance interval chart.
• Use the correct grade and type of oil.
• Buy from a reputable dealer.
For additional lubrication information, see TCMT-0021.
Maintain Proper Oil Level
Make sure oil is level with the filler opening. Being able to reach oil with your
finger does not mean oil is at proper level. (One inch of oil level is about one
gallon of oil.)
When adding oil, never mix engine oils and gear oils in the same transmis-
sion.
Oil Level
Improper Oil Level
Hole
Proper Oil Level
Hole

17
Service and Maintenance
Oil Filter
If your vehicle has a transmission oil filter, you must change the filter when
fluid or lubricant is changed.
The use of lubricants not meeting these requirements will affect warranty
coverage.
Additives and friction modifiers must not be introduced. Never mix engine
oils & gear oils in the same transmission.
For a list of Eaton Approved Synthetic Lubricants see TCMT-0020, or call 1-
800-826-HELP (4357).
Buy from a reputable dealer
For a complete list of approved and reputable dealers see TCMT-0020, or write
to:
Eaton Corporation
Truck Components
Global Marketing Services
P.O. Box 4013
Kalamazoo, MI 49003
www.roadranger.com
HIGHWAY USE
For transmissions equipped with oil filter,
P/N 4304827 Inspect filter for leaks or damage replace as necessary.
OFF-HIGHWAY USE
For transmissions equipped with oil filter,
P/N 4304827 Change filter every two years