Professional Service Technician WORKBOOK Eaton Fuller

Professional Service TechnicianWORKBOOK

2014, Issue 2 • Volume 46

Eaton Fuller Advantage™ Heavy-Duty Manual Transmissions

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Professional Service Technician Workbook

PROFESSIONAL SERVICE TECH WORKBOOK ISSUE 2/2014 VOL. 46

Peterbilt Dealer Training Director: Mike Arzamendi Peterbilt Editor: Mike Tenbush

© 2014 Peterbilt Motors Company, A Division of PACCAR

This workbook has been prepared with materials provided to Peterbilt Motors Company by its OEM supplier for the product featured.

Produced by Burgio, Cooney & Associates, Independence, MO • Phone: 816-353-3672, Fax: 816-353-4206, e-mail: [email protected]

Published by Peterbilt Motors Company. This material is intended for Peterbilt training purposes and may not be sold, given, loaned or reproduced, in whole or in part,

including photocopying, without the express written consent of Peterbilt Motors Company.

As you know, Peterbilt heavy-duty trucks are built with different types of transmissions depending upon the customer’s needs. Since Eaton has launched the Fuller Advantage™ Series of heavy-duty manual transmissions in 2014, it is important that service technicians are up-to-date on the maintenance and troubleshooting of these transmissions whenever customers bring them into the shop.

This Professional Service Technician Workbook basically will explain how to:

• Identify the Eaton Fuller Advantage™ transmission model and serial tag number on the truck.

• Perform preventive maintenance on Eaton Fuller Advantage heavy-duty manual transmissions.

• Perform general troubleshooting on common problems.

• Inspect the transmission for oil leaks.

• Inspect the transmission parts before reassembly.

• Perform basic troubleshooting on the air system.

• Follow lubrication specifications.

• Follow guidelines for clutch greasing.

Please refer to the Eaton Fuller Advantage Heavy-Duty Manual Transmissions TRSM0970 EN –US Service Manual for details.

Transmission Model and Serial Tag NumberTransmission model designation and other transmission identification information are stamped on the serial tag. To identify the transmission model and serial number, locate the tag on the transmission and then locate the numbers as shown in the diagram below.

The model number gives basic information about the transmission. An example is shown below.

The serial number is the sequential identification number of the transmission. When calling for service assistance or parts, have the model and serial number handy.

Important: Do not remove or destroy the identification tag.

Maintaining and Troubleshooting

Eaton ® TransmissionsFuller ® Transmissions

Model

nI delbmessAlaireS

Eaton CorporationKalamazoo, MI USA

Fuller

Advantage

O = Overdrive or X = Direct

M = Multi-torque

Foward Shift Bar Housing

Gear Ratio Set

Foward Speeds

Design Level

x 100 Normal Torque Capacity

F A O M (F) - 16 8 10 C

FA Fuller Advantage Tin Counter ShaftFAO With Overdrive

FAO(F) With Overdrive and Forward Shift Bar HousingFAOM With Multi-torque and Overdrive

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Model optionsThe torque rating of the transmission specified in the model number is in the torque capacity in lb-ft.

Two types of shift bar housings are available for this transmission:

1. The standard shift bar housing has a gear shift lever opening located toward the rear of the transmission.

2. The forward opening shift bar housing has a gear shift lever opening located 3” closer to the front of the transmission than the standard opening. The forward design allows greater flexibility in mounting the transmission and is indicated by an “F” in the model number.

The internal lubrication pump has a spray bar lubrication system.

A PTO-driven pump is externally mounted on the 6- or 8-bar bolt PTO openings and driven off the PTO gear. Power Take-Off (PTO) usage can be mounted in two ways:

• The 6- or 8-bolt openings are standard with the transmission. The PTO is mounted to the opening and driven from the PTO gear on the front counter shaft.

• The thru-shaft PTO mounts on the rear of the transmission. It requires a special auxiliary housing and main case counter shaft with internal splines.

Preventive MaintenanceHere are some inspection guidelines for preventive maintenance before transmission removal.

1. Air system and Connections: Check for leaks, worn air lines, loose connections and cap screws.

2. Clutch Housing Mounting: Check all cap screws of clutch housing flange 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. filler and Drain Plugs: Remove filler plugs and check level of lubricant at specified intervals. Tighten fill and drain plugs securely.

Oil Fill Plug

Oil Drain Plug

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5. Clutch Pedal shaft and Bores: Pry upward on shafts to check wear. If excessive movement is found, remove clutch release mechanism and check bushings on bores and wear on shafts. See OEM literature.

6. Lubricant: Change at specified service intervals. Use only the types and grades as recommended. See Manual TCMT0021, Roadranger® Lubrication Products.

7. Cap screws and Gaskets: Check all cap screws, especially those on PTO covers and rear bearing covers, for looseness that would cause oil leakage.

Check PTO opening and rear bearing covers for oil leakage due to faulty gaskets.

8. Gear shift Lever: Check for looseness and free play in housing. If lever is loose in housing, proceed to the next inspection item.

9. Gear shift Lever Housing Assembly: Remove air lines at slave valve and remove gear shift lever housing assembly from the transmission. Check the tension spring and washer for set and wear. Check the gear shift and lever spade pin and slot for wear.

General TroubleshootingDrivers will bring in their trucks with specific complaints about the transmission. The chart on the following pages contains some of the most common problems that may occur with this transmission along with the most common causes and solutions.

Complaint Cause What to Do Next

Noise: Growl/Rumble

Torsional Vibration. [Noise may be most pronounced when transmission is in a “float” (low torque) condition. May also be confined to a par- ticular vehicle speed.]

Check driveline angles for proper U-joint working angles.Check driveline for out of balance or damage.Check U-joints for proper phasing.Check clutch assembly for broken damper springs.Check for inadequate clutch disc damping.

Transmission bearing or gear failure. [Noise may be most pronounced under hard pull or coast (high torque).]

Check transmission oil for excessive metal particles.

Noise: Growl/Rumble at Idle (Idle Gear Rattle)

Excess engine torsional vibration at idle.

Check for low engine RPM.Check for uneven engine cylinder performance.Check for proper clutch damper operation.

Noise: High-Pitched Whine

Gear noise. Isolate as to axle or transmission noise. If transmission, isolate to specific gear or gears.

Check for worn or defective shift lever isolator.Check for direct cab or bracket contact with transmission (“grounding”).Check for proper driveline U-joint working angles.Check for damaged or worn gearing.

Shift Lever Slip-out (Transmission comes out of gear under torque)

Internal transmission problem. Check for excessively worn or damaged sliding clutches or shift yokes.

Transmission Goes into Neutral (Shift lever doesn’t move)

Low air pressure. Check air regulator pressure.

Internal transmission problem. Check for excessively worn or damaged range sliding clutch or yoke.

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Complaint Cause What to Do Next

Hard Lever Shifting (Shift lever is hard to gear into or out of gear)

Master clutch dragging.

Check driveline angles for proper U-joint working angles.Check driveline for out of balance or damage.Check U-joints for proper phasing.Check clutch assembly for broken damper springs.Check for inadequate clutch disc damping.

Shift linkage problem (remote shifter).

Check shift linkage or cables for proper adjustment, binding, lubrication or wear.

Shift bar housing problem. Check Shift Bar Housing components for binding, wear or damage.

Transmission Main Shaft problem.Check mainshaft for twist.Check sliding clutches for binding, damage, or excessive wear.

Driver technique. Driver not familiar or skilled with proper double-clutching technique. Driver contacting the clutch brake during shifts.

Shift Lever Jumpout (Shift lever comes out of gear on rough roads)

Loose or worn engine mounts. Check engine mounts for damage, wear or excessive looseness.

Shift lever problem.

Check shift lever floor boot for binding or stretching.Check shift lever isolator for excessive looseness or wear.Check for excessive offset or overhang on the shift lever.Check for extra equipment or extra weight added to shift lever or knob.

Worn or broke detent spring or mechanism.

Check for broken detent spring.Check for excessive wear on the detent key of detent plunger. Replace detent spring with heavier spring or add additional spring.

No Range Shift or Slow Range Shift (Also see “Air System Troubleshooting”)

Transmission air system problem.Perform air system troubleshooting procedure.Check for proper air signal from master valve.Check air module test ports for proper air delivery.

Range cylinder problem.Check for failed or damaged range piston, piston bar or cylinder.Check for failed or loose range piston snap ring.

Range yoke assembly problem.

Check for failed or damaged range yoke.Check for failed or loose range yoke snap rings.Check for excessively long fastener installed in rear support hole.Check for binding between range yoke bar and range alignment lock cover.

Range synchronizer problem.Check for failed or damaged Range Synchronizer, Sliding Clutch, or Mating Gear. Check for excessively worn Range Synchronizer Friction Material.

Grinding Noise on Range Shift

Driver not preselecting range shift. Instruct driver to preselect range shifts.Range synchronizer worn or defective.

Check range synchronizer and mating parts for excessive wear or damage.

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Oil Leak Inspection ProcessThe following flow chart shows a process for inspecting the transmission for oil leaks.

inspect for oil Leak

Determine if it is a LEAk or a WEEP

LEAK: Extremely wet or dripping of oil in the contaminated area.

step 1

1. Determine the origin of the leak path.

2. If the origin of leak is obvious, skip to step 3.

3. If the origin of the oil leak is not obvious, then use either of the two following steps to determine the oil leak:

NOTE: Do not use a high-pressure spray washer to clean the area. Use of a high-pressure spray may force contamination into the area of concern and temporarily disrupt the leak path.

a. Clean area with a clean, dry cloth or mild soluble degreaser and fill the transmission to the proper lube level.

oR

b. Clean the area as noted above and insert tracer dye into the transmission lube and fill transmission to proper lube level.

1. Clean suspected oil weep area with a clean, dry cloth or mild soluble degreaser.

2. Ensure lube is filled to the proper lube level.

3. Notify the customer that it is only a weep and it is not considered to be detrimental to the life of the transmission.

4. Repair is complete.

Leak Gasket/Rear seal

WEEP: Stained, damp, no drips, light oil film or dirt adhered to the contaminated area.

step 2

Operate vehicle to normal transmission operating temperature and inspect the area for oil leak(s) visually or if tracer dye was introduced use an UVL (Ultraviolet Light) to detect the tracer dye’s point of origin.

NOTE: When inspecting for the origin of the leak(s) make sure the assumed leak area is not being contaminated by a source either forward or above the identified area such as the engine, shift tower, shift bar housing, top mounted oil cooler, etc.

step 3

Once the origin of the leak is identified, repair the oil leak using proper repair procedures from the designated model service manual.

step 4

After the repair is completed, verify the leak is repaired and operate the vehicle to normal transmission operating temperature. Inspect repaired area to ensure oil leak has been eliminated. If the leak(s) still occurs, repeat steps or contact the Roadranger Call Center at 1-800-826-4357.

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Air System Overview and Basic TroubleshootingThe range shift air system consists of the air filter regulator, slave valve, Roadranger® valve, range cylinder, fittings and connecting air lines. The diagram below shows air system schematics.

Constant air from the air filter regulator is supplied to the “S” or the supply port of the slave valve and is passed through to the inlet or “S” port of the Roadranger valve.

While in Low RangeThe Roadranger valve is open and air is returned to the slave valve at the “P” or end port. This signals the valve to supply air in line between the low range or “L” port of the slave valve and the low range port of the range cylinder housing. Air received at this port moves the range piston to the rear and causes the auxiliary low range gear to become engaged.

While in High RangeThe Roadranger valve is closed and air is not returned to the slave valve. This signals the slave valve to supply air in line between the high range or “H” port of the valve and the high range port of the range cylinder cover. Air received at this port moves the range piston forward to engage the auxiliary drive gear with the sliding clutch and bypass the low range gear set.

Range shifts can be made only when the gear shift lever is in, or passing through Neutral. Thus, the range desired can be preselected while the shift lever is in a gear position. As the lever is moved through Neutral, the actuating plunger in the shift bar housing releases the slave valve piston, allowing it to move to the selected range position.

Basic Troubleshooting on the Air SystemIf the transmission fails to make a range shift or shifts too slowly, the fault may be in the range shift air system or actuating components of the Shift Bar Housing assembly slave valve on the side of the transmission.

To locate the trouble, make the following checks with normal vehicle air pressure applied to the system, but with the engine off.

Caution: never work under the vehicle while the engine is running as personal injury may result from the sudden unintended movement of vehicle under power.

incorrect Air Line Hook UpsWith the gear shift lever in Neutral, move the control that provides range selection up and down.

1. If the air lines are crossed between the range valve and slave valve, there will be constant air flowing from the exhaust port of the range valve while in high range.

2. If the airlines are crossed between the slave valve and range cylinder, the transmission gearing will not correspond with the range selection. A low range selection will result in a high range engagement and vice versa.

Air Inlet Port (OEM suppied)

Air Filter/Regulator

Roadranger Valve

O-Rings

Sheathing

1/8” I.D. Air Lines

Slave Valve

1/4” O.D. Air Lines

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Air LeaksWith the gear shift level in Neutral, coat all air lines and fittings with soapy water and check for leaks, moving the control that provides range selection up and down.

1. If there is a steady leak from the exhaust port of the range valve, o-rings and/or related parts of the range valves are defective.

2. If there is a steady leak from the breather of the slave valve, an o-ring in the valve is defective or there is a leak past o-rings of the range cylinder piston.

3. If the transmission fails to shift into low range or is slow to make the range shift and the case is pressurized, see the “air filter regulator” section.

4. Tighten all loose connections and replace defective o-rings and parts.

Air filter RegulatorWith the gear shift lever in Neutral, check the breather of the air filter regulator assembly. There should be no air leaking from this port. The complete assembly should be replaced if a steady leak is found.

Cut off the vehicle air supply to the air filter regulator assembly, disconnect the air line at the fitting in Supply Outlet and install an air gauge in the opened port. Bring the vehicle air pressure to normal. Regulated air pressure should be 57-63 PSI.

Important: Do not adjust screw at bottom of regulator to obtain correct readings. The air filter regulator has been pre-adjusted within the correct operating limits.

NOTE: Any deviation from these limits, especially with regulators that have been in operation for some time, is likely to be caused by dirt or worn parts. Replace the complete assembly, as the air regulator is not serviceable and verify that the new filter regulator has the correct air pressure.

Roadranger valveWith the gear shift lever in Neutral, select high range and disconnect the 5/32-inch O.D. air line at the outlet of “P” port of the Roadranger valve.

1. When low range is selected, a steady blast of air will flow from the opened port. Select high range to shut off air flow. This indicates the Roadranger valve is operating properly. Reconnect the air line.

2. If the Roadranger valve does not operate properly, check for restrictions and air leaks. Leaks indicate defective or worn o-rings.

High Range operationWith the gear shift lever in Neutral, select low range and disconnect the 1/4-inch I.D. air line at the port of range cylinder cover. Make sure this line leads from the high range or “H” port of the slave valve.

1. When high range is selected, a steady blast of air should flow from the disconnected line. Select low range to shut off air flow.

2. Move the shift lever to a gear position and select high range. There should be no air flowing from the disconnected line. Return the gear shift lever to the Neutral position. There should now be a steady flow of air from the disconnected line. Select low range to shut off air flow and reconnect air line.

3. If the air system does not operate accordingly, the slave valve or actuating components of the shift bar housing assembly are defective.

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Low Range operationWith the gear shift lever in Neutral, select high range and disconnect the 1/4-inch I.D. air line at the fitting on range cylinder housing. Make sure this line leads from the low range of “L” port of the slave valve.

1. When low range is selected, a steady blast of air should flow from the disconnected line. Select high range to shut off air flow.

2. Move the shift lever to a gear position and select low range. There should be no air flowing from the disconnected line. Return the gear shift lever to the Neutral position. There should now be a steady flow of air from the disconnected line. Select high range to shut off air flow and reconnect air line.

3. If the air system does not operate accordingly, the slave valve or actuating components of the shift bar housing assembly are defective.

Range CylinderIf any of the seals in the range cylinder assembly are defective, the range shift will be affected.

1. A leak at either “A” o-rings results in complete failure to make a range shift; steady flow of air from breather of the slave valve in both ranges.

2. A leak at “B” o-ring results in a steady flow of air to the atmosphere while in high range.

3. A leak at “C” o-ring results in a slow shift to low range and pressurizing of the transmission case.

Range Cylinder Assembly

filter Assembly

This element should be cleaned at each oil change, or more often under high humidity conditions. Replace if necessary.

High Range Air Port

Housing

Cover

Low Range Air Port

Piston

O-Rings

Filter Element

Housing

End Cap

Air Regulator

Plug

Breather Port

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Follow Lubrication Specificationsobserve the following cautions:• Do not introduce additives and friction modifiers.

• Never mix standard oils and synthetic transmission oils in the same transmission. When switching between types of lubricants, all areas of each affected component must be thoroughly drained.

• Do not mix lubricants of different grades. For a list of Eaton Approved Synthetic Lubricants, lubrication change and inspection intervals, see TCM10021 Roadranger® Lubricant Products. The use of lubricants not meeting these requirements will affect warranty coverage.

Transmission operating AnglesIf the transmission operating angle is more than 12 degrees, or approximately a 21% grade, improper lubrication will occur. The operating angle is the transmission mounting angle in the chassis plus the percent of upgrade (expressed in degrees).

For operating angles over 12 degrees, the transmission must be equipped with an oil pump or cooler kit to ensure proper lubrication.

Transmission filters should be changed during regular lubrication intervals. Inspection of the transmission filter should be conducted during preventative maintenance checks for damage or corrosion. Replace as necessary.

operating TemperaturesTransmissions must not be operated at temperatures that are consistently above 250°F. (121° C). Operation at temperatures above this limit causes loaded gear tooth temperatures to exceed 350° (177°) which will ultimately destroy the heat treatment of the gears.

The following conditions, in any combination, can cause operating temperatures that exceed 250°F (120°C):

• Operating consistently at high loads/slow speeds

• High ambient temperature

• Restricted air flow around the transmission

• Exhaust system too close to the transmission

• High horsepower operation

• Use of engine retarders

Maintenance and Lubricant Change intervalsTransmission inspections and lubricant changes are outlined below.

For a list of Eaton Roadranger-approved lubricants, see TCMT0020 Roadranger® Lubricant Products.

Interval DescriptionFirst 1,000 to 1,500 miles Inspect oil levels. Check for

leaks.Every 2,500 miles Inspect lubricant levels.

Perform transmission inspection.

Every 5 years or 500,000 miles, whichever occurs first

Change oil and filters.

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Clutch Greasing GuidelinesTo ensure long life and proper operation of the release mechanism of the clutch, it is important to properly lubricate the following areas:

Lubrication1. Release Bearing:

The cast iron bearing housing will be equipped with either a standard grease fitting or a lubrication tube extension. If a lubrication tube is not present, it is necessary to remove the inspection cover to gain access to the grease fitting. Apply grease until it purges from the rear of the housing. Grease on the clutch brake friction surface and the transmission Input Shaft will extend the life of the clutch brake and bronze bushings inside the release sleeve.

2. Release Bearing Wear Pads: Where the release fork contacts the bearing housing, there are small hardened steel pads. Apply a small amount of grease to the wear pads where the clutch release fork contacts.

3. Clutch Brake: The clutch brake friction material is designed to operate with lubricant. While lubricating the release bearing, grease should purge from the housing and contact the clutch brake. This is beneficial for long clutch brake life. If desired, a small amount of grease could be applied to both sides of the clutch brake.

4. Cross shaft Bushings: Lubricate both the left and right cross-shaft bushings per OEM recommendations.

5. Clutch Control Linkage: Lubricate the clutch linkage bell cranks and pivot pins per OEM recommendations.

6. Pilot Bearing: The pilot bearing inside the flywheel is a sealed for life bearing and requires no lubrication. Use a premium pilot bearing to prevent clutch drag and early bearing failures (C-3, C-4, C-5 Suffix).

Lubrication Tube AssemblyThe Eaton Lubrication Tube Assembly enables the release bearings in Eaton medium- and heavy-duty clutches to be greased without removing the bell housing inspection cover. The lubrication tube hose replaces the original Zerk fitting on the release bearing and protrudes through the bell housing window.

Length Part Number12-inch CLT0129-inch CLT0098-inch CLT0087-inch CLT0076-inch CLT006

Lube Hose kits for Hydraulic Release system

Kit DescriptionK-4050 Used with Solo Advantage™ clutchesA-7857 Used with Non-Solo Advantage™ clutches

Caution: incorrect grease and improper lube procedures will cause bearing wear pad wear. for a list of approved lubricants, see TCMT-0021.

Lubrication intervalThe UltraShift DM clutch does not require any lubrication or adjustment. Since there is no clutch linkage associated with this product, there is no linkage adjustment or maintenance requirements.

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Professional Service Technician WORKBOOK Eaton Fuller