Eaton TRDR1111 User manual

Driver Instructions
Eaton UltraShift® PLUS
TRDR1111 EN-US
December 2014
UltraShift® PLUS Vocational Extreme Performance (VXP)
FO-22E318A-VXP Military Application / Extreme Heavy-Haul Only

i
Warnings and Cautions
Warnings and Cautions
Definitions
Warning: Indicates you will be Severely Injured or Killed if you do not follow
the indicated procedure.
Caution: Indicates an Immediate Hazard, which could result in Severe Per-
sonal Injury if you do not follow the indicated procedure.
Important: Indicates vehicle or property damage could occur if you do not fol-
low the indicated procedure.
Note: Note indicates additional detail that will aid in the diagnosis or repair of
a component or system.
Warning
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 brake.
If engine cranks in any gear other than neutral, service vehicle
immediately.
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”.
Always ensure that fuel is at a sufficient operating level before operating
vehicle. A loss of engine power could result in inhibited shifting.
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ii
Warnings and Cautions
Caution
Do not release the parking brake or attempt to select a gear until the air pres-
sure is at the correct level.
Before operating the PTO, refer to “Transmission Power Take Off
Operation.”
Battery (+) and (-) must be disconnected prior to any type of welding on any
UltraShift® PLUS equipped vehicle.
Important
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 cross-
ing without a change of gears.
This can only be achieved by utilizing the MANUAL mode. Please refer to
pages 7 and 8 for correct MANUAL mode operation.
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iii
Table of Contents
Warnings and Cautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i
Operation
Shift Console Positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Gear Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Start-up and Power Down . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Reverse Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Drive Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
MANUAL Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
LOW Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Transmission Power Take Off (PTO) . . . . . . . . . . . . . . . . . . . 13
Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Service & Maintenance
General Model Information . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Proper Clutch Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Vehicle Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

1
Operation
Shift Console Positions
Warning: UltraShift PLUS initiates upshifts from MANUAL and LOW for
engine over speed protection. Some engines do not use the Eaton engine
overspeed protection.
R Selects Reverse (see page 4 for more details)
N Mode used for Start-up and Power-down
D Selects Drive (see page 6 for more details)
MANUAL Selects MANUAL (see page 7 for more details)
LOW Selects LOW (see page 9 for more details)
Service The service indicator alerts the driver of potential transmission
problems.
Upshift /
Downshift
Buttons
Used in the MANUAL mode to select upshifts and downshifts
and to change start gear, if available.
R - Reverse
N - Neutral
D - Drive
MANUAL
LOW
- Upshift
- Downshift
SERVICE
SHIFT
MANUAL
EATON FULLER
TRANSMISSIONS
LOW
D
N
R
Buttonnot used
Service Indicator
- Upshift
- Downshift
R - Reverse
N - Neutral
D - Drive
MANUAL
LOW
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2
Operation
Gear Display
The Gear Display indicates the current gear position of the transmission.
During an upshift or downshift the gear display may momentarily flash the tar-
get gear position.
The “DASH” indicates the transmission may be torque locked in gear. See
“Service and Maintenance Locked in Gear” section for more details.
“CA” will appear in the gear display if a clutch abuse event is occurring.
“AN” will appear in the gear display if the transmission goes into Auto Neutral.
In heavy-duty Fuller UltraShift™ PLUS Automated models, “GI” may briefly
appear in the gear display after the engine is started. This indicates that the
clutch release bearing will need to be greased soon. See “Optional Automated
Lube Schedule” section for more information.
Note: “GI” stands for grease interval and may be misread as “G1” on gear dis-
play.
Current Gear
GearShift
TransitionSuccessful Gear
Shift
Solid
May Momentarily
Flash
Solid

3
Operation
Start-up and Power Down
Start-up
1. Turn the ignition key to “ON” and allow the Fuller®UltraShift®PLUS
to power-up.
• Engine cranking is delayed until the transmission power-up is
complete and the gear display shows a solid “N.”
2. Start the engine.
3. Apply service brake.
• If the service brake is not applied while selecting a starting gear,
the initial start gear will not be found and the driver will have to
re-select Neutral and press the brake while re-selecting the
desired mode.
4. Select the desired mode and starting gear on the shift console.
Important: Any start gear up to the max start gear can be manually selected,
regardless of actual GCW or operating conditions. Manual selection of a start
gear that is too high for the vehicle conditions can cause damage to the drive-
train.
5. Release the vehicle parking brakes.
Important: If the driver presses and holds both the accelerator and service
brake pedals (even if done accidentally), the launch will be abrupt and the
engine and brake forces may rock and bounce the vehicle. Allow the Hill Start
Aid to hold the vehicle while moving foot from the service brake to the acceler-
ator.
6. Release service brake and apply accelerator.
Important: During the launch if the vehicle vibrates and engine RPM is low-
ered below the idle speed, then the start gear selection is too high. Stop the
vehicle and select a lower gear.
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4
Operation
Power Down
1. Select Neutral on the shift control.
• If gear display does not show solid “N,” neutral has not yet been
obtained.
Note: Neutral should always be reached before the Fuller UltraShift PLUS
power down is performed except in cases of emergency.
2. Set the vehicle parking brakes.
3. Turn off the ignition key and allow the engine to shut down.

5
Operation
Reverse Mode
• Selects default Reverse gear (see Note*).
• Each time Reverse is selected from Neutral, the default Reverse gear
is engaged.
• The vehicle will not engage Reverse above 2 mph.
• R1 to R2 and R3 to R4 shifts will only be made by manually using up
and downshift buttons while driving.
Note: The transmission cannot range shift while moving. Driver can split shift
while moving if the vehicle is equipped with a multi-speed auxiliary sec-
tion.
Note: *If the driver attempt to select a non-neutral mode without depressing
the service brakes the transmission will not shift into gear and transmis-
sion will have to be returned to Neutral. Depress the brakes before
selecting the desired mode again.
Important: Launching the vehicle in high range increases the likelihood of
clutch abuse, and depending on the level of usage, could have a detrimental
impact on clutch life.
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LO Range
HI Split
LO Range
LO Split
FullerUltraShift PLUS Vocational Extreme Performance (VXP)
FO-22E318A-VXP Military ApplicationExtreme Heavy-Haul
HI Range
LO Split
HI Range
HI Split

6
Operation
Drive Mode
• Automatically selects the start gear. The selected start gear will vary
depending on several vehicle inputs like load, grade, and axle/trans-
mission ratio. This start gear can be changed by using the up/down
buttons.
Important: Any start gear up to the max start gear can be manually selected,
regardless of actual GCW or operating conditions. Manual selection of a start
gear that is too high for the vehicle conditions can cause damage to the drive-
train.
• If the start gear is changed using the up/down buttons, it will remain
as the default until the vehicle is powered down or the selection is
changed with the buttons again.
• Automatically performs all upshifts and downshifts in all gears.
• A shift can be advanced by pressing the up/down buttons when the
transmission is near the shift point.
Important: If the driver requests an upshift, the transmission will attempt that
shift regardless of the operating conditions. If the transmission misses the
shift, it will attempt to engage whatever gear it can to keep the vehicle moving
in the intended direction. If the driver requests a downshift, the transmission
will complete the downshift as long as it will not over speed the engine rpm. If
the transmission misses the downshift, it will attempt to recover into whatever
gear it can to keep the vehicle moving in the intended direction.
Note: Manual upshifts need to be selected when the engine RPM is near 2100
RPM and manual downshifts need to be selected when the engine RPM
is near 1400 RPM.
Important: Prior to ascending a steep grade the driver should reduce default
start gear by one or ensure full throttle is applied for the duration of the grade
so the vehicle maintains the proper engine and vehicle speed during the entire
grade. Driver can button down by using the down arrow on the shift lever.
Note: *If the driver attempts to select a non-neutral mode without depressing
the service brakes the transmission will not shift into gear and the driver
will have to return to Neutral and depress the brakes before selecting the
desired mode again.
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7
Operation
Important: If the driver depresses and holds both pedals (even if done acci-
dentally) the launch will be abrupt and the engine and brake forces may rock
and bounce the vehicle. Releasing either pedal will stop this immediately.
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8
Operation
MANUAL Mode
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.
Important: Any start gear up to the max start gear can be manually selected,
regardless of actual GCW or operating conditions. Manual selection of a start
gear that is too high for the vehicle conditions can cause damage to the drive-
train.
• Driver manually selects the start gear and uses the up/down buttons
to shift.
• System holds current gear unless otherwise prompted by using up /
down-shift buttons, except for the “Transmission Override” condi-
tions noted below.
Important: If the driver requests an upshift, the transmission will attempt that
shift regardless of the operating conditions. The transmission shift quality
may be perceived as poor quality shifts or clunky shifts; however, this is by
design to ensure the transmission does everything it can to ensure it does not
miss the requested shift from the drivers input.If the transmission misses the
shift, it will attempt to engage whatever gear it can to keep the vehicle moving
in the intended direction. If the driver requests a downshift, the transmission
will complete the downshift as long as it will not over speed the engine rpm. If
the transmission misses the downshift, it will attempt to recover into whatever
gear it can to keep the vehicle moving in the intended direction.
Note: Manual upshifts need to be selected when the engine RPM is near 2100
RPM and manual downshifts need to be selected when the engine RPM
is near 1400 RPM.
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9
Operation
Warning: UltraShift PLUS initiates upshifts from MANUAL and LOW for
engine over speed protection. Some engines do not use the Eaton engine
overspeed protection.
• The system will automatically shift or inhibit shifts to prevent over-
speed or under-speed of the engine.
• The transmission may also deny a shift while ascending or descend-
ing grades if the load of the vehicle, and grade of the terrain in com-
bination with the drivetrain ratio and engine torque will fall outside of
the acceptable range to perform a shift. If the shift is denied it will
sound a tone.
Transmission Manual Override:
• If the vehicle is being back driven and the engine is approaching a
higher than normal level, the transmission system will override the
MANUAL position and perform and upshift.
• If the start gear is changed and it causes the engine to lug at takeoff,
the transmission system will override the MANUAL position and
select the best available gear.
Note: *If the driver attempts to select a non-neutral mode without depressing
the service brakes the transmission will not shift into gear and the driver
will have to return to Neutral and depress the brakes before selecting the
desired mode again.
Important: If the driver depresses and holds both pedals (even if done acci-
dentally) the launch will be abrupt and the engine and brake forces may rock
and bounce the vehicle. Releasing either pedal will stop this immediately.
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10
Operation
LOW Mode
LOW mode should be used 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.
• Selects lowest available gear for start gear. (see Note *). The starting
gear cannot be changed in LOW mode.
• If LOW is selected while moving, the transmission will not upshift
(except for the Transmission Override conditions noted below). The
transmission system will downshift at the earliest opportunity to pro-
vide maximum engine braking.
Transmission LOW Override
• If the vehicle is being back driven and the engine is approaching a
higher than normal level, the transmission system will override the
MANUAL position and perform and upshift.
Warning: UltraShift PLUS initiates upshifts from MANUAL and LOW for
engine over speed protection. Some engines do not use the Eaton engine
overspeed protection.
Note: At higher engine speeds additional engine braking in LOW Mode could
cause a loss of traction when on slippery surfaces.
Note: *If the driver attempts to select a non-neutral mode without depressing
the service brakes the transmission will not shift into gear and the driver
will have to return to Neutral and depress the brakes before selecting the
desired mode again.
Important: If the driver depresses and holds both pedals (even if done acci-
dentally) the launch will be abrupt and the engine and brake forces may rock
and bounce the vehicle. Releasing either pedal will stop this immediately.
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11
Operation
Creep Mode
• The Creep mode function allows the vehicle to be driven at a con-
stant speed at engine idle without the need to hold the throttle pedal
position. The mode is useful for very slow speed maneuvering or
applications where steady vehicle speed is required.
• By default, Creep mode can be activated while in MANUAL or LOW
mode (see Note below for Drive and Reverse). The vehicle speed is
determined by the selected gear ratio operating at governed low
engine idle speed. Any available gear may be selected. However,
the transmission will downshift or exit Creep mode to prevent stall-
ing if the engine lugs due to load conditions.
To engage Creep Mode:
1. Select LOW mode or MANUAL mode and desired gear (while
stopped or moving).
2. Apply the throttle pedal to accelerate the vehicle until the clutch is
closed (engaged).
3. Release the throttle pedal. The vehicle will continue moving at gov-
erned low engine idle speed.
To exit Creep Mode:
1. Apply the throttle pedal to accelerate temporarily or to select a higher
gear with the upshift button in MANUAL mode. Release the throttle
pedal to resume Creep mode in the selected gear.
2. Use the down shift button to select a lower gear while in Creep mode.
3. Dependent on engine configuration, cruise control may be used to
increase Engine idle speed.
Note: The transmission will exit Creep mode if the engine lugs below the
governed low engine idle speed. In this case, a lower gear should
be selected if available.
Driving in Creep Mode:
1. Apply the service brake pedal or shift into a non-Creep mode enabled
mode (Reverse, Neutral, or Drive).
Note: In some applications Creep mode may be desirable in Drive and/or
Reverse. If so, ServiceRanger diagnostic software can be used to
enable Creep mode in Drive and/or Reverse.

12
Operation
Sliding Trailer Axle
• Ensure axle rails and locks are properly maintained.
• Follow proper procedure for unlocking and sliding the trailer axles.
• Use Low mode (1st gear) for forward direction and Reverse (R1) for
reverse direction.
• Avoid repeat attempts if the sliding axle is not moving.
Note: If repeat attempts are made and the automated clutch starts to overheat,
the display will indicate “CA” along with a warning tone.
Trailer Connecting
• Prior to backing under the trailer, ensure proper trailer height.
• Use Low mode (1st gear) for forward direction and Reverse (R1) for
reverse direction.

13
Operation
Transmission Power Take Off (PTO)
UltraShift PLUS Multipurpose Vocational Extreme Performance (VXP)
FO-22E318A-VXP Military Application Extreme Heavy Haul Only
The ability to prevent a mode selection while the PTO is active is desired for
certain vocational applications.
A PTO configuration is available that allows or prevents a non-neutral mode
selection when a PTO is active. The default setting for this configuration is
“Disabled” which allows non-neutral mode selection and mobile operation
when the PTO is active. When set to “Enabled” and the PTO is active, non-neu-
tral mode selections and mobile operation is not allowed.
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. Depress the service brake.
3. Select “D” on the Shift Control. (This stops countershaft rotation for
PTO engagement.)
4. Select the transmission PTO switch.
5. Select “N” on the Shift Control.
6. Release the service brake to engage the clutch and the PTO.
7. Raise engine speed as required to operate PTO.
Note: To disengage the PTO, deselect the transmission PTO switch.

14
Operation
Mobile PTO Operation
The transmission countershaft PTO is used in this application and provides
limited mobile operation in the start gears. To engage the PTO for mobile
operation, perform the following steps:
1. Depress the service brake.
2. Release the parking brake.
3. Select “D” on the Shift Control. (This stops countershaft rotation for
PTO engagement.)
4. Select the transmission PTO switch.
5. Select “D,” MANUAL, “Neutral,” or “Reverse,” as required for vehicle
movement.
6. Release the service brake to engage the clutch and the PTO.
7. Raise engine speed as required to operate PTO.
Note: To disengage the PTO, deselect the transmission PTO switch.
Split Shaft PTO (SSPTO) Operation
To engage the split shaft PTO for stationary operation, perform the following
steps:
1. Apply the parking brake.
2. Select “N” on the Shift Control.
3. Depress the service brake.
4. Select the SSPTO switch. The SSPTO switch lamp should turn on.
5. Verify SSPTO switch lamp is on and SSPTO is engaged.
6. Select MANUAL and upshift/downshift buttons to select desired gear.
(Default gear ratio is 1:1.) The gear display will flash the SSPTO gear.
7. Release the service brake and apply accelerator until gear display
stops flashing. (This indicates the clutch is engaged.)
8. Use cruise control, accelerator, or remote throttle to reach desired
SSPTO speed.
Note: If the vehicle is equipped with remote Upshift/Downshift Buttons, the
transmission can be remotely shifted after the SSSPTO engagement pro-
cedure is completed. However the SSPTO may come to a stop while the
transmission is completing the shift.

15
Operation
Note: If the vehicle is equipped with a remote clutch control, the vehicle throt-
tle pedal cannot be used for transmission clutch engagement in SSPTO
mode, the remote clutch control must be used to engage the clutch.
Note: To disengage the SSPTO, deselect the SSPTO switch, deselect
MANUAL, release parking brake, or apply service brake. (Engine will
return to idle, clutch will disengage, and transmission will shift to Auto
Neutral.)
Soft Soil Operation (Heavy-Duty Models Only)
• The transmission system requires the ATC option to be enabled
when driving in soft soil/sand or snow/ice to prevent wheel slippage
and shifting issues. The ATC system has two modes, which are the
normal on mode for sand and loose road surface and the mud/snow
setting.
Normal Mode (Sand/Soft soil)
• The normal ATC option will engage the brakes on the wheel or side
that the wheel slip is occurring to help the vehicle regain traction.
The point at which the traction control will actuate the braking sys-
tem increases with throttle. Low throttle allows the system to brake
the wheels earlier and heavy/full throttle raises the point of the
acceptable wheel slip.
• If using Drive mode in soft soil/sand - Maintain the engine RPM
between 1000-1300 RPM to prevent unnecessary upshifting.
• If using MANUAL mode in soft soil/sand - Do not attempt an up-shift
and try to maintain the current gear.
• If the vehicle comes to a stop in the sand it may be necessary to back
up prior to attempting forward movement.
Mud/Snow/Ice Mode
• The mud/snow/ice ATC option can be selected by depressing the ATC
switch until the ATC lamp flashes. This mode raises the wheel slip
speed that is allowed before the traction control activates. The point
at which the traction control will actuate the braking system
increases with throttle. Low throttle allows the system to brake the
wheels earlier and heavy/full throttle raises the point of the accept-
able wheel slip.