Transmissions

Eaton Fuller UltraShift PLUS Automated Transmissions

Eaton Fuller UltraShift PLUS automated transmissions use shift selection software and electric clutch actuation; a clutch pedal is not needed to operate the vehicle. These transmissions use the four-position SmartShift control (see Fig. 8.1 ) on the steering column to select mode, direction, neutral, low, and to make manual shifts. To know what gear the transmission is in, see the current gear indicator on the dash. Forward shifts can be made either manually or automatically.

Power Up

NOTE: Engine cranking is delayed until the transmission power-up is complete and the gear display shows a solid "N".

1.

With the parking brake set, turn the ignition switch to the ON position.

2.

Start the engine.

3.

Apply the service brake.

NOTE: If the service brake is not applied while selecting a starting gear, the initial start gear will not be found and the driver will need to select Neutral and press the service brake while selecting the desired mode.

4.

Select the desired mode and starting gear. (Inappropriate start gear selections are ignored to avoid damaging the transmission.)

5.

Release the parking brake.

6.

Release the service brake and apply the accelerator.

Power Down

1.

Select Neutral on the shift control.

NOTE: If the gear display does not show a solid "N", neutral has not yet been obtained. Neutral should always be reached before powering down an UltraShift PLUS, except in cases of emergency.

2.

Set the parking brake.

3.

Turn off the ignition, and shut down the engine.

Reverse (R)

NOTE: If attempting to select a non-Neutral mode without applying the service brakes, the transmission will not shift into gear. To shift into gear, select Neutral, apply the service brakes, and select the desired mode again. Also, the vehicle will not engage reverse above 2 mph (3 km/h).

Reverse (R) is at the upper end of the four-position selector switch located at the end of the SmartShift control. To select R, press in the neutral lock button and move the selector switch to the position above neutral. The default Reverse gear is engaged.

NOTICE

Avoid launching the vehicle in high range. Launching the vehicle in high range increases the likelihood of clutch abuse and could be detrimental to clutch life.

Automatic Mode (AUTO)

In automatic drive mode (AUTO), upshifts and downshifts are made by the UltraShift PLUS without driver intervention. Press in the neutral lock button, move the selector switch to Drive (D), and press down on the throttle pedal. The transmission will shift automatically.

NOTE: If attempting to select a non-Neutral mode without applying the service brakes, the transmission will not shift into gear. To shift into gear, select Neutral, apply the service brakes, and select the desired mode again.

In Drive, the start gear is automatically selected. The selected start gear can vary depending on several vehicle inputs such as load, grade, and axle/transmission ratio. The start gear can be changed using the SmartShift control, provided the selected gear would allow the vehicle to launch without damaging the transmission. If the start gear is changed using the SmartShift control, it will be the default until the vehicle is powered down or the selection is changed again manually.

IMPORTANT: Prior to ascending a steep grade, either reduce the default start gear by one (using the SmartShift control) or apply full throttle for the duration of the grade so the vehicle maintains the proper engine and vehicle speed during the entire grade.

In Drive, the transmission automatically performs upshifts and downshifts. However, when the transmission is near the shift point, the shift can be forced using the upshift or downshift function of the SmartShift control.

NOTE: The transmission may deny a shift while ascending or descending a grade if the load of the vehicle and grade of the terrain in combination with the drivetrain ratio and engine torque fall outside of the acceptable range to perform a shift. If the shift is denied, a tone will sound.

Manual Mode (MAN)

In manual mode (MAN), the driver selects upshifts and downshifts instead of letting the UltraShift PLUS select them automatically. Manual shifting may be helpful when traversing a work site, railroad tracks, or steep grades, for example. To drive forward, press in the neutral lock button, move the selector switch to Drive (D), and press down on the throttle pedal. To shift up, pull the lever up (towards you); to shift down, push the lever down (away from you). The system holds the current gear unless a shift is requested or if the system initiates a manual mode override.

NOTE: The transmission may deny a shift while ascending or descending a grade if the load of the vehicle and grade of the terrain in combination with the drivetrain ratio and engine torque fall outside of the acceptable range to perform a shift. If the shift is denied, a tone will sound.

NOTE: If attempting to select a non-Neutral mode without applying the service brakes, the transmission will not shift into gear. To shift into gear, select Neutral, apply the service brakes, and select the desired mode again.

Manual Mode Override

The system is equipped with a manual mode override function. If the vehicle is being "back driven" (for example, descending a grade and vehicle speed exceeds engine speed) and the engine speed is excessively high, the system will upshift automatically. Also, if the start gear is changed and it causes the engine to lug at takeoff, the system will override the current position and select the best available gear.

Low (L)

Low (L) is at the lower end of the four-position selector switch located at the end of the SmartShift control. Use Low when wanting 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. To select Low, press in the neutral lock button and move the selector switch to the L position. The lowest available start gear will be selected (the starting gear cannot be changed in Low).

If Low is selected while moving, the transmission will not upshift (unless the system initiates a Low override). The system will downshift at the earliest opportunity to provide maximum engine braking.

NOTE: If attempting to select a non-Neutral mode without applying the service brakes, the transmission will not shift into gear. To shift into gear, select Neutral, apply the service brakes, and select the desired mode again.

Low Override

The system is equipped with a Low override function. If the vehicle is being "back driven" (for example, descending a grade and vehicle speed exceeds engine speed) and the engine speed is excessively high, the system will upshift automatically. Also, if the start gear is changed and it causes the engine to lug at takeoff, the system will override the current position and upshift.

Clutch Abuse Protection

Although a vehicle equipped with an UltraShift PLUS uses an automated clutch, the clutch can still overheat and slip with improper use. The clutch abuse protection feature helps protect the clutch if the automated clutch starts to overheat. When the clutch abuse protection feature initiates and sounds a warning tone, full clutch actuation must be completed quickly. If it is not completed quickly enough, the system will either open the clutch (if the throttle pedal is not being pressed) or close the clutch (if the throttle pedal is being pressed). If the abuse continues, the system will open the clutch and take away throttle control briefly to allow the clutch to cool down.

To protect the clutch:

Select the lowest possible start gear for the application.

Use Creep Mode when appropriate.

Use the service brakes and the Hill Start Aid when launching on a grade.

Minimize the time it takes to engage the clutch from rest.

Do not use the throttle to hold the vehicle on a grade; use the service brakes.

Do not use the throttle to stop roll back on an incline after Hill Start Aid disengages; use the service brakes, and then relaunch.

Do not continually start and stop, especially when loaded; use a lower gear or Creep Mode.

Creep Mode

The Creep Mode function allows the vehicle to maintain a constant speed at engine idle without the driver holding the throttle pedal position. This mode is useful for very low-speed maneuvering and applications where steady vehicle speed is required. The vehicle speed is determined by the selected gear ratio operating at governed low engine idle speed. Any available gear may be selected, though the transmission will downshift or exit Creep Mode to prevent stalling if the engine lugs due to load conditions.

By default, Creep Mode can be activated while in Manual Mode or Low. Eaton's ServiceRanger diagnostic software can be used to enable Creep Mode in Automatic Mode and/or Reverse.

Engaging Creep Mode

To engage Creep Mode:

1.

Select Low or Manual Mode and the 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 governed low engine idle speed.

Exiting Creep Mode

To exit Creep Mode, apply the throttle pedal to accelerate temporarily, or select a higher gear in Manual Mode. (Creep Mode can be resumed in the selected gear by releasing the throttle pedal.)

NOTE: The transmission will exit Creep Mode if the engine lugs 150 rpm below the governed low engine idle speed. In this case, a lower gear should be selected if available.

Hill Start Aid

UltraShift PLUS transmissions are equipped with a Hill Start Aid (HSA) feature to prevent the vehicle from rolling while on grades steeper than 3% and allow for a controlled launch. A grade sensor is used to determine when to engage the feature.

HSA is "on" by default. It can be turned off by pressing and releasing the override switch on the dash. HSA will turn back on after the first successful launch.

When the vehicle is stopped on a grade greater than 3% and in a forward mode or reverse, depress the service brakes then release them. The vehicle will begin to move after 3 seconds, and the clutch will perform partial engagements to slow the vehicle motion. Either step on the brake or apply the throttle to continue negotiating the grade.

Engine Overspeed Protection

The system will upshift if necessary to prevent engine overspeed in Drive, Manual, and Low.

Shuttle Shifting

Shuttle shifting from reverse to any forward mode is only allowed if the vehicle speed is approximately zero.

Auto Start Gear Selection and Override

The UltraShift PLUS system uses various inputs to automatically select the best start gear in Drive and Manual. This selection can be changed using the SmartShift control; however, if the selection requested could cause damage or engine lugging, the request will be denied and a tone will sound.

Skip Shifting

When appropriate, the UltraShift PLUS system may skip shift in Drive. When prevailing conditions like load and grade allow, skip shifts can be performed in Manual mode using the SmartShift control.

Auto Neutral

The UltraShift PLUS system will automatically shift to neutral if the vehicle is left in Drive and the parking brake is set. "AN" will show on the gear display. To re-engage the transmission, select Neutral and then either Drive or Reverse on the shift control (it will re-engage regardless of whether the parking brake is released).

Automatic Traction Control

The UltraShift PLUS system requires the Automatic Traction Control (ATC) option to be enabled when driving in soft soil/sand to prevent wheel slippage and shifting issues. The ATC system has two modes: "normal" (for sand and loose road surface) and a mud/snow setting.

ATC Normal Mode

In normal mode, the system will engage the brakes on the wheel or side that the wheel slip is occurring to help the vehicle gain traction. 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; heavy/full throttle raises the point of the acceptable wheel slip.

Adhere to the following points when driving in ATC normal mode:

If using Automatic mode in soft soil and/or sand, maintain the engine speed between 1000 and 1300 rpm to prevent unnecessary upshifting.

If using Manual mode in soft soil and/or sand, do not attempt an upshift 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.

ATC Mud/Snow Mode

To select the mud/snow mode, depress the ATC switch. 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; heavy/full throttle raises the point of the acceptable wheel slip.

Load-Based Shifting

The UltraShift PLUS system is adaptive and will change the shift points based on grade, engine RPM, throttle position, and vehicle load. After changing loads or powering up, the system needs to relearn these inputs for the first few shifts to make the proper adjustments.

Coasting

When coasting to a stop on level terrain, the UltraShift PLUS system may not downshift into the lower gears. It will select a gear after the throttle is applied.

Freightliner SmartShift™ Shift Control

General Information, SmartShift

The SmartShift transmission control is an electronic transmission control device. It is installed with the following transmissions:

Eaton® Fuller® AutoShift™

Eaton Fuller UltraShift PLUS

ZF-FreedomLine

It replaces the typical floor-mounted shift lever or dash-mounted push button control.

SmartShift accepts driver requests for transmission functions and transmits them through hard wiring to the transmission control unit (TCU). SmartShift is a true shift-by-wire system.

SmartShift offers two main advantages over conventional transmission control devices. Without a floor-mounted shift control, usable cab space is increased. Access to the sleeper is improved by removing the shift lever from the floor.

The SmartShift control mounts to the right-hand side of the steering column and is operated by the fingers of the driver's right hand, allowing both hands to remain on the steering wheel.

A two-position slide switch is mounted on the body of the control lever just before the paddle widens out. The slide switch allows the driver to choose automatic (AUTO) mode or manual (MAN) mode.

In AUTO mode, gears shift automatically, without driver interaction. Manual gear shifts are accomplished by a momentary pull or push on the control in the plane perpendicular to the steering wheel. Pull upward (toward you) on the control to upshift and push downward (away from you) to downshift. The control is spring-loaded and returns to mid-position when released after an upshift or downshift.

For the Eaton Fuller automated transmissions, a four-position (R, N, D, L) selector switch ( Fig. 8.1 ) is located at the end of the lever. For the FreedomLine transmission, a three-position (R, N, D) selector switch ( Fig. 8.2 ) is located at the end of the lever.

To upshift manually, pull the lever up (towards you). To downshift manually, push the lever down (away from you).

1. SmartShift Control Lever
2. Slide Switch (forward driving mode switch)
3. MAN Mode (of slide switch)
4. AUTO Mode (of slide switch)
5. Upshift Direction
6. Reverse Position (of selector switch)
7. Selector Switch
8. Neutral Lock Button
9. Neutral Position (of selector switch)
10. Drive Position (of selector switch)
11. Low Position (of selector switch)
12. Downshift Direction

Fig. 8.1, Four-Position SmartShift Control (with Eaton Fuller AutoShift, and UltraShift PLUS)

To upshift manually, pull the lever up (towards you). To downshift manually, push the lever down (away from you).

1. SmartShift Control Lever
2. Slide Switch
3. MAN Mode (of slide switch)
4. AUTO Mode (of slide switch)
5. Upshift Direction
6. Reverse Position (of selector switch)
7. Selector Switch
8. Neutral Lock Button
9. Neutral Position (of selector switch)
10. Drive Position (of selector switch)
11. Downshift Direction

Fig. 8.2, Three-Position SmartShift Control (with FreedomLine transmission)

Embedded in the selector switch is a small neutral lock button to prevent accidental shifts into gear from neutral. Any time you shift through N, press down on the neutral lock button to move the switch from neutral (N) to another gear, such as drive (D), low (L), or reverse (R). When shifting to N, it is not necessary to press the neutral lock button.

Eaton Fuller AutoShift Automated Transmissions

Refer to the Eaton website for additional information,www.roadranger.com.

General Information, AutoShift

10-Speed RT/RTO Models

Eaton Fuller 10-speed AutoShift transmissions have 10 forward speeds and two reverse speeds. The transmission consists of a 5-speed front section and a 2-speed rear section. The driver must use the clutch to start and stop the vehicle.

The driver does not need to break torque or increase or decrease engine speed to synchronize the shift. The transmission signals the engine controller when to break torque and the engine controller automatically increases or decreases engine speed. When engine speed is correct, the transmission engages the next gear and signals the engine controller to resume operation.

The AutoShift system consists of the following components:

The SmartShift control paddle on the steering column. See Fig. 8.1 .

The gear display module ( Fig. 8.3 ) mounted on the dashboard indicates the current gear position or transmission status. The display also flashes the next gear to be engaged while the transmission is in neutral during a gear change.

A. Gear Display Module
B. Module Detail

1. Current Gear
2. 9th Gear Engaged
3. In 9th Gear, Preselected Toward 10th
4. Out Of Gear, Waiting For Engine/Transmission RPM To Synchronize
5. 10th Gear Engaged

Fig. 8.3, Gear Display Module

The shifter mechanism performs shifts at the front portion of the transmission. It preselects the shift to neutral and completes the gear change after driver input.

The Electronic Control Unit (ECU) includes two controllers: a transmission ECU and a system ECU. The transmission ECU controls all transmission shift functions and the system ECU manages all vehicle interfaces for transmission shift functions.

An electronic range valve, controlled by the transmission ECU, is used to perform range shifts.

Operation, AutoShift with SmartShift

Automatic and Manual Modes

A two-position slide switch (forward driving mode switch) is located near the end of the control ( Fig. 8.1 ). The switch positions are labelled MAN (manual shift mode) and AUTO (automatic drive mode).

NOTE: In automatic drive mode, upshifts and downshifts require no driver interaction. Move the selector switch to the drive (D) position, disengage the clutch to engage the gear selected, engage the clutch and drive the vehicle. In manual shift mode, upshifts and downshifts require either a pull upward or push downward on the control.

Driver Message Center

Gear information is presented to the driver via a LCD display on the dash. In automatic drive mode, the number of the forward gear currently engaged appears continually on the message display screen when in drive (D). In manual shift mode, the current gear is displayed until a new gear is requested. When neutral (N) is engaged, "N" will appear on the message display screen. When reverse (R) is engaged, either "RL" or "RH" will appear on the message display screen.

IMPORTANT: The information shown on the message display screen indicates the state of the transmission only, not the state of the SmartShift control.

Neutral Position

Select neutral by sliding the selector switch to the "N" position.

NOTE: Neutral is always available during operation. When in neutral, upshift and downshift requests are ignored. If the mode selector switch is moved from neutral (N) to drive (D) while the vehicle is moving, the transmission will shift into a gear causing the engine to go to a high torque level, under the engine's rated torque.

Selecting a Starting Gear

1.

In automatic mode, select drive (D) by sliding the selector switch downward to the next position below the neutral position.

2.

Disengage the clutch to engage the gear selected. Engage the clutch and drive the vehicle.

Changing the Default Starting Gear

To select a starting gear other than the default starting gear, follow the instructions below.

1.

Make sure the vehicle is stopped and in drive.

2.

In either automatic or manual mode, pull upward on the control (to increase), or push downward (to decrease). Each pull upward on the control increases the starting gear by one gear, but no higher than fourth gear.

3.

The number of the gear selected will flash on the message display screen until the driver engages the clutch. This gear will be stored in memory as the default starting gear until either a different starting gear is selected by the driver or the engine is shut down.

NOTE: The transmission may also be programmed so that it is not possible to select a starting gear other than the preprogrammed default starting gear.

Upshifting

NOTE: With the transmission in drive (D) in the automatic mode, upshifts require no driver interaction.

1.

With the transmission in drive in the manual mode, request an upshift by pulling upward on the control. If the requested gear is available, the transmission will upshift.

NOTE: A single, momentary pull upward on the control selects the next higher gear when it is available. Two consecutive, momentary upward pulls will cause a skip shift when the next two higher gears are available and conditions are right.

2.

To skip shift, move the control two times in less than 1/2 second. The number of the gear engaged will appear on the message display screen.

NOTE: The Eaton Fuller AutoShift 18-speed transmission is able to perform triple upshifts when the next three higher gears are available and conditions are right. To triple-shift this transmission, move the control three times in less than 1/2 second.

If a requested gear is not available, an audible warning will sound and the gear display module will indicate that the gear is not available. An unavailable requested upshift is not stored in memory. The upshift must be requested again.

Downshifting

NOTE: With the transmission in drive (D) in the automatic mode, downshifts require no driver interaction.

1.

With the transmission in drive in the manual mode, request a downshift by pushing downward on the control. If the requested gear is available, the transmission will downshift.

NOTE: A single, momentary push downward on the control selects the next lower gear when it is available. Two consecutive, momentary downward pushes will cause a skip shift, when the next two lower gears are available and conditions are right.

2.

To skip shift, move the control two times in less than 1/2 second. The number of the gear engaged will appear on the message display screen.

NOTE: The Eaton Fuller AutoShift 18-speed transmission is able to perform triple downshifts when the next three lower gears are available and conditions are right. To triple shift this transmission, move the control three times in less than 1/2 second.

If a requested gear is not available, an audible warning will sound and the gear display module will indicate that the requested gear is not available. Unlike upshifting, an unavailable requested downshift is stored in memory and the shift will be made when the gear is available. The time limit for this memory is a programmable parameter.

Start-Up

1.

With the parking brake applied, press the clutch all the way down to the floor.

2.

Start the engine.

3.

Check to make sure the transmission is in neutral.

4.

With the transmission in neutral, release the clutch.

NOTE: This allows the speed sensor on the input shaft to get a reading.

5.

Press down on the clutch again and release the parking brake.

6.

Select the desired starting gear.

7.

Release the clutch.

Reverse

1.

To engage reverse (R), slide the selector switch upward to the next position above the neutral position and disengage the clutch.

NOTE: AutoShift 10- and 18-speed transmissions have a dual-range reverse. Reverse low (RL) is the default reverse gear.

2.

Select reverse high (RH) by pulling upward on the control.

NOTE: Reverse may be engaged below a programmable forward speed in order to rock the vehicle. If reverse is selected above the programmed forward speed, an audible warning will sound and a message indicating that the gear is not available will appear on the message display screen.

Low Gear Operation

Use low (L) when descending steep hills and using compression braking. Engine speed will be increased by 200 rpm and shift points will be offset by 200 rpm. The efficiency of the exhaust brake will be maximized.

Using the Clutch

Use the clutch to start and stop the vehicle.

ZF-FreedomLine Automated Transmissions

Refer to the Meritor website for additional information,www.meritor.com.

General Information, FreedomLine

FreedomLine is a fully-automated manual transmission that features only an accelerator and brake pedal in the cab. Clutch actuation is fully automated. On Freightliner vehicles, it will be operated by a custom version of the SmartShift controller. On Columbia vehicles, dash messages will appear on the round Meritor message center display.

This transmission requires an additional 10-liter air reservoir. After any transmission service, it will be necessary to charge this tank with air before the vehicle can be operated.

Operation, FreedomLine

1.

With the parking brake engaged and/or the brake pedal pressed down, select neutral (N) by pressing in the safety release and moving the selector switch to the center position. See Fig. 8.2 .

2.

With the transmission in neutral, start the engine. Allow the air pressure to build to 100 psi (689 kPa) to ensure clutch engagement before moving the vehicle.

3.

With air pressure built up, select drive (D) by by pressing in the safety release and moving the selector switch downward to the position below neutral. Release the parking brake and/or pedal.

NOTE: When D is selected, the transmission controller starts up in the default starting gear.

4.

Press down on the accelerator pedal to allow the vehicle to move forward. The vehicle will not move until the pedal is depressed.

A vehicle equipped with the FreedomLine fully-automated transmission can roll backwards when stopped on a hill or grade, or when the vehicle is starting from a stop on a hill or grade. This can result in serious personal injury or property damage.

5.

To stop on a hill or grade , press and hold the brake pedal to keep the vehicle from moving.

6.

To start from a full stop on hill or grade , quickly move your foot from the brake pedal and press firmly on the accelerator pedal.

Automatic and Manual Modes

The SmartShift selector has a slide switch located on the body of the control lever just before the paddle widens out. The slide switch controls the forward driving mode, automatic or manual.

In automatic drive mode, upshifts and downshifts are made by the transmission without driver intervention. Press in the safety release, move the selector switch to drive (D), and press down on the accelerator pedal. On the driver message center display, the first character is a special character to indicate automatic mode.

In manual drive mode, upshifts and downshifts are made by the driver:

To shift up, pull the lever up (towards you).

To shift down, push the lever down (away from you).

On the driver message center display, the first character is blank to indicate manual mode.

NOTE: Automatic shifting is possible only in forward gear. When the selector switch is in reverse (R), all shifts are done manually, regardless of the position of the slide switch.

Gear Positions

Neutral

Neutral (N) is in the center of the three-position selector switch located at the end of the SmartShift control lever. To select neutral, press in the safety release and move the selector switch to the center position.

Neutral is always available during operation. When in neutral, requests to upshift or downshift are ignored. If the selector switch is moved from neutral to drive while the vehicle is moving, the transmission will shift into a gear within the engine's operating torque range.

Reverse

To select reverse (R), press in the safety release and move the selector switch upward to the position above neutral.

NOTE: When the selector switch is in reverse (R), all shifts are done manually, regardless of the position of the slide switch.

The vehicle must come to a complete stop before selecting reverse. If reverse is selected with the vehicle moving, an audible warning will sound. Once the vehicle has come to a complete stop, reverse low can be engaged.

There are two reverse gears. Reverse low (RL) is the default reverse gear. To select reverse high (RH), pull the control lever up (towards you). You can shift between RL and RH "on the fly," without stopping first.

Upshifting

NOTE: A request to upshift or downshift can only be accepted in the manual mode.

With the transmission in drive, to request an upshift, pull the control lever up (towards you). If the gear is available, the transmission will upshift.

An unavailable request to upshift is not stored in memory. The upshift must be requested again. Skip shifting in manual mode is not available with the ZF Meritor version of SmartShift.

Downshifting

NOTE: A request to upshift or downshift can only be accepted in the manual mode.

With the transmission in drive, to request a downshift, push the control lever down (away from you). If the gear is available, the transmission will downshift.

An unavailable request to downshift is not stored in memory. The downshift must be requested again. Skip shifting in manual mode is not available with the FreedomLine version of SmartShift.

IMPORTANT: A downshift request can never result in a shift into neutral, even if the vehicle is in the drive position in the lowest possible gear.

Selecting A Nondefault Starting Gear

NOTE: For the clutch to engage, pressure in the primary air system must be at least 100 psi (689 kPa).

1.

Select drive (D) by pressing in the safety release and moving the selector switch downward to the position below neutral.

2.

Select manual mode (MAN) by moving the two-position slide switch towards the steering column until it is in the manual position.

3.

To increase the starting gear, pull the lever up (towards you). To decrease the starting gear, push the lever down (away from you).

4.

Select automatic mode (AUTO), if desired, by moving the two-position slide switch away from the steering column until it is in the automatic position.

Driver Message Center

On the Columbia, the gear is displayed on the round Meritor message center display. See Fig. 8.4 .

Fig. 8.4, Round Meritor Display

The first character of the display is either blank, to indicate the transmission is in manual mode, or an up-and-down arrow to indicate the transmission is in automatic mode.

NOTE: Pre-production vehicles will have a small numeric "10" in place of the up-and-down arrow when in automatic mode.

The next two characters indicate the current gear. For forward drive gears, this appears as a two-digit number ( Examples : "03, "11"). For reverse, two letters appear, either "RL" for low reverse (the default), or "RH" for high reverse. For neutral, a single letter "N" appears.

Eaton Fuller Range-Shift Transmissions

Refer to the Eaton website for additional information,www.roadranger.com.

General Information, Eaton Fuller Range-Shift

To operate a range-shift transmission, move the shift lever through all the low gear positions and then activate a range switch to provide an additional set of ratios in the high range. Using the same shift lever positions as in low range, move the shift lever through each position as before. On some models, the initial low gear is often used only in low range.

IMPORTANT: Not all lever positions are used in each range and the shift patterns vary between transmissions. Be sure to read the shift pattern decal on the dash for the operating instructions for the specific transmission installed in your vehicle.

9-Speed RT/RTX Models

Eaton Fuller 9-speed transmissions have a 5-speed front section and a 2-speed rear range section. The low gear in the front sections of the RT and RTX transmissions is used only as a starting ratio. The remaining gear positions of the above transmissions are used once in the low range and once in the high range.

See Fig. 8.5 for the 9-speed range-shift shift patterns.

A. High Range
B. Low Range

Fig. 8.5, Eaton Fuller 9-Speed Transmission Shift Patterns

10-Speed FR/FRO and RT/RTO/RTX Models

Eaton Fuller 10-speed transmissions have 10 selective, evenly-spaced forward ratios. Each transmission has a 5-speed front section and a 2-speed rear range section. The 10 forward speeds are obtained by twice using a 5-speed shift pattern: the first time in low range, the second time in high range. See Fig. 8.6 for the shift patterns.

A. High Range
B. Low Range

Fig. 8.6, Eaton Fuller 10-Speed Transmission Shift Patterns

NOTE: The 4th/9th and the 5th/10th shift positions in the RT (direct ratio) and RTX (overdrive ratio) transmissions are directly opposite in the RTO (overdrive ratio) transmissions

Operation, Eaton Fuller Range-Shift

1.

When operating off-highway, or under adverse conditions, always use low gear (if so equipped) when starting to move the vehicle.

1.

When operating on-highway, with no load, or under ideal conditions, use 1st gear when starting to move the vehicle (except when equipped with a 9-speed RTO transmission, then always start in low gear).

1.

For all conditions, use the highest gear that is still low enough to start the vehicle moving with engine idling, and without slipping the clutch excessively.

2.

Use the clutch brake to stop gear rotation when shifting into low (or 1st) or reverse when the vehicle is stationary. The clutch brake is actuated by depressing the clutch pedal all the way to the floor.

2.

For normal upshifts and downshifts, only a partial disengagement of the clutch is necessary to break engine torque.

3.

Do not make range shifts with the vehicle moving in reverse gear.

4.

Never attempt to move the range preselection lever with the gear shift lever in neutral while the vehicle is moving. Preselection with the range preselection lever must be made prior to moving the shift lever out of gear into neutral.

5.

Do not shift from high range to low range at high vehicle speeds.

6.

Double-clutch between all upshifts and downshifts.

7.

After your shifting ability improves, you may want to skip some of the ratios. This may be done only when operating conditions permit, depending on the load, grade, and road speed.

Upshifting

1.

Position the gear shift lever in neutral. Start the engine, and bring the air system pressure up to 100 to 120 psi (689 to 827 kPa).

2.

Position the range preselection lever down, into low range.

3.

Press the clutch pedal to the floor; shift into low or 1st gear ( Table 8.1 ), then engage the clutch, with the engine at or near idle speed, to start the vehicle moving. Accelerate to 80 percent of engine governed speed.

Eaton Fuller Shift Progressions
TRANS. MODEL	LOW RANGE		HIGH RANGE
TRANS. MODEL	Off-Highway	On-Highway	HIGH RANGE
9-Speed Direct or Overdrive (RT or RTX)
10-Speed Direct or Overdrive (RT or RTX)

Table 8.1, Eaton Fuller Range-Shift Shift Progressions

4.

Shift progressively upward from low or 1st gear, to the top gear in low range ( Table 8.1 ), double-clutching between shifts, and accelerating to 80 percent of engine governed speed.

5.

While in the top gear of the low range shift pattern, and ready for the next upshift, flip the range preselection lever up into high range. Double-clutch through neutral, and shift into the bottom gear in high range ( Table 8.1 ). As the shift lever passes through neutral, the transmission will automatically shift from low range to high range.

6.

With the transmission in high range, shift progressively upward through each of the high range gears ( Table 8.1 ), double-clutching between shifts.

Downshifting

1.

With the transmission in high range, shift progressively downward to the bottom gear in high range, double-clutching between shifts.

2.

When in the bottom gear of the high range shift pattern, and ready for the next downshift, push the range preselection lever down into low range. Double-clutch through neutral, and shift into the top gear of the low range shift pattern. As the shift lever passes through neutral, the transmission will automatically shift from high range to low range.

3.

With the transmission in low range, downshift through the low range gears as conditions require.

IMPORTANT: Never use the clutch brake when downshifting, or as a brake to slow the vehicle.

Eaton Fuller Splitter and Range-Shift Transmissions

Refer to the Eaton website for additional information,www.roadranger.com.

General Information, Eaton Fuller Splitter and Range-Shift

Combination splitter and range-shift transmissions allow the choice of two splitter ratios in each lever position as well as the additional ratio provided in each lever position after shifting to the other range.

IMPORTANT: Not all lever positions are used in each range and the shift patterns vary between transmissions. Be sure to read the shift pattern decal on the dash for the operating instructions for the specific transmission installed in your vehicle.

13-Speed RTLO Models

Eaton Fuller 13-speed transmissions have thirteen forward speeds and two reverse speeds. Each transmission consists of a 5-speed front section, and a 3-speed auxiliary section. The auxiliary section contains low- and high-range ratios, plus an overdrive splitter gear. See Fig. 8.7 for the shift pattern.

A. High Range
B. Low Range
C. Overdrive (forward)
D. Direct Drive (rearward)

1. Splitter Control Button

Fig. 8.7, Eaton Fuller 13-Speed Transmission Shift Pattern

All of the 13 speeds are controlled with one shift lever. A range preselection lever and a splitter control button are built into the shift knob. The range preselection lever controls range selection and the splitter control button (located on the side of the shift knob) controls gear splits.

Low gear in the front section is used only as a starting ratio. The remaining four forward positions are used once in the low range and once in the high range. However, each of the four high range gear positions can be split with the underdrive ratio (RT models), or overdrive ratio (RTO models) of the splitter gear. Ratios cannot be split while the transmission is in low range.

18-Speed RTLO Splitter and Range-Shift Models

Eaton Fuller 18-speed transmissions have 18 forward speeds and four reverse speeds. These transmissions consisting of a 5-speed front section and a 3-speed auxiliary section. The auxiliary section contains low and high range ratios, plus an overdrive splitter gear.

One ratio in the front section (low) is used as a starting ratio; it is never used when the transmission is in high range. Low gear can be split to provide both a direct and an overdrive ratio.

The other four ratios in the front section are used once in low range and once again in high range; however, each of the five ratios (low–1–2–3–4) in low range and each of the four ratios (5–6–7–8) in high range can be split with the overdrive splitter gear.

All of the 18 speeds are controlled with one shift lever. A range preselection lever and a splitter control button are built into the shift knob. The range preselection lever controls range selection and the splitter control button (located on the side of the shift knob) controls gear splits.

Operation, Eaton Fuller Splitter and Range-Shift

IMPORTANT: The shifter knob has an interlock feature that prevents the splitter control button from being moved forward when the range preselection lever is down (in low range); when in high range and the splitter control button is in the forward position, the range preselection lever cannot be moved down.

1.

When operating off-road, or under adverse conditions, always use low gear when starting to move the vehicle forward.

1.

When operating on-highway, with no load, or under ideal conditions, use 1st gear when starting to move the vehicle forward.

1.

For all conditions, use the highest gear that is still low enough to start the vehicle moving with the engine at or near idle speed, and without slipping the clutch excessively.

2.

Use the clutch brake to stop gear rotation when shifting into low (or 1st) or reverse when the vehicle is stationary. The clutch brake is actuated by depressing the clutch pedal all the way to the floor.

2.

For normal upshifts and downshifts, only a partial disengagement of the clutch is necessary to break engine torque.

3.

Use double-clutching between all upshifts and downshifts that require movement of the shift lever. Splitting of the high range gears does not require movement of the shift lever.

4.

Never move the shift lever into low gear while in high range.

5.

Never move the splitter control button while in neutral.

6.

Do not preselect with the splitter control button; after moving the control button, complete the shift immediately.

7.

Except when downshifting from 5th direct to 4th gear, never push the range preselection lever down into low range while operating in high range—the splitter will become inoperative.

8.

Do not shift from high range to low range at high vehicle speeds.

9.

Do not make range shifts with the vehicle moving in reverse gear.

10.

Never attempt to move the range preselection lever with the gear shift lever in neutral while the vehicle is moving. Preselection with the range preselection lever must be made prior to moving the shift lever out of gear into neutral.

11.

After your shifting ability improves, you may want to skip some of the ratios. This may be done only when operating conditions permit, depending on the load, grade, and road speed.

Upshifting

1.

Position the gear shift lever in neutral. Start the engine, and bring the air system pressure up to 100 to 120 psi (689 to 827 kPa).

2.

Position the range preselection lever down, into low range. See Fig. 8.7 or Fig. 8.8 .

A. High Range
B. Low Range
C. Overdrive (forward)
D. Direct Drive (rearward)

1. Splitter Control Button

Fig. 8.8, Eaton Fuller 18-Speed Transmission Shift Pattern

3.

Make sure the splitter control button is in the direct (rearward) position. See Fig. 8.7 or Fig. 8.8 .

4.

For 13-speed transmissions:

4.

Press the clutch to the floor, shift into low or 1st gear; then engage the clutch, with the engine at or near idle speed, to start the vehicle moving. Accelerate to 80 percent of engine governed speed.

4.

For 18-speed transmissions:

4.

Press the clutch to the floor, shift into low; then engage the clutch, with the engine at or near idle speed, to start the vehicle moving.

4.

To shift from low direct to low overdrive, move the splitter control button ( Fig. 8.8 ) into the overdrive (forward) position, then immediately release the accelerator. Press and release the clutch pedal. After releasing the clutch, accelerate again.

5.

For 13-speed transmissions:

5.

Shift upward from low to 1st gear, 2nd, etc. until 4th gear, double-clutching between shifts, and accelerating to 80 percent of engine governed speed. See Fig. 8.7 .

5.

For 18-speed transmissions:

5.

Shift upward from low overdrive to 1st direct by first moving the splitter control button into the direct (rearward) position ( Fig. 8.8 ). Move the shift lever, double-clutching, to the 1st gear position.

5.

Continue upshifting through the shift pattern. Double-clutch during lever shifts (1st to 2nd to 3rd to 4th); single-clutch during split shifts (1st direct to 1st overdrive, etc.).

6.

When in 4th gear (13-speed transmissions) or 4th overdrive (18-speed transmissions) and ready to shift up to 5th gear, use the range shift lever as follows:

6.

For 13-speed transmissions:

6.

While in 4th gear, pull the range shift preselection lever up, into high range. The transmission will automatically shift from low to high range as the shift lever passes through neutral. Then, disengage the clutch; double-clutch through neutral; move the shift lever to 5th gear; engage the clutch, and accelerate the engine.

6.

For 18-speed transmissions:

6.

While in 4th overdrive, pull the range shift preselection lever up, into high range. The transmission will automatically shift from low to high range as the shift lever passes through neutral.

6.

Move the shift lever, double-clutching, to the 5th gear position. Just before making final clutch engagement, move the splitter control button to the direct (rearward) position; then engage the clutch and accelerate. Do not move the control button while the shift lever is in neutral.

7.

Shift up through the high range gears as follows:

7.

For 13-speed transmissions:

7.

To shift from 5th direct to 5th overdrive, move the splitter control button ( Fig. 8.7 ) into the overdrive (forward) position, then immediately release the accelerator. Press and release the clutch pedal. After releasing the clutch, accelerate again.

7.

Continue upshifting through the shift pattern. Double-clutch during lever shifts (6th to 7th to 8th); single-clutch during split shifts (6th direct to 6th overdrive, etc.).

7.

For 18-speed transmissions:

7.

To shift from 5th direct to 5th overdrive, move the splitter control button ( Fig. 8.8 ) into the overdrive (forward) position, then immediately release the accelerator. Press and release the clutch pedal. After releasing the clutch, accelerate again.

7.

Continue upshifting through the shift pattern. Double-clutch during lever shifts (6th to 7th to 8th); single-clutch during split shifts (6th direct to 6th overdrive, etc.).

Downshifting

1.

Downshift from 8th overdrive to 8th direct without moving the shift lever. Flip the splitter control button to the direct (rearward) position, then immediately release the accelerator, and disengage the clutch. Engage the clutch, and accelerate the engine only after the transmission has shifted.

2.

Start the downshift from 8th direct to 7th overdrive by flipping the splitter control button to the overdrive (forward) position; then, immediately double-clutch through neutral, moving the shift lever from 8th to 7th gear.

3.

Shift downward through each of the high range gears, alternating the procedures in steps 1 and 2, above, until reaching 5th direct.

4.

While in 5th direct and ready for the downshift to 4th (13-speed transmissions) or 4th overdrive (18-speed transmissions), push the range preselection lever down. Then, double-clutch through neutral and move the shift lever to the 4th gear position. On 18-speed transmissions, move the splitter control button to the overdrive (forward) position before engaging the clutch. Do not move the control button while the shift lever is in neutral.

5.

Continue downshifting from 4th to 1st as follows:

5.

For 13-speed transmissions:

5.

Downshift through the low range gears as conditions require.

5.

For 18-speed transmissions:

5.

Continue downshifting from 4th overdrive to 4th direct, then 4th direct to 3rd overdrive, 3rd overdrive to 3rd direct, etc. Single-clutch when split shifting (direct to overdrive, overdrive to direct). Double-clutch when making lever shifts (4th to 3rd, 3rd to 2nd, etc.).

IMPORTANT: Never use the clutch brake when downshifting, or as a brake to slow the vehicle.

Eaton Fuller Deep-Reduction Transmissions

Refer to the Eaton website for additional information,www.roadranger.com.

General Information, Deep Reduction

IMPORTANT: Not all lever positions are used in each range and the shift patterns vary between transmissions. Be sure to read the shift pattern decal on the dash for the operating instructions for the specific transmission installed in your vehicle.

9-Speed RTO–LL Models

Eaton Fuller 9-speed deep-reduction transmissions have a 5-speed front section, and a 2-speed rear-range section, with a deep reduction gear. The deep reduction (low-low) gear is used only when operating under adverse conditions. Low gear in the front section is used only for rough, off-highway conditions, as a starting ratio. Both the low gear and 1st gear in the low range can be split, using the deep reduction button, for another reduction ratio in those shift lever positions. The remaining four forward positions are used once in the low range and once in the high range. Reverse in the low range can also be split with the deep reduction button for a lower ratio.

10-Speed RT–LL, RTO–LL and RTX–LL Models

Eaton Fuller 10-speed deep-reduction transmissions have a 5-speed front section, and a 2-speed rear range section, with a deep reduction button. The low-low, deep reduction gear is used only when operating under adverse conditions. Low gear in the front section is used only for rough, off-highway conditions, as a starting ratio. The remaining four forward positions are used once in the low range and once in the high range. See Fig. 8.9 for the shift pattern.

A. High Range
B. Low Range
C. Deep Reduction IN (forward)
D. Deep Reduction OUT (rearward)

1. Deep Reduction Button

Fig. 8.9, Eaton Fuller 10-Speed Deep-Reduction Transmission Shift Patterns

NOTE: The 3rd/7th and 4th/8th shift positions in the RT and RTX-LL transmissions are opposite of the RTO-LL transmissions.

15-Speed RT/RTO Deep-Reduction Models

Eaton Fuller 15-speed deep-reduction transmissions have a 5-speed front section, and a 2-speed rear range section. They also have five additional deep reduction ratios. The 5-speed front section, and the low and high range sections provide 10 evenly and progressively spaced forward speeds. The five deep reduction ratios are also evenly and progressively spaced; however, they do overlap the low range ratios, and should be used only when operating under adverse conditions. See Fig. 8.10 for the shift patterns.

A. RT Models
B. RTO Models

1. High Range
2. Low Range
3. Deep Reduction
4. High Range
5. Low Range
6. Forward for IN
7. Rearward for OUT

Fig. 8.10, Eaton Fuller 15-Speed Deep-Reduction Transmission Shift Patterns

NOTE: The 4th/9th, and the 5th/10th shift positions in the RT (direct ratio) transmissions are directly opposite in the RTO (overdrive ratio) transmissions.

Operation, Deep Reduction

IMPORTANT: The shifter knob has an interlock feature that prevents the deep reduction button from being moved forward when the range preselection lever is up (in high range); when in low range and the deep reduction button is in the forward position, the range preselection lever cannot be moved up.

1.

For all driving conditions, use the highest gear that is still low enough to start the vehicle moving with the engine idling, and without slipping the clutch excessively.

2.

Use the clutch brake to stop gear rotation when shifting into low-low, low-1st (whichever is used as a starting ratio) or reverse, when the vehicle is stationary. The clutch brake is actuated by depressing the clutch pedal all the way to the floor.

2.

For normal upshifts and downshifts, only a partial disengagement of the clutch is necessary to break engine torque.

3.

Double-clutch between all upshifts and downshifts.

4.

Never move the shift lever into low gear while in high range.

5.

Do not preselect with the deep reduction button. When making the shift from a deep reduction ratio to a low range ratio, move the deep reduction button from a forward position to a rearward position, then complete the shift immediately.

6.

Never move the deep reduction button from a rearward position to a forward position when the transmission is in high range.

7.

Do not shift from high range to low range at high vehicle speeds.

8.

Do not make range shifts with the vehicle moving in reverse gear.

9.

Never attempt to move the range preselection lever with the gear shift lever in neutral while the vehicle is moving. Preselection with the range preselection lever must be made prior to moving the shift lever out of gear into neutral.

10.

After your shifting ability improves, you may want to skip some of the ratios. This may be done only when operating conditions permit, depending on the load, grade, and road speed.

Upshifting

There are several patterns of upshifting, depending on the vehicle load and the road conditions. See Table 8.2 for suggested shifting sequences. Deep reduction gears are best suited for heavy loads and steep inclines. Low gear (in 10-speed transmissions) is best suited for off-highway use.

The following instructions are recommended for starting a loaded vehicle moving, under adverse conditions.

1.

Position the gear shift lever in neutral. Start the engine, and bring the vehicle air system pressure up to 100 to 120 psi (689 to 827 kPa).

2.

Position the range preselection lever down, into low range.

3.

Move the deep reduction button to the forward position, to engage the deep reduction gears.

4.

Depress the clutch pedal to the floor; shift into low-low gear (9/10-speed transmissions) or 1st gear of deep reduction (15-speed transmissions); then engage the clutch, with the engine at or near idle speed, to start the vehicle moving. Accelerate to 80 percent of engine governed speed.

5.

For 9/10-speed transmissions:

5.

When ready for the next upshift, move the deep reduction button rearward, then break the torque on the gears by momentarily releasing the accelerator or depressing the clutch pedal. Do not move the shift lever.

5.

For 15-speed transmissions:

5.

Shift upward from 1st gear of deep reduction to 5th gear of deep reduction, double-clutching between shifts and accelerating to 80 percent of engine governed speed. See Table 8.2 .

5.

When ready for the next upshift, move the deep reduction button from the forward position to the rearward position, then double-clutch through neutral, and move the shift lever to the 4th gear position in the low range.

6.

Shift upward from low gear (9/10-speed transmissions) or 4th gear (15-speed transmissions), to the top gear in low range ( Table 8.2 ), double-clutching between shifts, and accelerating to 80 percent of engine governed speed.

7.

While in the top gear of the low range shift pattern, and ready for the next upshift, flip the range preselection lever up into high range. Double-clutch through neutral, and shift into the bottom gear in high range ( Table 8.2 ). As the shift lever passes through neutral, the transmission will automatically shift from low range to high range.

Eaton Fuller Deep-Reduction and Range-Shift Shift Progressions
TRANSMISSION MODEL	DEEP REDUCTION	LOW RANGE		HIGH RANGE
TRANSMISSION MODEL	Adverse Conditions Only	Off-Highway and Adverse Conditions	On-Highway and Ideal Conditions	All Conditions
15-Speed RT and RTX

Table 8.2, Eaton Fuller Deep-Reduction and Range-Shift Shift Progressions

8.

With the transmission in high range, shift progressively upward through each of the high range gears ( Table 8.2 ), double-clutching between shifts.

Alternate Upshifting Procedures (15-Speed Transmissions Only)

The shift from deep reduction to low range can also be made from 2nd, 3rd, or 4th gear of deep reduction, but must be made to the next gear lower in the low range. The shift from 2nd gear of deep reduction to 1st gear in low range (or 3rd gear of deep reduction to 2nd gear in low range, and 4th gear of deep reduction to 3rd gear in low range), is an upshift, and the same procedure should be followed as that shown for shifting from 5th gear of deep reduction to 4th gear in low range. See step 5, under "Upshifting."

Downshifting

1.

With the transmission in high range, shift progressively downward to the bottom gear in high range, double-clutching between shifts.

2.

When in the bottom gear of the high range shift pattern, and ready for the next downshift, push the range preselection lever down into low range. Double-clutch through neutral, and shift into the top gear of the low range shift pattern. As the shift lever passes through neutral, the transmission will automatically shift from high range to low range.

3.

With the transmission in low range, downshift through the low range gears, as conditions require.

IMPORTANT: Never use the clutch brake when downshifting, or as a brake to slow the vehicle.

Eaton Fuller Super 10, Top 2, and Lightning Semi-Automated Transmissions

Refer to the Eaton website for additional information,www.roadranger.com.

General Information, Super 10/Top 2/Lightning

Super 10, Top 2, and Lightning transmissions have 10 selective forward ratios and a 2-speed rear splitter section. Half of the 10 speed ratios are shifted with the shift lever and the other half are shifted by moving the shift button. See Fig. 8.11 for the Super 10 and Top 2 shift knob, and Fig. 8.12 for the Lightning shift knob.

A. Splitter Shift Button
B. Gears 2, 4, 6, 8, 10 when button is forward
C. Gears 1, 3, 5, 7, 9 when button is rearward

Fig. 8.11, Super 10 and Top 2 Shift Knob

1. Shift Button
2. Service Light

Fig. 8.12, Lightning Shift Knob

There are three types of shifts used with these transmissions. Button-only and combination button/lever shifts are both full gear changes. The lever-only shift skips a gear.

The button-only shift is a gear split shift that occurs by moving the shift button.

The lever-only shift occurs when the shift lever is moved without moving the shift button.

The combination button/lever shift is a gear ratio change that occurs when both the shift button and the shift lever are moved.

The small red service light on the Lightning shift knob illuminates for a few seconds when the engine is turned on. This confirms that the transmission electronics are operating properly.

NOTE: If the service light stays on or flashes, or does not illuminate when the engine starts, take the vehicle to an authorized Freightliner or Eaton service facility as soon as possible.

See Fig. 8.13 for the Super 10 shift pattern, which is also used by Top 2 and Lightning when the cruise control is off. Top 2 and Lightning transmissions are equipped with the Top 2 feature that allows the transmission, with cruise control on, to automatically shift between the top two gears (9th-10th) without the need for a button-only shift. See Fig. 8.14 .

NOTE: The Top 2 and Lightning transmissions use the Super 10 shift pattern when cruise control is off.

Fig. 8.13, Super 10 Shift Pattern

Fig. 8.14, Top 2 and Lightning Shift Patterns (with cruise control on)

IMPORTANT: Not all lever positions are used in each range and the shift patterns vary between transmissions. Be sure to read the shift pattern decal on the dash for the operating instructions for the specific transmission installed in your vehicle.

Operation, Super 10/Top 2/Lightning

Keep the transmission in gear at all times while the vehicle in motion. Coasting in neutral could lead to transmission damage.

1.

When operating off-highway, or under adverse conditions, always use low gear (if so equipped) when starting to move the vehicle.

1.

When operating on-highway, with no load, or under ideal conditions, use 1st gear when starting to move the vehicle.

1.

For all conditions, use the highest gear that is still low enough to start the vehicle moving with engine idling, and without slipping the clutch excessively.

2.

Use the clutch brake to stop gear rotation when shifting into 1st or reverse when the vehicle is stationary. The clutch brake is actuated by depressing the clutch pedal all the way to the floor.

2.

For normal upshifts and downshifts, only a partial disengagement of the clutch is necessary to break engine torque.

3.

Do not make splitter shifts with the vehicle moving in reverse gear.

4.

The shift lever should not be moved to the center or left rail positions at vehicle speeds above 40 mph (65 km/h).

5.

Double-clutch between all upshifts and downshifts.

6.

After your shifting ability improves, you may want to skip some of the ratios. This may be done only when operating conditions permit, depending on the load, grade, and road speed.

7.

Avoid hunting for neutral by moving the gear shift lever from the left rail to right rail. This action can cause excessive transmission wear.

Upshifting

1.

Position the gear shift lever in neutral. Start the engine, and bring the air system pressure up to 100 to 120 psi (689 to 827 kPa).

2.

Press the clutch pedal to the floor. Shift into 1st gear, then engage the clutch, with the engine at or near idle speed, to start the vehicle moving.

3.

Button-only shift—Preselect the next gear by sliding the shift button forward. Break torque by releasing the throttle or by depressing the clutch pedal. Decrease engine speed to synchronize the engine speed with the transmission speed. The shift will complete when the engine rpm has decreased to the proper speed.

3.

The button-only shift is used for gear changes from 1st to 2nd, 3rd to 4th, 5th to 6th, 7th to 8th, and 9th to 10th.

4.

Lever-only shift—Break torque by releasing the throttle and depressing the clutch pedal. Double-clutching, move the shift lever to the next desired gear position. Decrease engine speed to synchronize the engine speed with the transmission speed. The shift will complete when the engine rpm has decreased to the proper speed.

4.

The lever-only shift is used to skip a full gear. With the shift button rearward—1st to 3rd, 3rd to 5th, 5th to 7th, and 7th to 9th. With the shift button forward—2nd to 4th, 4th to 6th, 6th to 8th, 8th to 10th.

NOTE: Lever-only shifts skip an entire gear ratio and will require the engine rpm to decrease twice the amount of a normal shift.

5.

Combination button/lever shift—Preselect the next gear by sliding the shift button rearward. Break torque by releasing the throttle and depressing the clutch pedal. Double-clutch and move the shift lever to the next desired gear position.

5.

The combination button/lever shift is used for gear changes from 2nd to 3rd, 4th to 5th, 6th to 7th and 8th to 9th.

Downshifting

Do not attempt a button-only downshift at too high an engine speed (generally above 1400 rpm). Doing so could result in damage to the engine, transmission, and/or driveline.

1.

Button-only shift—With the throttle still applied, preselect the next gear by sliding the shift button rearward. Break torque by releasing the throttle or by depressing the clutch pedal. Increase engine speed to synchronize the engine speed with the transmission speed. The shift will complete when the engine rpm has increased to the proper speed.

1.

The button-only shift is used for gear changes from 10th to 9th, 8th to 7th, 6th to 5th, 4th to 3rd, and 2nd to 1st.

Do not attempt a lever-only downshift at too high an engine speed (generally above 1000 rpm). Doing so could result in damage to the engine, transmission, and/or driveline.

2.

Lever-only shift—Break torque by releasing the throttle and depressing the clutch pedal. Double-clutching, move the shift lever to the next desired gear position.

2.

The lever-only shift is used to skip a full gear. With the shift button rearward—9th to 7th, 7th to 5th, 5th to 3rd, and 3rd to 1st. With the shift button forward—10th to 8th, 8th to 6th, 6th to 4th and 4th to 2nd.

IMPORTANT: Never use the clutch brake when downshifting, or as a brake to slow the vehicle.

Do not attempt a combination button/lever downshift at too high an engine speed (generally above 1400 rpm). Doing so could result in damage to the engine, transmission, and/or driveline.

3.

Combination button/lever shift—With the throttle still applied, preselect the next gear by sliding the shift button forward. Break torque by releasing the throttle and depressing the clutch pedal. Double-clutch and move the shift lever to the next desired gear position.

3.

The combination button/lever shift is used for gear changes from 9th to 8th, 7th to 6th, 5th to 4th, and 3rd to 2nd.

Meritor Range-Shift Transmissions

Refer to the Meritor website for additional information,www.meritor.com.

General Information, Meritor Range-Shift

To operate a range-shift transmission, move the shift lever through all the low gear positions and then activate a range switch to provide an additional set of ratios in the high range. Using the same shift lever positions as in low range, move the shift lever through each position as before. On some models, the initial low gear is often used only in low range.

IMPORTANT: Not all lever positions are used in each range and the shift patterns vary between transmissions. Be sure to read the shift pattern decal on the dash for the operating instructions for the specific transmission installed in your vehicle.

9-Speed M and MO Models

Meritor 9-speed transmissions have a 5-speed front section, and a 2-speed auxiliary section. The low gear in the front sections of the "A" and "B" ratio transmissions is used only as a starting ratio. The high gear in the front section of the "R" ratio transmissions is used only as the top gear. The remaining gear positions of the above transmissions are used once in the low range and once in the high range. See Fig. 8.15 for the shift patterns.

A. All M and MX Transmissions
B. All MO Transmissions

1. High Range
2. Low Range

Fig. 8.15, Meritor 9-Speed Transmission Shift Patterns

NOTE: The 3rd/7th and 4th/8th shift positions in the M and MX (direct ratio) are opposite of the MO (overdrive ratio) transmissions. The MX-R ratio transmissions have the 1st/5th shift positions where low is in the A and B ratio transmissions. The top gear in the MX-R ratio transmissions is called 9th gear.

10-Speed M Models

Meritor 10-speed transmissions have 10 evenly-spaced forward ratios. Each transmission consists of a 5-speed front section, and a 2-speed auxiliary section. The 10 forward speeds are obtained by twice using a 5-speed shift pattern: the first time in low range; the second time in high range. See Fig. 8.16 for the shift pattern.

A. All M Transmissions
B. All MO Transmissions
C. High Range
D. Low Range

Fig. 8.16, Meritor 10-Speed Transmission Shift Patterns

Operation, Meritor Range-Shift

Reverse

To drive in reverse, push the range selector lever down to put the transmission in the low range. Push the clutch pedal to the bottom of travel so the clutch brake slows the transmission for initial gear engagement. Holding the clutch pedal at the bottom of travel, shift into reverse.

Slowly release the clutch pedal to move the vehicle in reverse.

Upshifting

1.

To drive forward, make sure the vehicle is completely stopped and the range selector lever is pushed down to put the transmission in the low range.

1.

Push the clutch pedal to the bottom of travel so the clutch brake slows the transmission for initial gear engagement; holding the clutch pedal at the bottom of travel, shift into low.

2.

Slowly release the clutch pedal to begin moving the vehicle forward.

3.

To upshift into 1st gear, only partial depression of the clutch pedal is needed. Do not push the clutch pedal all the way to the floor and engage the clutch brake; instead, partially depress the clutch pedal, and move the shift lever into neutral.

4.

Release the clutch, and allow the engine to decelerate until the road speed and the engine rpm match.

5.

Partially depress the clutch pedal, and move the shift lever into first gear.

6.

Double-clutch and continue upshifting until you reach the top gear in the low range, 4th gear in 9-speed models and 5th gear in 10-speed models. See Table 8.3 .

Meritor Range-Shift Shift Progressions
TRANS. MODEL	LOW RANGE		HIGH RANGE
TRANS. MODEL	Off-Highway	On-Highway	HIGH RANGE
9-Speed Direct (M)
9-Speed Overdrive (MO)
10-Speed Direct or Overdrive (M)
10-Speed Overdrive (MO)

Table 8.3, Meritor Range-Shift Shift Progressions

7.

To upshift into high range—with the transmission still in the highest low range gear—move the range selector lever up to put the transmission into high range, then partially depress the clutch pedal and move the shift lever into neutral. As the shift lever passes through neutral, the transmission will automatically shift from low range to high range.

8.

Release the clutch pedal, and let the engine slow until the road speed and engine rpm match.

9.

Partially depress the clutch pedal, and move the shift lever into the lowest gear in the high range, 5th gear in 9-speed models and 6th gear in 10-speed models.

10.

Double-clutch to continue upshifting.

Downshifting

1.

With the transmission in high range, shift progressively downward to the bottom gear in high range, 5th gear in 9-speed models and 6th gear in 10-speed models. Double-clutch between shifts. See Table 8.3 .

2.

When in the bottom gear of the high range shift pattern, and ready for the next downshift, push the range selection lever down into low range. Double-clutch through neutral, and shift into the top gear of the low range shift pattern. As the shift lever passes through neutral, the transmission will automatically shift from high range to low range.

3.

With the transmission in low range, downshift through the low range gears as conditions require.

IMPORTANT: Never use the clutch brake when downshifting, or as a brake to slow the vehicle.

Meritor Splitter and Range-Shift Transmissions

Refer to the Meritor website for additional information,www.meritor.com.

General Information, Meritor Splitter and Range-Shift

Combination splitter and range-shift transmissions allow the choice of two splitter ratios in each lever position as well as the additional ratio provided in each lever position in high range after shifting to the other range.

IMPORTANT: Not all lever positions are used in each range and the shift patterns vary between transmissions. Be sure to read the shift pattern decal on the dash for the operating instructions for the specific transmission installed in your vehicle.

13-Speed MO Models

Meritor 13-speed transmissions have 13 forward speeds and two reverse speeds. Each transmission consists of a 5-speed front section, and a 3-speed auxiliary section. The auxiliary section contains low and high range ratios, plus an overdrive splitter gear for high range. See Fig. 8.17 .

A. High Range
B. Low Range
C. Overdrive
D. Direct Drive

1. Splitter Control Button

Fig. 8.17, Meritor 13-Speed Transmission Shift Pattern

All of the thirteen speeds are controlled with one shift lever. Low gear in the front section is used only as a starting ratio. The remaining four forward positions are used once in the low range and once in the high range.

The range selection lever is on the back of the shift knob. When in the top gear position of the low range, toggle the range lever up just before shifting into the lowest gear position in the high range.

The splitter control button is on the side of the shift knob. Each of the four high range gear positions can be split with the overdrive ratio of the splitter gear. Ratios cannot be split while the transmission is in low range.

Operation, Meritor Splitter and Range-Shift

IMPORTANT: The shifter knob has an interlock feature that prevents the splitter control button from being moved up when the range selection lever is down (in the low range); when the transmission is in the high range, and the splitter control button is up, the range selection lever cannot be moved down.

Reverse

To drive in reverse, push the range selector lever down to put the transmission in the low range. Push the clutch pedal to the bottom of travel so the clutch brake slows the transmission for initial gear engagement; holding the clutch pedal at the bottom of travel, shift into reverse.

Slowly release the clutch pedal to move the vehicle in reverse.

Upshifting

1.

To drive forward, make sure the vehicle is completely stopped and the range selector lever is pushed down to put the transmission in the low range.

1.

Push the clutch pedal to the bottom of travel so the clutch brake slows the transmission for initial gear engagement; holding the clutch pedal at the bottom of travel, shift into low.

2.

Slowly release the clutch pedal to begin moving the vehicle forward.

3.

To upshift into 1st gear, only partial depression of the clutch pedal is needed. Do not push the clutch pedal all the way to the floor and engage the clutch brake; instead, partially depress the clutch pedal, and move the shift lever into neutral.

4.

Release the clutch pedal, and allow the engine to decelerate until the road speed and the engine rpm match.

5.

Partially depress the clutch pedal, and move the shift lever into 1st gear.

6.

Double-clutch to continue upshifting until in fourth gear. See Table 8.3 .

7.

To upshift into high range—with the transmission still in 4th gear—push the range selection lever up to put the transmission into high range, then partially depress the clutch pedal and move the shift lever into neutral. As the shift lever passes through neutral, the transmission will automatically shift from low range to high range.

8.

Release the clutch pedal, and let the engine slow until the road speed and engine rpm match.

9.

Partially disengage the clutch, and move the shift lever into 5th gear.

10.

To upshift from 5th gear into 5th overdrive, flip the splitter control button up to the overdrive position; then, immediately release the accelerator, and press and release the clutch pedal. It is not necessary to move the shift lever when shifting from direct to overdrive; the transmission will shift when synchronization with the engine's speed is reached. Accelerate the engine only after the transmission has shifted.

11.

To shift from 5th overdrive to 6th direct, partially disengage the clutch, shift into 6th—but before engaging the clutch—flip the splitter control button down into the direct drive position; then engage the clutch, and accelerate the engine.

11.

Do not move the control button while the shift lever is in neutral.

12.

Shift upward through each of the high range gears, alternating the procedures in steps 10 and 11, above.

Downshifting

1.

Downshift from 8th overdrive to 8th direct without moving the shift lever. Flip the splitter control button down to the direct drive position, then immediately release the accelerator, and press and release the clutch pedal. Accelerate the engine only after the transmission has shifted.

2.

To downshift from 8th direct to 7th overdrive, flip the splitter control button up to the overdrive position, then immediately double-clutch through neutral, moving the shift lever from 8th to 7th gear.

3.

Downshift through each of the high range gears alternating the procedures in steps 1 and 2, above, until reaching 5th direct.

4.

While in 5th direct, and ready for the next downshift, push the range selection lever down into low range. Double-clutch through neutral, and shift into 4th gear. See Fig. 8.17 . As the shift lever passes through neutral, the transmission will automatically shift from high range to low range.

5.

With the transmission in low range, downshift through the low range gears as conditions require.

IMPORTANT: Never use the clutch brake when downshifting, or as a brake to slow the vehicle.

Meritor Engine Synchro Shift (ESS) Automated Models

General Information, ESS

9–Speed and 10–Speed M, MO, RS, and RSX Models

Meritor 9-speed and 10-speed automated transmissions do not require use of the clutch except to start and stop the vehicle.

NOTE: Meritor M and MO series ESS transmissions are available only on vehicles equipped with either Caterpillar or Cummins electronic engines. Meritor RS and RSX series ESS transmissions are only available on vehicles equipped with Detroit Diesel electronic engines.

The ESS system works with the engine fuel control system to automatically synchronize engine rpm to road speed during gear changes. Use the clutch only to start and stop the vehicle and to shift into forward or reverse. The HI and LO ranges are automated, so the driver does not have to select ranges. A "break torque" feature allows the driver to move the shift lever and take the transmission out of gear without changing throttle position. Throttle position can be maintained while braking and downshifting through the gears when stopping the vehicle, as well as on steep grades.

The major components of the ESS system are the system switch, shift-intent switch, input and output shaft speed sensors, a Neutral position sensor, and an electro-pneumatic solenoid.

Operation, ESS

The ESS system collects and relays information pertaining to the positions of the shift-intent and system switches ( Fig. 8.18 ), transmission input and output shaft speeds, and shift lever position. The information is received by the engine Electronic Control Module (ECM) which signals the fuel control system to increase or decrease engine rpm to match road speed. The ECM also controls HI and LO range selection in the auxiliary case on the rear of the transmission.

1. Shift-Intent Switch
2. System Switch

Fig. 8.18, ESS Shift Handle

A. Press the top portion (engage the first position) of the shift-intent switch to begin an upshift.
B. Press the top portion again (engage the second position) to break torque.

Fig. 8.19, ESS Upshifting Using the Shift-Intent Switch

The system switch ( Fig. 8.18 ) is the lower switch located on the driver's side of the shift handle. It controls ESS system operation. When in the down position, the system is operating and the word ON is visible on the switch. In the up position, the word OFF is visible, the system is not operating, and the transmission can be shifted manually.

The shift-intent switch ( Fig. 8.18 ) is the upper switch on the driver's side of the shift handle. It has four positions and controls upshifting and downshifting by communicating to the ECM the driver's intention of changing gears.

NOTE: If the system switch is OFF, use the shift-intent switch to select between ranges. Push the top of the switch ( Fig. 8.19 ) to select the HI range on upshifts and the bottom of the switch ( Fig. 8.20 ) to select the LO range on downshifts.

A. Press the bottom portion (engage the first position) of the shift-intent switch to begin a downshift.
B. Press the bottom portion again (engage the second position) to break torque.

Fig. 8.20, ESS Downshifting Using the Shift-Intent Switch

Ensure that the transmission is in neutral (N) when you start the vehicle. If the vehicle is started in gear, it will suddenly move forward or backward which could result in personal injury and damage to property and the transmission.

Starting the Vehicle

1.

Ensure that the shift lever is in the neutral (N) position.

2.

Push the clutch pedal to the bottom of its travel to engage the clutch brake.

3.

Start the engine.

4.

Slowly release the clutch pedal.

5.

Allow the system air to build up to the range specified on the gauge.

6.

Release the parking brake.

Shifting Into a Starting Gear

Always use the proper starting gear. Do not shift into neutral and coast, as this will result in damage to the transmission.

1.

Press the system switch down, into the ON position, to activate the ESS system.

2.

Press the top portion of the shift-intent switch.

IMPORTANT: Use the clutch brake only when initially engaging a gear with the vehicle standing still.

3.

Push the clutch pedal to the bottom of its travel so that the clutch brake stops the transmission input shaft from rotating.

4.

Move the shift lever and engage a starting gear.

5.

Slowly release the clutch pedal.

NOTE: If you do not shift the transmission out of neutral into a gear within two seconds, the ESS system will "time out" and deactivate. The transmission returns to manual operation. To reactivate the ESS system, press the shift-intent switch again. See the following procedures for upshifting and downshifting for instructions on how to use the shift-intent switch.

Upshifting

1.

To upshift into the next higher gear:

1.1

Press the top portion of the shift-intent switch.

1.2

Apply pressure with the shift lever toward the neutral position.

1.3

Press the top portion of the shift-intent switch again, far enough so that the switch goes into a second position inside the body of the shift handle. Then release the switch. See Fig. 8.19 . This will break torque.

1.4

Immediately move the shift lever to the neutral position.

1.5

Allow engine rpm to slow down enough to synchronize with road speed.

1.6

Move the shift lever to the next higher gear.

2.

To upshift through the rest of the gears, repeat the substeps above. Before each upshift, push the top of the shift-intent switch into the shift handle body to break torque. The range shift is automatic.

3.

To skip a gear, press the shift-intent switch into the shift handle body, while in Neutral, one time for every gear that is skipped.

Downshifting

1.

To downshift into the next lower gear.

1.1

Press the bottom portion of the shift-intent switch.

1.2

Apply pressure with the shift lever toward the neutral position.

1.3

Press the bottom portion of the shift-intent switch again, far enough so that the switch goes into a second position inside the body of the shift knob. Then release the switch. See Fig. 8.20 . This will break torque.

1.4

Immediately move the shift lever to the neutral position.

1.5

Allow engine rpm to speed up enough to synchronize with road speed.

1.6

Move the shift lever to the next lower gear.

2.

To downshift through the rest of the gears, repeat the substeps above. Before each downshift, push the bottom of the shift-intent switch into the shift handle body to break torque. The range shift is automatic.

3.

To skip a gear, press the shift-intent switch into the shift handle, while in neutral, one time for every gear that is skipped.

Reverse

1.

Press the system switch on the shift handle so that it is in the ON position and the ESS system is activated.

2.

Push the clutch pedal to the bottom of its travel so that the clutch brake stops the transmission input shaft from rotating.

3.

Move the shift lever and engage reverse.

4.

Slowly release the clutch pedal and move the vehicle in the reverse direction.

NOTE: If a HI reverse range is required, follow the steps below.

5.

Press the system switch on the shift handle so that it is in the OFF position and the ESS system is deactivated.

6.

Press the top portion of the shift-intent switch to engage the HI range.

7.

Push the clutch pedal to the bottom of its travel so that the clutch brake stops the transmission input shaft from rotating.

8.

Move the shift lever and engage reverse.

9.

Slowly release the clutch pedal and move the vehicle in the reverse direction.

9.

See Fig. 8.21 for two ESS 9-speed shift patterns and one ESS 10-speed shift pattern.

A. 9-Speed Shift Pattern with LO Gear
B. 9-Speed Shift Pattern
C. 10-Speed Shift Pattern

Fig. 8.21, Meritor ESS 9- and 10-Speed Shift Patterns

Eaton Fuller UltraShift PLUS Automated Transmissions

Eaton Fuller UltraShift PLUS automated transmissions use shift selection software and electric clutch actuation; a clutch pedal is not needed to operate the vehicle. These transmissions use the four-position SmartShift control (see Fig. 8.1 ) on the steering column to select mode, direction, neutral, low, and to make manual shifts. To know what gear the transmission is in, see the current gear indicator on the dash. Forward shifts can be made either manually or automatically.

Power Up

NOTE: Engine cranking is delayed until the transmission power-up is complete and the gear display shows a solid "N".

1.

With the parking brake set, turn the ignition switch to the ON position.

2.

Start the engine.

3.

Apply the service brake.

NOTE: If the service brake is not applied while selecting a starting gear, the initial start gear will not be found and the driver will need to select Neutral and press the service brake while selecting the desired mode.

4.

Select the desired mode and starting gear. (Inappropriate start gear selections are ignored to avoid damaging the transmission.)

5.

Release the parking brake.

6.

Release the service brake and apply the accelerator.

Power Down

1.

Select Neutral on the shift control.

NOTE: If the gear display does not show a solid "N", neutral has not yet been obtained. Neutral should always be reached before powering down an UltraShift PLUS, except in cases of emergency.

2.

Set the parking brake.

3.

Turn off the ignition, and shut down the engine.

Reverse (R)

NOTE: If attempting to select a non-Neutral mode without applying the service brakes, the transmission will not shift into gear. To shift into gear, select Neutral, apply the service brakes, and select the desired mode again. Also, the vehicle will not engage reverse above 2 mph (3 km/h).

Reverse (R) is at the upper end of the four-position selector switch located at the end of the SmartShift control. To select R, press in the neutral lock button and move the selector switch to the position above neutral. The default Reverse gear is engaged.

NOTICE

Avoid launching the vehicle in high range. Launching the vehicle in high range increases the likelihood of clutch abuse and could be detrimental to clutch life.

Automatic Mode (AUTO)

In automatic drive mode (AUTO), upshifts and downshifts are made by the UltraShift PLUS without driver intervention. Press in the neutral lock button, move the selector switch to Drive (D), and press down on the throttle pedal. The transmission will shift automatically.

NOTE: If attempting to select a non-Neutral mode without applying the service brakes, the transmission will not shift into gear. To shift into gear, select Neutral, apply the service brakes, and select the desired mode again.

In Drive, the start gear is automatically selected. The selected start gear can vary depending on several vehicle inputs such as load, grade, and axle/transmission ratio. The start gear can be changed using the SmartShift control, provided the selected gear would allow the vehicle to launch without damaging the transmission. If the start gear is changed using the SmartShift control, it will be the default until the vehicle is powered down or the selection is changed again manually.

IMPORTANT: Prior to ascending a steep grade, either reduce the default start gear by one (using the SmartShift control) or apply full throttle for the duration of the grade so the vehicle maintains the proper engine and vehicle speed during the entire grade.

In Drive, the transmission automatically performs upshifts and downshifts. However, when the transmission is near the shift point, the shift can be forced using the upshift or downshift function of the SmartShift control.

NOTE: The transmission may deny a shift while ascending or descending a grade if the load of the vehicle and grade of the terrain in combination with the drivetrain ratio and engine torque fall outside of the acceptable range to perform a shift. If the shift is denied, a tone will sound.

Manual Mode (MAN)

In manual mode (MAN), the driver selects upshifts and downshifts instead of letting the UltraShift PLUS select them automatically. Manual shifting may be helpful when traversing a work site, railroad tracks, or steep grades, for example. To drive forward, press in the neutral lock button, move the selector switch to Drive (D), and press down on the throttle pedal. To shift up, pull the lever up (towards you); to shift down, push the lever down (away from you). The system holds the current gear unless a shift is requested or if the system initiates a manual mode override.

NOTE: The transmission may deny a shift while ascending or descending a grade if the load of the vehicle and grade of the terrain in combination with the drivetrain ratio and engine torque fall outside of the acceptable range to perform a shift. If the shift is denied, a tone will sound.

NOTE: If attempting to select a non-Neutral mode without applying the service brakes, the transmission will not shift into gear. To shift into gear, select Neutral, apply the service brakes, and select the desired mode again.

Manual Mode Override

The system is equipped with a manual mode override function. If the vehicle is being "back driven" (for example, descending a grade and vehicle speed exceeds engine speed) and the engine speed is excessively high, the system will upshift automatically. Also, if the start gear is changed and it causes the engine to lug at takeoff, the system will override the current position and select the best available gear.

Low (L)

Low (L) is at the lower end of the four-position selector switch located at the end of the SmartShift control. Use Low when wanting 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. To select Low, press in the neutral lock button and move the selector switch to the L position. The lowest available start gear will be selected (the starting gear cannot be changed in Low).

If Low is selected while moving, the transmission will not upshift (unless the system initiates a Low override). The system will downshift at the earliest opportunity to provide maximum engine braking.

NOTE: If attempting to select a non-Neutral mode without applying the service brakes, the transmission will not shift into gear. To shift into gear, select Neutral, apply the service brakes, and select the desired mode again.

Low Override

The system is equipped with a Low override function. If the vehicle is being "back driven" (for example, descending a grade and vehicle speed exceeds engine speed) and the engine speed is excessively high, the system will upshift automatically. Also, if the start gear is changed and it causes the engine to lug at takeoff, the system will override the current position and upshift.

Clutch Abuse Protection

Although a vehicle equipped with an UltraShift PLUS uses an automated clutch, the clutch can still overheat and slip with improper use. The clutch abuse protection feature helps protect the clutch if the automated clutch starts to overheat. When the clutch abuse protection feature initiates and sounds a warning tone, full clutch actuation must be completed quickly. If it is not completed quickly enough, the system will either open the clutch (if the throttle pedal is not being pressed) or close the clutch (if the throttle pedal is being pressed). If the abuse continues, the system will open the clutch and take away throttle control briefly to allow the clutch to cool down.

To protect the clutch:

Select the lowest possible start gear for the application.

Use Creep Mode when appropriate.

Use the service brakes and the Hill Start Aid when launching on a grade.

Minimize the time it takes to engage the clutch from rest.

Do not use the throttle to hold the vehicle on a grade; use the service brakes.

Do not use the throttle to stop roll back on an incline after Hill Start Aid disengages; use the service brakes, and then relaunch.

Do not continually start and stop, especially when loaded; use a lower gear or Creep Mode.

Creep Mode

The Creep Mode function allows the vehicle to maintain a constant speed at engine idle without the driver holding the throttle pedal position. This mode is useful for very low-speed maneuvering and applications where steady vehicle speed is required. The vehicle speed is determined by the selected gear ratio operating at governed low engine idle speed. Any available gear may be selected, though the transmission will downshift or exit Creep Mode to prevent stalling if the engine lugs due to load conditions.

By default, Creep Mode can be activated while in Manual Mode or Low. Eaton's ServiceRanger diagnostic software can be used to enable Creep Mode in Automatic Mode and/or Reverse.

Engaging Creep Mode

To engage Creep Mode:

1.

Select Low or Manual Mode and the 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 governed low engine idle speed.

Exiting Creep Mode

To exit Creep Mode, apply the throttle pedal to accelerate temporarily, or select a higher gear in Manual Mode. (Creep Mode can be resumed in the selected gear by releasing the throttle pedal.)

NOTE: The transmission will exit Creep Mode if the engine lugs 150 rpm below the governed low engine idle speed. In this case, a lower gear should be selected if available.

Hill Start Aid

UltraShift PLUS transmissions are equipped with a Hill Start Aid (HSA) feature to prevent the vehicle from rolling while on grades steeper than 3% and allow for a controlled launch. A grade sensor is used to determine when to engage the feature.

HSA is "on" by default. It can be turned off by pressing and releasing the override switch on the dash. HSA will turn back on after the first successful launch.

When the vehicle is stopped on a grade greater than 3% and in a forward mode or reverse, depress the service brakes then release them. The vehicle will begin to move after 3 seconds, and the clutch will perform partial engagements to slow the vehicle motion. Either step on the brake or apply the throttle to continue negotiating the grade.

Engine Overspeed Protection

The system will upshift if necessary to prevent engine overspeed in Drive, Manual, and Low.

Shuttle Shifting

Shuttle shifting from reverse to any forward mode is only allowed if the vehicle speed is approximately zero.

Auto Start Gear Selection and Override

The UltraShift PLUS system uses various inputs to automatically select the best start gear in Drive and Manual. This selection can be changed using the SmartShift control; however, if the selection requested could cause damage or engine lugging, the request will be denied and a tone will sound.

Skip Shifting

When appropriate, the UltraShift PLUS system may skip shift in Drive. When prevailing conditions like load and grade allow, skip shifts can be performed in Manual mode using the SmartShift control.

Auto Neutral

The UltraShift PLUS system will automatically shift to neutral if the vehicle is left in Drive and the parking brake is set. "AN" will show on the gear display. To re-engage the transmission, select Neutral and then either Drive or Reverse on the shift control (it will re-engage regardless of whether the parking brake is released).

Automatic Traction Control

The UltraShift PLUS system requires the Automatic Traction Control (ATC) option to be enabled when driving in soft soil/sand to prevent wheel slippage and shifting issues. The ATC system has two modes: "normal" (for sand and loose road surface) and a mud/snow setting.

ATC Normal Mode

In normal mode, the system will engage the brakes on the wheel or side that the wheel slip is occurring to help the vehicle gain traction. 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; heavy/full throttle raises the point of the acceptable wheel slip.

Adhere to the following points when driving in ATC normal mode:

If using Automatic mode in soft soil and/or sand, maintain the engine speed between 1000 and 1300 rpm to prevent unnecessary upshifting.

If using Manual mode in soft soil and/or sand, do not attempt an upshift 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.

ATC Mud/Snow Mode

To select the mud/snow mode, depress the ATC switch. 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; heavy/full throttle raises the point of the acceptable wheel slip.

Load-Based Shifting

The UltraShift PLUS system is adaptive and will change the shift points based on grade, engine RPM, throttle position, and vehicle load. After changing loads or powering up, the system needs to relearn these inputs for the first few shifts to make the proper adjustments.

Coasting

When coasting to a stop on level terrain, the UltraShift PLUS system may not downshift into the lower gears. It will select a gear after the throttle is applied.

Ultrashift Diagnostics

System Problem

In the event of a problem, do the following steps.

1.

Note the driving conditions at the time the problem occurred.

2.

Record the status of the transmission at the time of the problem (AUTO or MAN mode, gear setting R, N, D, or L, current gear, engine speed, etc.)

3.

Reset the system, using the procedure below.

Reset Procedure

Transmission operation can sometimes be restored by doing the following reset procedure:

1.

Stop the vehicle when it is safe to do so. Set the parking brake.

2.

Place the selector switch in neutral and turn off the ignition.

3.

Check all harness connectors as described in Chapter 11 .

4.

Wait at least two minutes with the engine shut down.

5.

Restart the engine.

If the problem continues, contact an authorized Freightliner or Eaton service facility.