Transmissions
Eaton® Fuller® Straight-Shift Models
Refer to the Eaton website for additional information, www.roadranger.com .
General Information, Eaton Straight-Shift
Eaton Fuller straight-shift model transmissions are not synchronized. They have seven forward speeds and one reverse speed. See Fig. 8.1 for the shift pattern. They are designed for use with on-highway, fuel economy engines, where a minimum of shifting is desired and less gear reduction is acceptable.
Fig. 8.1, Eaton Fuller Straight-Shift Model Transmissions Shift Pattern
Operation, Eaton Straight-Shift
1.
Always use 1st gear when starting to move the vehicle forward.
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.
Use double-clutching between all upshifts and downshifts.
4.
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.
IMPORTANT: Never use the clutch brake when downshifting, or as a brake to slow the vehicle.
Upshifting
1.
Position the gear shift lever in neutral, then start the engine. Bring the air system pressure up to 100 to 120 psi (689 to 827 kPa).
2.
Depress 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. Accelerate to engine governed speed.
3.
Once governed speed has been reached, disengage the clutch, and shift the lever to neutral. Engage the clutch; allow the engine speed to drop about 800 rpm (the rpm drop may vary with engines of different governed speeds), then disengage the clutch. Move the shift lever to 2nd gear, then engage the clutch, and accelerate to engine governed speed.
3.
Continue shifting upward, from 2nd to 3rd gear, 3rd to 4th gear, and 4th to 5th gear, using the same sequence. See Fig. 8.1 for the shift pattern.
4.
Again, at governed speed, disengage the clutch, and shift into neutral. Engage the clutch; allow the engine speed to drop about 500 rpm (rpm drop may vary with engines of different governed speeds), then disengage the clutch. Move the shift lever to 6th gear, then engage the clutch, and accelerate to engine governed speed.
4.
Shift into 7th gear, using the same sequence.
Downshifting
When downshifting, shift down from 7th gear through each lower gear, as follows:
1.
Allow the engine speed to drop about 500 rpm (rpm drop may vary with engines of different governed speeds) below the governed speed. Depress the clutch pedal enough to release the torque, then shift into neutral. Engage the clutch and bring the engine rpm up to governed speed. Disengage the clutch, shift into gear, and engage the clutch smoothly.
1.
Follow the same sequence to downshift from 6th into 5th gear.
2.
When in 5th gear, and ready for the next downshift, allow the engine speed to drop about 800 rpm (rpm drop may vary with engines of different governed speeds) below the governed speed. Depress the clutch pedal enough to release the torque, then shift into neutral. Engage the clutch and bring the engine rpm up to governed speed. Disengage the clutch, shift into 4th gear, and engage the clutch smoothly.
2.
Follow the same sequence to downshift from 4th into 3rd, 3rd into 2nd, and from 2nd into 1st gear.
IMPORTANT: Never use the clutch brake when downshifting, or as a brake to slow the vehicle.
Eaton Fuller Range-Shift Models
Refer to the Eaton website for additional information, www.roadranger.com .
General Information, Eaton Range-Shift
Range-Shift transmissions are typically upshifted by moving the shift lever through all of the low gear positions and then activating a range switch to provide an additional set of ratios in the high range using the same shift lever positions as used in low range. The shift lever then is moved sequentially through each position as before but all the positions now provide a higher gear ratio. The initial low gear is often used only in low range.
Eaton Fuller Range-Shift transmissions are not synchronized in the front section, but the range section is synchronized to prevent grinding gears during range shifts.
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, RTO, and RTX Models
Eaton Fuller 9-speed range-shift model transmissions have a 5-speed front section, and a 2-speed rear range section. The low gear in the front sections of the RT-8609 and A and B ratio transmissions is used only as a starting ratio. The high gear in the front section of the "P" 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. 8.2 for the shift patterns, noting that the 3rd/7th and 4th/8th shift positions in the RT (direct ratio) and RTX-B (overdrive ratio) transmissions are opposite of the RTO (overdrive ratio) transmissions. The RTX-P ratio transmissions have the 1st/5th shift positions where LO is in the A and B ratio transmissions. The top gear in the RTX-P ratio transmissions is called 9th gear.
10-Speed RT, RTO, and RTX Models
Eaton Fuller 10-speed range-shift model transmissions have ten selective, evenly-spaced forward ratios. Each transmission consists of a 5-speed front section, and a 2-speed rear range section. The ten 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. 8.3 for the shift patterns, noting that 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.
- A. All RT and RTX-B Transmissions
- B. All RTO Transmissions
- C. All RTX-P Transmissions
- D. Up for High Range
- E. Down for Low Range
Fig. 8.2, Eaton Fuller 9-Speed Range-Shift Transmissions Shift Patterns
- A. All RT and RTX Transmissions
- B. All RTO Transmissions
- C. Up for High Range
- D. Down for Low Range
Fig. 8.3, Eaton Fuller 10-Speed Range-Shift Model Transmissions Shift Patterns
Operation, Eaton 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.
Use double-clutching 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.
Depress 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.
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.
CAUTION
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. With the lever in high range, double-clutch through neutral, and shift into the bottom gear of the high range ( Table 8.1 ). As the shift lever passes through neutral, the transmission will automatically shift from low range to high range.
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Eaton Fuller Shift Progressions
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TRANS. MODEL
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LOW RANGE
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HIGH RANGE
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Off-Highway
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On-Highway
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9-Speed Direct or Overdrive (RT or RTX)
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9-Speed Direct (RTX-P)
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9-Speed Overdrive (RTO)
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10-Speed Direct or Overdrive (RT or RTX)
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10-Speed Overdrive (RTO)
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Table 8.1, Eaton Fuller Shift Progressions
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.
CAUTION
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. With the lever in low range, double-clutch through neutral, and shift into the top gear of the low range. 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 Models
Refer to the Eaton website for additional information, www.roadranger.com .
General Information, Eaton 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 ratios 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 RTO Models
Eaton Fuller 13-speed RTO model 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. 8.4 for the shift patterns.
All of the thirteen speeds are controlled with one shift lever. Built into the shift knob of the lever, are a range preselection lever and a splitter control button (on the side of the shift knob), that control range selection and gear splits, respectively.
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.
- A. Up for High Range
- B. Down for Low Range
- C. Forward for Overdrive
- D. Rearward for Direct
- 1. Splitter Control Button
Fig. 8.4, Eaton Fuller 13-Speed RTO Model Transmissions Shift Patterns
18-Speed RTLO Models
Eaton Fuller 18-speed RTLO model transmissions have eighteen forward speeds and four reverse, 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.
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 eighteen speeds are controlled with one shift lever. Built into the shift knob of the lever, are a range preselection lever and a splitter control button (on the side of the shift knob), that control range selection and gear splits, respectively.
Operation, Eaton Splitter and Range-Shift
IMPORTANT: On 13-speed transmissions, 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).
- A. Up for High Range
- B. Down for Low Range
- C. Forward for Overdrive
- D. Rearward for Direct
- 1. Splitter Control Button
Fig. 8.5, Eaton Fuller 18-Speed RTLO Model Transmission Shift Patterns
4.
For 13-speed transmissions:
4.
Depress 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.
Depress 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. 8.5 ) 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. 8.4 .
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. 8.5 ). 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. 8.4 ) 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. 8.5 ) 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 Models
Refer to the Eaton website for additional information, www.roadranger.com .
General Information, Deep-Reduction
10-Speed RTO Models
Eaton Fuller 10-speed RTO model transmissions have a 5-speed front section, and a 2-speed rear-range section, with a deep reduction gear. 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. 8.6 for the shift pattern, noting that the 3rd/7th and 4th/8th shift positions in the RTX-LL transmissions are opposite of the RTO-LL transmissions.
- A. All RTO Transmissions
- B. All RTX Transmissions
- C. Up for High Range
- D. Down for Low Range
- E. Forward for IN
- F. Rearward for OUT
- 1. Deep Reduction Button
Fig. 8.6, Eaton Fuller 10-Speed RTO Model Transmissions Shift Patterns
15-Speed RT, RTO, and RTX Models
Eaton Fuller 15-speed RT, RTO, and RTX model 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 ten 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. 8.7 for the shift patterns, noting that 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, 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.
- A. Eaton Fuller RT and RTX transmissions shift pattern
- B. Eaton Fuller RTO transmissions shift pattern
- 1. High Range
- 2. Low Range
- 3. Deep Reduction
- 4. High Range
- 5. Low Range
- 6. Forward for IN
- 7. Rearward for OUT
Fig. 8.7, Eaton Fuller 15-Speed RT, RTO and RTX Model Transmissions Shift Patterns
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.
Use double-clutching 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 (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 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 (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.
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Eaton Fuller Shift Progressions
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TRANSMISSION MODEL
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DEEP REDUCTION
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LOW RANGE
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HIGH RANGE
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Adverse Conditions Only
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Off-Highway and Adverse Conditions
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On-Highway and Ideal Conditions
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All Conditions
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15-Speed RTO
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15-Speed RT and RTX
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Table 8.2, Eaton Fuller 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.
2.
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 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. 8.8 for the Super 10 and Top 2 shift knob, and Fig. 8.9 for the Lightning shift knob.
- A. 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. 8.8, Super 10 and Top 2 Shift Knob
- 1. Shift Button
- 2. Service Light
Fig. 8.9, 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. 8.10 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. 8.11 .
NOTE: The Top 2 and Lightning transmissions use the Super 10 shift pattern when cruise control is off.
Fig. 8.10, Super 10 Shift Pattern
Fig. 8.11, 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
CAUTION
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 range 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.
Depress 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
CAUTION
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.
CAUTION
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.
CAUTION
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.
Eaton Fuller AutoShift™ Automated Transmissions
Refer to the Eaton website for additional information, www.roadranger.com .
General Information, AutoShift
18-Speed RTLO Models
Eaton Fuller 18-speed RTLO model transmissions have 18 forward speeds and four reverse speeds. The transmission consists of a 5-speed front section and a 3-speed rear section. The driver must use the clutch to start and stop the vehicle.
10-Speed RTO Models
Eaton Fuller 10-speed RTO model 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.
Both 10- and 18-speed AutoShift models are partially automated transmissions. 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 Gear Display Module ( Fig. 8.12 ), mounted on the dashboard, indicates the current gear position. 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. 8.12, Gear Display Module
The Driver Command Console (DCC) replaces the shift lever and controls the transmission's shift patterns. On newer models, the SmartShift™ controller replaces the DCC. If your vehicle is equipped with a SmartShift controller, see the information under the heading "Freightliner SmartShift Transmission Shift Control."
The Standard DCC ( Fig. 8.13 ) has indicators for the three forward positions: Drive, Low (2nd gear), and Low1 (1st gear), plus Reverse and Neutral positions. Service and wait lamps are also located on the console. The gear select handle contains only a gear select lever detent button.
- A. Console Top View
- B. Select Handle Side View
- 1. Indicator Lamps
- 2. Gear Position Indicator
- 3. Detent Button
Fig. 8.13, Standard Driver Command Console (DCC)
- A. Console Top View
- B. Select Handle Side View
- 1. Indicator Lamps
- 2. Gear Position Indicator
- 3. Upshift Button
- 4. Detent Button
- 5. Downshift Button
Fig. 8.14, Enhanced Driver Command Console (DCC)
The Enhanced DCC ( Fig. 8.14 ) has indicators for the three forward positions: Drive, Hold, and Low, plus Reverse and Neutral positions. Service and wait lamps are also located on the console. The gear select handle contains upshift and downshift buttons and a gear select lever detent button.
The shifter 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
WARNING
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
NOTE: To drive in reverse, first depress the clutch.
1.
Move the gear select lever to the "R" position.
2.
On 10-speed models, select either LO or HI reverse by depressing either the downshift or upshift button ( Fig. 8.14 ) on the gear select handle (if equipped).
2.
On 18-speed models, four reverse gears are available. Select either low range, low split (1R); low range, high split (R); high range, low split (1H); high range, high split (H).
3.
Release the clutch.
NOTE: The clutch must be used for starting and stopping.
Driving in the "D" Mode
NOTE: The drive mode is used for normal driving conditions.
1.
Fully depress the clutch.
2.
Move the gear select lever from neutral to drive.
NOTE: The clutch must be fully depressed to shift from neutral to drive.
3.
Upshifting and downshifting are performed automatically with no driver interaction required.
NOTE: The clutch must be used for starting and stopping.
Parking the Vehicle
1.
With the clutch pedal depressed, move the gear select lever to neutral.
2.
Ensure that a solid "N" appears on the gear display module. See Fig. 8.12 .
NOTE: If the gear display does not show a solid "N," the transmission is not yet in neutral.
3.
Set the parking brakes.
4.
Slowly release the clutch pedal.
Selecting the Starting Gear (push button equipped gear select handle only)
NOTE: On vehicles equipped with upshift and downshift buttons ( Fig. 8.14 ) on the gear select handle (enhanced DCC), you may select the starting gear. The gear you select is only active while the vehicle is running. The transmission resets to the default starting gear after you have shut off the engine. Depending on the vehicle's load, you may select gears 1 through 5 as the starting gear.
1.
With the vehicle stopped, place the gear select lever in the "D" or "H" position to select a starting gear.
2.
Select the starting gear with the upshift or downshift buttons on the gear select handle.
Driving in the "H" Mode (if equipped)
NOTE: You must use the upshift and downshift buttons on the gear select handle to change gears while in the "H" (hold) mode.
1.
Depress the clutch pedal.
2.
Place the shift lever in the "H" mode.
3.
Select the starting gear you want.
4.
Slowly release the clutch pedal.
Upshifting
NOTE: In the "H" mode you, the driver, decide when to upshift and downshift.
1.
Accelerate.
2.
Press the upshift button on the gear select handle. To skip shift, press twice.
3.
The transmission automatically selects and shifts to the next gear.
Downshifting
1.
Decelerate.
2.
Press the downshift button on the gear select handle. To skip shift, press twice.
3.
The transmission automatically selects and shifts to the next gear.
Spicer Straight-Shift Models
Refer to the Spicer/TTC website for additional information, www.ttcautomotive.com .
General Information, Spicer Straight-Shift
Spicer 7-speed series transmissions are synchronized in all gears except 1st and reverse. They have seven forward gears and one reverse gear. See Fig. 8.15 for the shift pattern.
Fig. 8.15, Spicer 7-Speed Transmission Shift Pattern
Operation, Spicer Straight-Shift
1.
Always use 1st gear when starting to move the vehicle forward.
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. For normal upshifts and downshifts, only a partial disengagement of the clutch is necessary to break engine torque.
3.
Double-clutch only when shifting out of neutral, or when shifting down into 1st.
Upshifting
1.
Position the gear shift lever in neutral, then start the engine. 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. Accelerate to engine governed speed.
3.
Once governed speed has been attained, disengage the clutch enough to break torque, and move the shift lever to 2nd gear. Then engage the clutch, and accelerate back to engine governed speed.
4.
Continue shifting upward, using the same sequence described in step 3 above. See Fig. 8.15 for the shift pattern.
Downshifting
When downshifting, shift progressively down through each successive lower gear, as follows:
1.
Depress the clutch pedal enough to release the torque, shift into the next lower gear, and engage the clutch smoothly while accelerating the engine to keep the vehicle moving at the desired speed.
2.
Continue downshifting, as conditions require, using the same sequence described above. When shifting down into 1st gear, remember that 1st gear isn't synchronized. Double-clutch when shifting down into 1st gear.
IMPORTANT: Never use the clutch brake when downshifting, or as a brake to slow the vehicle.
Meritor™ Range-Shift Models
Refer to the Meritor website for additional information, www.arvinmeritor.com .
General Information, Meritor Range-Shift
Range-shift transmissions are typically upshifted by moving the shift lever through all of the low gear positions and then activating a range switch to provide an additional set of ratios in the high range using the same shift lever positions as used in low range. The shift lever then is moved sequentially through each position as before but all the positions now provide a higher gear ratio. 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 Models
Meritor 9-speed M, MO, RM, RMO, and RMX model 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. 8.16 for the shift patterns.
- A. All Standard "A" and "B" Ratios
- B. RMO Models with "A" and "B" Ratios
- C. All "R" Ratios
- 1. Up for High Range
- 2. Down for Low Range
Fig. 8.16, Meritor 9-Speed Transmission Shift Patterns
NOTE: The 3rd/7th and 4th/8th shift positions in the standard "A" and "B" ratio transmissions (both direct drive and overdrive) are opposite of the RMO model (overdrive only) transmissions.
The "R" ratio transmissions have the 1st/5th shift positions where low is in the "A" and "B" ratio transmissions. The top gear in the "R" ratio transmissions is called 9th gear.
10-Speed Models
Meritor 10-speed transmissions have ten evenly-spaced forward ratios. Each transmission consists of a 5-speed front section, and a 2-speed auxiliary section. The ten 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. 8.17 for the shift patterns.
- A. All Standard Models
- B. RMO Models Only
- C. Up for High Range
- D. Down for Low Range
Fig. 8.17, Meritor 10-Speed Transmission Shift Patterns
NOTE: The 4th/9th and 5th/10th shift positions in the standard "A" and "B" ratio transmissions (both direct drive and overdrive) are opposite of the RMO model (overdrive only) transmissions.
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 to continue upshifting until the top gear in the low range-4th gear in 9-speed models, 5th gear in 10-speed models. See Table 8.3 .
|
Meritor Shift Progressions
|
|||
|---|---|---|---|
|
MODEL
|
LOW RANGE
|
HIGH RANGE
|
|
|
Off-Highway
|
On-Highway
|
||
|
9-Speed Standard
|
|
|
|
|
9-Speed "R" Ratio
|
|
|
|
|
9-Speed RMO Models
|
|
|
|
|
10-Speed Standard
|
|
|
|
|
10-Speed RMO Models
|
|
|
|
Table 8.3, Meritor 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, 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, 6th gear in 10-speed models-double-clutching 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 Models
Refer to the Meritor website for additional information, www.arvinmeritor.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 ratios 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 Models
Meritor 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. 8.18 .
- A. Up for High Range
- B. Down for Low Range
- C. Up for Overdrive
- D. Down for Direct
- 1. Splitter Control Button
Fig. 8.18, Meritor 13-Speed Transmission Shift Pattern
All of the thirteen speeds are controlled with one shift lever. Built into the shift knob of the lever, are a range selection lever and a splitter control button (on the side of the shift knob), that control range selection and gear splits, respectively.
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 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. 8.18 . 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
Refer to the Meritor website for additional information, www.arvinmeritor.com .
General Information, ESS
9–Speed and 10–Speed M, MO, RS, and RSX Models
Meritor 9–Speed and 10–Speed M, MO, RS, and RSX Model 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. 8.19 ), 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. 8.19, ESS Shift Handle
The system switch ( Fig. 8.19 ) 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. 8.19 ) 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.
- 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. 8.20, ESS Upshifting Using the Shift-Intent Switch
- 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. 8.21, ESS Downshifting Using the Shift-Intent Switch
WARNING
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
CAUTION
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. 8.20 . 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. 8.21 . 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. 8.22 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. 8.22, Meritor ESS 9- and 10-Speed Shift Patterns