Eaton TRSM0605 User manual

Service Manual
Fuller Heavy Duty Transmissions
TRSM0605
October 2007

(CJ Eaton Corporation
Transmission Div. -1972
Service
Manual
•Operation
•Lubrication
•Maintenance
•Repair
RT-613
Series
Fuller
Twin Countershaft
Road ranger®
Transmissions
1
Eaton Corporation
Transmission Division
Kalamazoo, Michigan

TABLE OF CONTENTS
Designations ------------------------------------------------------------------------ 3 Inspection ------------------------------------------ ---------------------------------- 47
Description
___________________ ------------------------------------------------------ 4
Reassembly Precautions
_____________________________________________________ 49
Specifications
------------------------------------------------------------------------ 4
Gear Ratios -------------------------------------------------------------------------- 5 Reassembly Instructions
I.
Front Section ___________________________________________________________ _50
Operation ------------------------------------------------------------------------------ 6
A. Right Reverse Idler Gear __________________________________ _50
Lubrication -------------------------------------------------------------------------- 8
B. Countershafts ------------------------------------------------------ 5 l
C.
Mainshaft ____________________________________________________________ 54
Check Chart _______ ---------------------------------- _____________________________ l 0
D. Mainshaft Installation _______________________________________ _58
Disassembly Precautions _____________________________________________________ l l E.
Clutch Shaft _______________________________________________________ 60
F. Right Countershaft Bearings ______________________________ 61
Disassembly Instructions
G. Left Reverse Idler Gear ______________________________________ 61
I. Shifting Controls ______________________________________________________ 12
A. Air System __________________________________________________________ 13
II. Auxiliary Intermediate Housing
______________________________ 62
B. Gear Shift Lever Housing __________________________________ l 6
A. Auxiliary Drive Gear Assembly __________________________ 62
C. Shift
Bar Housing ________________________________________________ l 7
B. Intermediate Section ____________________________________________ 63
II.
Companion Flange and Clutch Housing __________________ 20
III. Auxiliary Rear Housing ____________________________________________ 22
III. Auxiliary
Rear Housing ____________________________________________ 66
A. Tailshaft and Rear Bearing Assembly ________________ 66
A. Rear Housing ______________________________________________________ 22
B. Auxiliary Shift Cylinder ______________________________________ 26
B. Synchronizer Assembly ______________________________________ 69
C. Auxiliary Shift Cylinder
____________________________________ 70
C. Synchronizer Assembly ______________________________________ 28
D. Installation
of the Rear Housing ________________________ 72
D. Tailshaft
and Low Speed Gear Assembly _________ 29
IV. Auxiliary Intermediate Housing
______________________________ 32 IV.
Companion Flange and Clutch Housing __________________ 75
A. Housing and Gearing _________________________________________ _32
B. Auxiliary Drive Gear Assembly __________________________ 35 V. Shifting Controls
______________________________________________________ 76
V.
Front Section ___________________________________________________________ _36
A. Shift Bar Housing ---------------------------------------------- 76
A. Right Countershaft Bearings ______________________________ 36
B. Gear Shift Lever Housing ___________________________________ 79
B. Clutch Shaft _______________________________________________________ _38
C. Air System __________________________________________________________ 80
C. Left Reverse Idler Gear -------------------------------------- 40
D. Mainshaft ------------------------------------------------------------ 41
Range Shift Air System ________________________________________________________ 83
E.
Countershaft Assemblies ___________________________________ _45
F. Right Reverse Idler Gear ___________________________________ _46 Tool Reference ____________________________________________________________________ 92
2

LETTER DESIGNATIONS
"R" -Roadranger® transmission.
"T" -Twin Countershaft type.
"O" -Indicates overdrive.
Unless stated otherwise, this manual applies to all models in the RT-613 series which
includes: RT-613,
RT0-613.
NOTE
Illustrated parts lists with parts numbers are available upon re-
quest.
3

DESCRIPTION
Models in the RT-613 series are twin countershaft, Road-
ranger transmissions with 13 forward speeds and 3 reverse.
These units consist
of a 5-speed front section and a 3-
range auxiliary section.
Ratios in the front section are used once through
INTER-
MEDIATE range of the auxiliary and once through DI-
RECT range. This provides a simple Roadranger repeat
shift pattern.
All speeds are controlled with one lever.
The range selec-
tion
is made with a 3-position selector valve mounted on top
of the gear shift lever.
The twin countershaft design, developed by Fuller, splits
torque evenly between two countershafts, reducing gear
tooth pressure
and wear. The floating mainshaft gears of
this design eliminate gear bushings and sleeves as gears
"float" between mating gears on the countershafts.
FLOATING GEAR PRINCIPLE
Malnshaft gear "floats"
between countershaft gears
-no bushing, no shaft sleeve
Malnshafl entirely
free of gear
Twin countershafl gears rotate malnshafl gear
SPECIFICATIONS
Speeds - 13 forward, 3 reverse.
Torque Capacity -600 lb.-ft.
Clutch Housing Size -
SAE No. 2, gray iron, deep only,
6-5
/8", for push or pull type clutches.
Power Take-off -
Openings: Two SAE standard for 6 /8 pitch gears.
Right Side: Regular duty type, 6 bolt.
PTO shaft pro-
jections limited.
Bottom Side: Heavy duty type, 8 bolt.
4
PTO Gear Speeds -
Right and Bottom: 33-tooth 6/8 pitch gears turning at
.723 engine speed.
Weight -620 lbs.
Length- 34-11/16" from face of clutch housing to end
of splines on tailshaft.
Oil Capacity -16 pints, depending upon inclination of en-
gine
and transmission. There are two internal oil troughs
for improved lubrication.

______________________________ l·
1
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GEAR RATIOS
RT-613 RT0-613
Speed Ratio %Step Ratio
%Step
13th 1.00 .80
24 25
12th 1.24 1.00
29 29
Direct Range 11th 1.60 1.29
28 28
10th 2.05 1.65
28 27
9th 2.62 2.11
Range Shift
26
28-
8th 3.29 2.65
24
24
7th
4.09 3.29
29 29
Intermediate
6th
5.26 4.24
Range 28 28
5th 6.74 5.43
28 28
4th 8.64 6.96
Range Shift 27
27-
3rd 10.96 8.83
28 28
2nd 14.04 11.31
28 28
Low Range 1st 18.00 14.50
Dir. Rev. 2.77
Inter. Rev. 9.12
Low Rev. 19.00
5

OPERATION
In the following instructions it is assumed that the driver is familiar with motor trucks and
tractors, and that he can
coordinate the necessary movements of the shift lever and clutch pedal
to make progressive and selective gear engagements in either direction, up or down.
Use Normal Double Clutching Pro-
cedures Between Shifts.
Shift this Pattern with Selector Valve
in LOW Range
Shift this Pattern with Selector Valve
in INTERMEDIATE Range
Shift this Pattern with Selector Valve
in DIRECT
---. Qf
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I
RT-613 Gear Shift Lever Pattern and Selector Valve Positions
'
SELECTOR VALVE
..,___ __ NEUJRAL-----t
4-5-6-7-8 ----
1-2-3----- ....
NOTE: For RT0-613 models, the 7 /12
and 8/13 speed locations are reversed.
UPSHIFTING
1. With the transmission in neutral, start
engine and bring vehicle's air pressure to
normal.
2. Make sure the selector valve is in the
LOW range position.
3. Shift into the 1st speed gear position.
See page relating to transmission counter-
shaft brake.
9
NEUTW.
6
6
4. Shift from 1st speed through 2nd and to
the 3rd speed gear position.
cp
NEUTRAL
cb
5. Move the selector frem LOW to IN-
TERMEDIATE range, and immediately
shift to the 4th speed gear position. After
the selector valve is moved, the auxiliary
will shift as soon as there is a relief in
torque.
9
NEUTRAL
6

--------------------------------•·'ii;id"·H*
6. Shift progressively from 4th through 5th,
6th, and 7th to the 8th speed gear position.
cp
llDITUI.
cb
7. Move the selector from INTERMEDI-
ATE to DIRECT range.
8. Move the gear shift lever to the 9th
speed gear position. The auxiliary section
will automatically shift from INTERMEDI-
ATE to DIRECT when the gear shift lever
reaches neutral.
9
llEllTUI.
6
9. Shift upward from 9th through 10th,
11th and 12th to the 13th speed gear po-
sition.
DOWNSHIFTING
1. Move the shift lever from the 13th speed
position
through each successive lower
speed to the
9th speed gear position.
Gp
llDITUI.
®
2. When in 9th and ready for the next
down shift, move the selector valve from
DIRECT to INTERMEDIATE range.
3. Move the shift lever to the
8th speed
gear position. As the lever reaches neutral
the auxiliary will automatically shift
from
DIRECT to INTERMEDIATE range.
9
llEUTUL
6
4. Shift from the 8th speed gear position
through each gear and to 4th.
cp
llEUTUL
cb
5. Move the selector valve from INTER-
MEDIATE to LOW and immediately shift
to the 3rd speed gear position. The auxil-
iary section will shift as soon as there is a
relief in torque.
9
llDITUI.
cb
6. Downshift from 3rd to 2nd and to 1st.
7
Figure 2.
Model RT-613 transmission is equipped
with either a Transmission Countershaft
Brake,
or an Upshift Clutch Brake.
Transmission Countershaft Brake ...
Model TCB-6 or TCB-8 . . . To be used
only to assist initial gear engagement in
first or reverse when vehicle is standing still.
Disengage clutch, press
down control but-
ton and shift into first or reverse. (Figure
1.)
This is an air-operated mechanical brake
which slows down the transmission gearing
by forcing a piston against the transmis-
sion's PTO gear.
Model TCB-6
mounts on the 6-bolt PTO
opening, model TCB-8 mounts on the 8-
bolt PTO opening.
Do not use an upshift brake. Use only
when vehicle is standing still.
Upshift Clutch Brake ... To provide a
brake for initial gear engagement in first or
reverse, and to provide a brake capable of
use for upshifting when required with ad-
verse conditions.
Brake is activated
by extreme clutch pedal
travel during regular upshift sequence.
(Figure 2.)
The upshift clutch brake is a disc-type brake
incorporated into the clutch and transmis-
sion drive gear cover assemblies.
When activated the upshift clutch brake
slows down the transmission gearing.
Do not use when downshifting. Do not
use as a brake to slow vehicle.

1111=1;1e3u.n•--------------------------------
LUBRICATION
P
roper lubrication procedures are the key to a
good all-round 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.
Oil is important, because here are some of the
things
it must do:
• Provide a protective film -
To
protect surface of heavily
loaded parts such as gear teeth
and bearings, thus preventing
metal
to metal contact which
causes scoring, scuffing
and seizure.
• Act as a coolant -
To dissipate heat.
• Have sufficient fluidity -
To follow, coat and cushion
all loaded surfaces.
• Be chemically stable -
To withstand heat and agitation
without
separation, gumming-up, oxidizing or
corroding.
• Be non-foaming -
To prevent excessive foam and increased
volume under severe conditions.
• Be free of sediment and water -
To prevent sludge and rust.
F
uller Transmissions are designed so that the
internal parts operate in a bath
of oil circulated
by the motion of gears and shafts. Grey iron parts
have built-in channels where needed,
to help
lubricate bearings 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.
8
Lubrication Change and Inspection
HIGHWAY USE
Fi rs! 3,000 to
5,000 miles (4827 to 8045 Km) Change transmission oil on new units.
Every 5,000
miles (8045 Km) Inspect Oil Level. Check for leaks.
Every 50,000
miles (80450 Km) Change transmission oil.
OFF-HIGHWAY
First 30 hours
Change transmission oil on new units.
Every 40 hours Inspect oil level. Check for leaks.
Every 500 hours
Change transmission oil where severe dirt
conditions exist.
Every1 ,000 hours
Change transmission oil (Normal off-highway use).
Change oil filter element, if so equipped, at each oil change.
Recommended Lubricants
ON-HIGHWAY VEHICLES
Type Grade
Heavy Duty Engine Oil SAE 50 or SAE 40
MIL-L-2104C,
or MIL-L-46152,
or APl-SE, or APl-CC SAE 30
Mineral Gear Oil SAE90
Rand 0 Type SAE BOW
OFF-HIGHWAY
Heavy Duty Engine Oil SAE 50 or SAE 40
MIL-L-2104C, or MIL-L-46152,
or APl-SE,
or APl-CC SAE 30
Temperature
Above+ 10°F.
(-12.5oc.)
Below+ 10°F.
Above + 10°F.
Below+ 10°F.
Above+ 10°F.
Below+ 100F.
Special Recommendation -For extreme cold weather
where temperature is consistently below 0° F.
Heavy Duty Engine Oil SAE 20W
MIL-L-2104C,
or MIL-L-46152,
or APl-SE, or APl-CC
Miscellaneous Lubricants
Below ooF.
(-18°C.)
0-Rings and Surfaces -Dow Corning #200
Silicone, 30,000 Centistokes. Union Carbide
L-45 Silicone, 30,000 Centistokes.

_________________________________ l
511
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Proper Oil Level
Make sure oil is level with filler opening. Because
you can reach oil with
your finger does not mean
oil is at proper level.
Oil Level
YES
NO
Draining Oil
Drain transmission while oil is warm. To drain oil
remove the drain plug at bottom of case. Clean
the drain plug before re-installing.
Refilling
Clean area 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 rear opening on single
countershaft models; fill to level of both openings
on
twin countershaft models.
The exact amount of oil will depend on the
transmission inclination and model. In every
instance, tiff to the level
of the filler opening.
Do not over fill -this will cause oil
to be forced
out of the case through mainshaft openings.
Adding Oil
It is recommended that types and brands of oil not
be intermixed because of possible incompatibility.
Operating Temperature
It is important that the transmission operating
temperature does not exceed 250° F. (120° C.)
for an extended period of time. Operating
temperatures above 250°
F. will cause breakdown
of the oil and shorten transmission life.
The following conditions in any combination can
cause operating
temperatures of over 250° F:
(1) operating consistently at roadspeeds under
20 MPH, (2) high engine RPM, (3) high ambient
temperature, (4) restricted air flow around
transmission,
(5) exhaust system too close to
transmission, (6) high horsepower, overdrive
operation. High
operating temperatures may
require
more frequent oil changes.
External cooler kits are available to keep the
transmission operating
temperature under 250° F.
when the conditions described above are
encountered. 9
Proper Lubrication
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20 30
12°
en
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5°48' c'.5
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3°26'
50 50
Transmission Mounting Angle
If the transmission operating angle is more than 12
degrees,
improper lubrication can occur. The
operating angle is the transmission mounting
angle in the chassis plus the percent of upgrade
(expressed in degrees).
The above
chart illustrates the safe percent of
upgrade on which the transmission can be used
with various chassis
mounting angles. For example:
If you have a 4 degree transmission mounting
angle, then 8 degrees (or 14 percent of grade) is
equal
to the limit of 12 degrees. If you have a
0 degree mounting angle, the transmission can be
operated on a 12
degree (21 percent) grade.
Anytime
the transmission operating angle of 12
degrees is exceeded
for an extended period of
time the transmission should be equipped with an
oil pump or cooler kit to insure proper lubrication.
Note on the chart the effect low oil levels can have
on safe
operating angles. Allowing the oil level to
fall Y2" below the filler plug hole reduces the
degree
of grade by approximately 3 degrees
(5.5 percent).
Proper Lubrication Levels are Important!

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11
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M;i•----------------------
PREVENTIVE MAINTENANCE CHECK CHART
CHECKS WITHOUT PARTIAL DISASSEMBLY
OF CHASSIS OR CAB
1. Air System and Connections
a. Check for leaks, worn air lines, loose connections and
capscrews. See Air Systems.
2. Clutch Housing Mounting
a. Check all capscrews in bolt circle of clutch housing for
looseness.
3. Clutch Release Bearing
a. Remove hand hole cover and check radial and axial clear-
ances in release bearing.
b.
Check relative position of thrust surface of release bearing
with
thrust sleeve on push type clutches.
4. Clutch Pedal Shaft and Bores
a. Pry upward on shafts to check wear.
b.
If excessive movement is found, remove clutch release
mechanism
and check bushings in bores and wear on
shafts.
10
5. Gear Lubricant
a. Change at specified service intervals.
b. Use only gear oils as recommended. See Lubrication sec-
tion.
6. Filler and Drain Plugs
a. Remove filter plugs and check level of lubricant at speci-
fied intervals. Tighten filler and drain plugs securely.
7. Gear Shift Lever
a. Check for looseness and free play in housing. If lever is
loose
in housing, proceed with Check No. 8.
8. Gear Shift Lever Housing Assembly
a. Remove air lines at air valve and remove the gear shift
lever housing assembly
from transmission.
b.
Check tension spring and washer for set and wear.
c.
Check the gear shift lever pivot pin and pivot pin slot for
wear.
d.
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.
e.
If so equipped, check 0-ring in housing for wear or cracks.
CHECKS WITH DRIVE LINE DROPPED
9. Universal Joint Companion Flange Nut
a. Check for tightness. Tighten to recommended torque.
CHECKS WITH UNIVERSAL JOINT
COMPANION FLANGE REMOVED
10. Output Shaft
a. Check splines for wear from movement and chucking ac-
tion of the universal joint companion flange.
b.
Pry upward against output shaft to check radial clearance
in mainshaft rear bearing.
11. Mainshaft Rear Bearing Cover
a. Check oil seal for wear.

_________________________ l4ۤijldhijJ@qiMijf
GENERAL PRECAUTIONS FOR DISASSEMBLY
IMPORTANT: Read this section before starting
the detailed disassembly procedures.
It is assumed in the detailed disassembly instructions
that the lubricant has been drained from the transmission, the
necessary linkage and air lines removed and the transmission
has been removed from the chassis. Removal
of the gear shift
lever housing assembly
is included in the detailed instructions;
however, this assembly must also be removed from transmis-
sion before removing unit from vehicle.
Air lines from the range shift and splitter gear controls
must be disconnected
at the transmission before removing
unit from vehicle.
Follow each procedure closely in each section, making
use
of both the text and pictures.
1. BEARINGS -Carefully wash and relubricate all bear-
ings as removed and protectively wrap until ready for use.
Remove bearings with pullers designed for this purpose.
BEARING
REMOVED
WITH
CHISEL, DAMAGED
OUTER RACE.
BEARING
REMOVED
WITH
PUNCH, DAMAGED
SHIELD.
11
2. ASSEMBLIES -When disassembling the various assem-
blies, such as the mainshaft, countershafts and shifting
bar
housing, lay all parts on a clean bench in the same se-
quence as removed. This procedure will simplify reassem-
bly and reduce the possibility
of losing parts.
00
3. SNAP RINGS -Remove snap rings with pliers designed
for this purpose. Rings removed
in this manner can be re-
used.
4. INPUT SHAFT -The clutch or input shaft can be re-
moved without removing the countershafts, mainshaft
or
drive gear. Refer to page 38.
5. CLEANLINESS -Provide a clean place to work. It is
important that no dirt or foreign material enters the unit
during repairs.
The outside of the unit should be carefully
cleaned before starting the disassembly.
Dirt is abrasive
and can damage bearings.
6. WHEN DRIVING -Apply force to shafts, housings,
etc., with restraint. Movement of some parts is restricted.
Do not apply force after the part being driven stops solidly.
Use soft hammers and bars for all disassembly work.

DISASSEMBLY INSTRUCTIONS
I. SHIFTING CONTROLS
AIR FILTER/REGULATOR
ASSEMBLY
1/4" l.D.
12
LINE

A. Removal and Disassembly of the Range Shift Air System
1. If so equipped, disconnect the two Ys" OD countershaft
brake control air lines
at the control valve.
2. Loosen the clamp
and remove the countershaft brake
control valve from the shifting lever.
3. Disconnect the Vs"
OD air line at the TCB-6 brake on
the right side PTO opening.
13
4. Disconnect the Vs" OD air line at the tee block fitting be-
tween the air filter
and regulator.
5. Disconnect the Ys"
OD range shift control air line at the
rear port of the slave air valve.
6. Disconnect the Vs" OD range shift air line at the for-
ward
port of the slave air valve.

_____________________ _
A. Removal and Disassembly of the Range Shift Air System -Continued
7. Disconnect the Ys" OD range shift control air line at the
intermediate shift cylinder.
NOTE: If desired, the gearshift lever housing, control valve
and air lines can now be removed from the shift bar hous-
ing as a unit by turning
out the four capscrews at the base
of the gearshift lever housing.
8. Disconnect the three Ys"
OD air lines at the control
valve.
9. Loosen the jam
nut and turn the nut and control valve
from the shifting lever. Remove the air lines, sheathing
and 0-rings from the lever.
14
10. Remove the ID air line between the air valve and
the direct range
port of the auxiliary shift cylinder.
11. Remove the "
ID air line between the air valve and
the low range
port of the auxiliary shift cylinder.
12. Remove the
ID air line between the air valve and
the air filter/regulator assembly. If so equipped, the
hose-retaining clamp will have
to be removed to allow
removal
of the air line.

13. Remove the " ID air line between the air filter /regu-
lator assembly and the intermediate shift cylinder.
14. Turn out the two capscrews and remove the air filter/
regulator assembly.
For further disassembly of the unit,
refer to page 85.
15. Turn out the four retaining capscrews and remove the
slave air valve from the transmission.
For further dis-
assembly of the valve, refer to page 84.
15
16. Remove the hat-type sleeve from the bore in the valve.
17. Remove the spring
and plunger from the bore in the
transmission.

B. Removal and Disassembly of the Gear Shift Lever Housing Assembly
PIVOT PIN
C»,,"
I
0-RING
BOOT
GASKET
LEVER
ca-WASHER
iS-SPRING
I. Turn out the four retaining capscrews, jar lightly to
break the gasket seal, and lift the assembly from the shift
bar housing.
16
2. Secure the assembly upside down in a vise and remove
the tension spring
by prying it up and over the spring
retainers, one coil
at a time.
3. Remove the washer and lever
from the housing.
4. Remove the housing from the vise and, if necessary, re-
move the nut, washer, pivot pin, and
0-Ring.

C. Removal and Disassembly of the Shift Bar Housing
/--SHIFT BAR HOUSING
1st- REVERSE SHIFT
BAR
2nd -3rd SPEED -
SHIFT YOKE
17
\
2nd -3rd SPEED
SHIFT BAR
4th -5th SPEED SHIFT
BAR

C. Removal and Disassembly of the Shift Bar Housing -Continued
1. Turn out the 13 retaining capscrews, jar to break gasket
seal, and remove the shift bar housing from the trans-
mission.
2. Turn out the two capscrews and remove the tension
spring cover.
3. Remove the three tension springs.
18
4. Remove the three tension balls located under the springs.
NOTE: For ease of reassembly, lay all parts on a clean
bench in order of removal. Bars not being removed must be
kept in the neutral position
or interlock parts will lock the
bars.
5. Place the shift bar housing in a vise, cut the lockwire,
turn out the lockscrew and pull the 1st-reverse shift bar
from the housing, removing the yoke.
6.
Cut the lockwire, turn out the lockscrew and pull the
2nd-3rd speed shift bar from the housing, removing the
interlock pin from the neutral notch; remove yoke.