Operation

Operation
Driver Instructions
Eaton Fuller Advantage®
Heavy-Duty Automated
Transmissions
TRDR0980 EN-US
January 2017
FA(M)-XX810B-EA3
FAO-XX810C-EA3
FAO(M)-XX810C-EA3
FAO(M)-XX810S-EC3
FAO(M)-XX810S-EN3
FAO(M)-XX810S-EP3
Warnings and Cautions
Warnings and Cautions
Definitions
!
Warning: Indicates you will be Severely Injured or Killed if you do not follow
the indicated procedure.
!
Caution: Indicates an Immediate Hazard, which could result in Severe Personal Injury if you do not follow the indicated procedure.
!
Important: Indicates vehicle or property damage could occur if you do not follow the indicated procedure.
Note: Note indicates additional detail that will aid in the diagnosis or repair of
a component or system.
! Warning
Read the entire driver instructions before operating this transmission.
Before starting a vehicle always be seated in the driver's seat, select “N” on
the shift control, and set the parking brake.
If engine cranks in any gear other than neutral, service vehicle
immediately.
Before working on a vehicle, parking the vehicle, or leaving the cab with the
engine running, place the transmission in neutral, set the parking brakes, and
block the wheels.
For safety reasons, always engage the service brakes prior to selecting gear
positions from “N”.
Always ensure that fuel is at a sufficient operating level before operating
vehicle. A loss of engine power could result in inhibited shifting.
i
Warnings and Cautions
! Caution
Do not release the parking brake or attempt to select a gear until the air pressure is at the correct level.
Before operating the PTO, refer to “Transmission Power Take Off
Operation.”
Battery (+) and (-) must be disconnected prior to any type of welding on any
Fuller Advantage equipped vehicle.
! Important
It is a requirement that the driver of a commercial vehicle specified under
paragraph A sections 1-6 of FMCSA regulation 392.10 need only cross railroad grade crossings in a gear that permits the vehicle to complete the crossing without a change of gears.
This can only be achieved by utilizing the MANUAL mode. Please refer to
pages 7 and 8 for correct MANUAL mode operation.
ii
Table of Contents
Warnings and Cautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i
Operation
Shift Console Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gear Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Start-up and Power Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reverse Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MANUAL Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LOW Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transmission Shift Console Mode Configuration / Operation
Standard (Eaton Default) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Urge to Move . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Creep . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Blended Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transmission Configuration Switch . . . . . . . . . . . . . . . . . . . . .
Transmission Power Take Off (PTO)
Stationary PTO Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mobile PTO Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Soft Soil Operation (Heavy-Duty Models Only) . . . . . . . . . . . . . . . .
Sliding Trailer Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Trailer Connecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation with Paving Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transfer Dump Application Power Down and Start-up . . . . . . . . . .
Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
2
3
4
5
7
9
10
11
12
13
14
17
18
18
19
19
20
20
23
Service & Maintenance
General Model Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Proper Clutch Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Proper Transmission Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . .
Vehicle Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
28
30
32
33
36
iii
Operation
Shift Console Modes
Button not used
Service Indicator
SERVICE
- Upshift
R
R - Reverse
N
N - Neutral
D
D - Drive
MANUAL
SHIFT
- Downshift
LOW
EATON FULLER
TRANSMISSIONS
MANUAL
LOW
R
Selects Reverse (see page 4 for more details)
N
Mode used for Start-up and Power down
D
Selects Drive (see page 5 for more details)
MANUAL
Selects MANUAL (see page 7 for more details)
LOW
Selects LOW (see page 9 for more details)
Service
Alerts driver of potential transmission problems
Upshift /
Downshift
Buttons
Used in the MANUAL mode to select upshifts and downshifts
and to change start gear, if available.
Note: The Transmission Shift Console Mode Configuration determines clutch
operation during vehicle launch. (See page 10 for detailed information
regarding clutch engagement options and operation instructions).
!
Warning: The Fuller Advantage® Automated Transmission initiates upshifts
from MANUAL and LOW for engine overspeed protection. Some engines do
not use the Eaton engine overspeed protection.
1
Operation
Gear Display
The Gear Display indicates the current gear position of the transmission.
During an upshift or downshift the gear display may momentarily flash the target gear position.
Transition
Successful Gear
Current Gear
Shift
Solid
Solid
May Momentarily
Flash
The “DASH” indicates the transmission may be torque locked in gear. See
“Service and Maintenance Locked in Gear” section for more details.
“CA” will appear in the gear display if a clutch abuse event is occurring.
“AN” will appear in the gear display if the transmission goes into Auto Neutral.
In heavy-duty Fuller Advantage® Automated models, “GI” may briefly appear
in the gear display after the engine is started. This indicates that the clutch
release bearing will need to be greased soon. See “Optional Automated Lube
Schedule” section for more information.
Note: “GI” stands for grease interval and may be misread as “G1” on gear display.
2
Operation
Start-up and Power Down
Start-up
1.
Turn the ignition key to “ON” and allow the Fuller Advantage® Automated Transmission to power-up.
Note: Engine cranking is delayed until the transmission power-up is
complete and the gear display shows a solid “N.”
2.
3.
Start the engine.
Apply 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 have to
re-select Neutral and press the brake while re-selecting the desired
mode.
4.
Select the desired mode and starting gear on the shift console.
Note: The transmission will override inappropriate start gear selections to avoid driveline damage.
5.
6.
Release the vehicle parking brakes.
Release service brake and apply accelerator.
Note: The Transmission Shift Console Mode Configuration determines clutch
operation during vehicle launch. (See page 10 for detailed information
regarding clutch engagement options and operation instructions).
Power Down
1.
3
!
Select Neutral on the shift control.
• If gear display does not show solid “N,” neutral has not yet been
obtained.
Important: Neutral should always be reached before initiating power
down, except in cases of emergency.
2.
3.
Set the vehicle parking brakes.
Turn ignition key to “OFF” and allow the engine to shut down.
Operation
Reverse Mode
•
Reverse Mode selects default Reverse gear.
Note: If you attempt to select a non-neutral mode without depressing
the service brakes the transmission will not shift into gear and you
will have to return to Neutral and depress the brakes before selecting
the desired mode again.
•
Each time Reverse is selected from Neutral, the default Reverse gear
is engaged.
•
The vehicle will not engage Reverse above 2 mph.
!
Caution: Launching the vehicle in high range increases the likelihood
of clutch abuse, and depending on the level of usage, could have a
detrimental impact on clutch life.
Fuller Advantage®Automated 10-Speed
LO Range
HI Range
4
Operation
Drive Mode
•
Automatically selects the start gear. The selected start gear will vary
depending on several vehicle inputs like load, grade, and axle/transmission ratio. This start gear can be changed by using the up/down
buttons, as long as the selection still falls into a gear that would allow
the vehicle to launch without allowing the transmission to obtain
damage.
Note: If driver attempts to select a non-neutral mode without
depressing the service brakes the transmission will not shift into
gear and you will have to return to Neutral and depress the brakes
before selecting the desired mode again.
•
If the start gear is changed using the up/down buttons, it will remain
as the default until the vehicle is powered down or the selection is
changed with the buttons again.
•
A shift can be advanced by pressing the up/down buttons when the
transmission is near the shift point.
Note: Multiple gear upshifts and downshifts may be allowed when
the shift buttons are pushed multiple times (Each button push equals
one gear change request).
5
•
The transmission may also deny a shift while ascending or descending grades if the load of the vehicle and grade of the terrain in combination with the drivetrain ratio and engine torque will fall outside of
the acceptable range to perform a shift. If the shift is denied it will
sound a tone.
•
As a truck is approaching a hill (or grade) and requires more power
to maintain a constant vehicle speed, SmartAdvantage will provide
the truck with extra torque when it is needed. If the additional toque
is not sufficient, and the truck begins to lose vehicle speed, the
transmission will shift to a lower gear. With a smaller step (gear
split) between the Direct Drive (9th) and Overdrive (10th) gears, the
transmission is capable of downshifting earlier.
Operation
•
Downshifting earlier is a smarter use of direct drive which will combine higher torque with higher RPMs, thus generating more power
which will reduce the vehicle road speed loss. All this takes place
smoothly and swiftly while maintaining the engine in a fuel efficient
RPM range.
•
The close step ratio and SmartAdvantage provides a balance of performance; delivering power when conditions demand it - such as a
combination of steep grade roads, heavy loads, and / or cruise
speeds above 65 mph.
!
!
Important: Prior to ascending a steep grade you should reduce your
default start gear by one or ensure you apply full throttle for the
duration of the grade so the vehicle maintains the proper engine and
vehicle speed during the entire grade. You can button down by using
the down arrow on the shift lever.
Important: If you depress and hold both pedals (even if done accidentally) the launch will be abrupt and the engine and brake forces
may rock and bounce the vehicle. Releasing either pedal will stop
this immediately.
6
Operation
MANUAL Mode
MANUAL mode should be used whenever the driver wants to select the shifts
instead of letting UltraShift select them automatically. For example, when the
driver is moving around the yard, over railroad tracks, or on steep grades.
•
Driver manually selects the start gear and uses the up/down buttons
to shift.
Note: Multiple gear upshifts and downshifts may be allowed when
the shift buttons are pushed multiple times (Each button push equals
one gear change request).
Note: If you attempt to select a non-neutral mode without depressing
the service brakes the transmission will not shift into gear and you
will have to return to Neutral and depress the brakes before selecting
the desired mode again.
•
System holds current gear unless otherwise prompted by using up/
down buttons, except for the “Transmission Override” conditions
noted below.
Note: For optimal vehicle performance, it is recommended the vehicle be operated in “D” Drive mode.
MANUAL / Hold Mode
7
•
The ability to restrict driver use of MANUAL mode is configurable.
The default setting for this configuration is “Disabled”, which allows
standard MANUAL mode operation in all gears.
•
When configured the MANUAL mode becomes a Hold gear function
only (i.e. up/down buttons have no effect). In addition, provides an
alert tone every 10 seconds.
•
If the driver has selected MANUAL mode, and the transmission is in
a gear equal to or greater than the configured Hold Gear; the transmission will remain in the current gear, up/down buttons are disabled (except for “Transmission Override” conditions).
•
Gears lower than the configured hold gear will allow standard MANUAL mode operation.
Operation
!
Warning: The Fuller Advantage® Automated Transmission initiates
upshifts from MANUAL and LOW for engine over speed protection.
Some engines do not use the Eaton engine overspeed protection.
•
The system will automatically shift or inhibit shifts to prevent overspeed or under-speed of the engine.
•
The transmission may also deny a shift while ascending or descending grades if the load of the vehicle, and grade of the terrain in combination with the drivetrain ratio and engine torque will fall outside of
the acceptable range to perform a shift. If the shift is denied it will
sound a tone.
Transmission Manual Override
•
If the vehicle is being back driven and the engine is approaching a
higher than normal level, the transmission system will override the
MANUAL position and perform an upshift.
!
Warning: The Fuller Advantage® Automated Transmission initiates
upshifts from MANUAL and LOW for engine over speed protection.
Some engines do not use the Eaton engine overspeed protection.
•
If the start gear is changed and it causes the engine to lug at takeoff,
the transmission system will override the MANUAL position and
select the best available gear.
!
Important: If you depress and hold both pedals (even if done accidentally) the launch will be abrupt and the engine and brake forces
may rock and bounce the vehicle. Releasing either pedal will stop
this immediately.
8
Operation
LOW Mode
LOW mode should be used any time you want to maximize engine braking and
minimize the use of the brake pedal. For example, when driving down long
grades or when coming to a stop.
•
Selects lowest available gear for start gear. The starting gear cannot
be changed in LOW mode.
Note: If you attempt to select a non-neutral mode without depressing
the service brakes the transmission will not shift into gear and you
will have to return to Neutral and depress the brakes before selecting
the desired mode again.
•
If LOW is selected while moving, the transmission will not upshift
(except for the Transmission Override conditions noted below). The
transmission system will downshift at the earliest opportunity to provide maximum engine braking.
!
Warning: The Fuller Advantage® Automated Transmission initiates
upshifts from MANUAL and LOW for engine over speed protection.
Some engines do not use the Eaton engine overspeed protection.
Note: At higher engine speeds additional engine braking in LOW
Mode could cause a loss of traction when on slippery surfaces.
!
9
Important: If the driver depress and hold both pedals (even if done
accidentally) the launch will be abrupt and the engine and brake
forces may rock and bounce the vehicle. Releasing either pedal will
stop this immediately.
Operation
Transmission Shift Console Mode Configuration /
Operation
Note: Urge to Move and Blended Pedal should not be enabled with CNG
engines.
Note: The Blended Pedal clutch control feature is not available in Drive Mode.
The Transmission Shift Mode Configuration determines clutch operation when
in Reverse/Drive/Manual/Low Mode.
These clutch control engagement options allow optimum mobility for the vehicle application. Each shifter mode can be independently configured to function
with one of the clutch control features below. The default clutch engagement
configuration in all modes is set at Standard from the factory, but can be
changed using Eaton ServiceRanger.
Standard (Eaton Default)
•
Standard allows the driver full control of clutch engagement and the
clutch will open as the accelerator is released, the service brake is
applied and the vehicle comes to a stop.
-
When a gear is engaged; the clutch remains open until the driver
releases the service brake and applies the accelerator.
-
The clutch will open as the accelerator is released, the service
brake is applied and the vehicle comes to a stop.
-
A more aggressive clutch engagement is used in standard
mode.
Launching:
1.
Engage the desired gear.
2.
Release service brake.
3.
Apply accelerator.
Stopping:
1.
Release the accelerator.
2.
Apply service brake.
10
Operation
Urge to Move
•
Urge to Move allows the vehicle to automatically start moving when
the transmission is in gear and the driver releases the service brake.
After the vehicle has launched the vehicle will creep at a constant
speed at engine idle without the need to hold the throttle pedal position. The configuration is useful for stop and go applications allowing
the vehicle to launch and creep without applying the accelerator.
•
The vehicle speed is determined by the selected gear ratio operating
at governed low engine idle speed. Any available start gear may be
selected. However, the transmission will downshift or exit Creep if
the engine lugs 150 rpm below the governed low engine idle speed
due to load conditions.
-
When a gear is engaged and the driver releases the service
brake; the clutch will close automatically providing vehicle
movement.
-
The clutch will remain closed; allowing the vehicle to creep at
constant engine idle after the service brake is released.
-
The clutch will also open if the engine lugs 150 rpm below the
governed low engine idle speed.
Launching:
1.
Engage the desired gear.
2.
Release service brake (vehicle will automatically launch and creep at
constant engine idle).
•
3.
Upshifts and Downshifts can be made while at constant engine
idle by pushing the Upshift / Downshift buttons. The transmission may deny a shift and sound a tone if the load of the vehicle
or grade of the terrain falls outside the acceptable range to perform a shift.
Apply accelerator to accelerate the vehicle above idle.
Stopping:
1.
Release the accelerator (vehicle will creep at constant engine idle).
•
2.
11
Upshifts and Downshifts can be made while at constant engine
idle by pushing the Upshift / Downshift buttons.
Apply service brake.
Operation
Creep
•
Creep allows the vehicle to be driven at a constant speed at engine
idle without the need to hold the throttle pedal position. The configuration is useful for slow speed applications where steady vehicle
speed is required (e.g. dump / spreader applications).
•
The vehicle speed is determined by the selected gear ratio operating
at governed low engine idle speed. Any available gear may be
selected. However, the transmission will downshift or exit Creep if
the engine lugs 150 rpm below the governed low engine idle speed
due to load conditions.
-
When a gear is engaged; the clutch remains open until the driver
releases the service brake and applies the accelerator.
-
The clutch will close and remain closed after the accelerator is
released, allowing the vehicle to creep at constant engine idle.
-
The clutch will also open if the engine lugs 150 rpm below the
governed low engine idle speed due to load conditions.
Launching:
1.
Engage the desired gear.
2.
Release service brake.
3.
Apply the throttle pedal to accelerate the vehicle until the clutch is
closed (engaged).
4.
Release the throttle pedal (vehicle will creep at constant engine idle).
•
5.
Upshifts and Downshifts can be made while at constant engine
idle by pushing the Upshift / Downshift buttons. The transmission may deny a shift and sound a tone if the load of the vehicle
or grade of the terrain falls outside the acceptable range to perform a shift.
Apply accelerator to accelerate the vehicle above idle.
12
Operation
Stopping:
1.
Release the accelerator (vehicle will creep at constant engine idle).
•
2.
Upshifts and Downshifts can be made while at constant engine
idle by pushing the Upshift / Downshift buttons.
Apply service brake.
Blended Pedal
•
Blended Pedal allows the driver to directly control the clutch engagement through accelerator positioning. Initial accelerator pedal travel
provides direct control of clutch engagement with engine held at idle;
considerable accelerator pedal travel will transition to normal closed
clutch engine throttle operation. The configuration is useful for very
slow speed applications where a specific vehicle speed is required.
•
The vehicle speed is determined by the accelerator positioning and
selected gear ratio. Any available gear may be selected. However, the
prolonged use of Blended Pedal in too high of a gear could increase
the likelihood of clutch abuse.
Note: If the automated clutch does start to overheat, the display will show
“CA” along with a warning tone. Full clutch actuation must be completed quickly. If the abuse continues, the system will open the clutch
and take away throttle control for a short period of time to allow the
clutch to cool down.
13
-
When a gear is engaged; the clutch remains open until the driver
releases the service brake and applies the accelerator.
-
Initial accelerator pedal travel provides direct control of clutch
engagement with engine held at idle; considerable accelerator
pedal travel will transition to normal closed clutch engine throttle operation.
-
The clutch will open as the accelerator is released.
-
The service brake can be used on grades to assist in keeping the
vehicle from rolling back.
Operation
Launching:
1.
Engage the desired gear.
2.
Release service brake.
3.
Apply the amount of throttle pedal needed to accelerate the vehicle to
the desired speed or desired distance.
4.
Apply full accelerator to accelerate the vehicle above idle.
Stopping:
1. Release the accelerator.
2.
Apply service brake.
Transmission Configuration Switch
The vehicle may be equipped with a Transmission Configuration switch. There
are a variety of available Transmission Configuration switches depending on
your vehicle make and model.
The Transmission Configuration Switch allows the vehicle to be tailor to match
specific operation needs. Once configured the driver has the ability to switch
between the preconfigured Primary and Secondary set of transmission
configurations when desired. Example on next page.
Transmission Model
FAO(M)-XX8310S-EX3
Configuration Name
Primary Configuration
Value
Secondary Configuration
Value
Default Start Gear
2
2
Maximum Start Gear
3
2
Coast Down Gear
5
5
Default Reverse Gear
R1
R1
Maximum Reverse
Gear
R2
R1
Reverse Configuration Standard
Blended Pedal
Drive Configuration
Urge to Move
Standard
14
Operation
Transmission Model
FAO(M)-XX8310S-EX3
Manual Configuration
Creep
Blended Pedal
Low Configuration
Standard
Blended Pedal
Shift Point Calibration
Economy
Performance
Vocational Shift
Response
Economy
Fast
Transmission Configuration Switch Operation
The Transmission Configuration switch should be used whenever the driver
wants to select the secondary configurations. To select the secondary
configuration settings, perform the following steps:
Eaton Cobra Lever:
1. Select Secondary Configuration Settings
•
Press and hold the Upshift button for 4 seconds.
Note: The gear display will display “C2” on the gear display every 15 seconds
indicating the transmission is using the Secondary Configuration
settings.
2. Re-select Primary Configuration Settings
•
Press and hold the Downshift button for 4 seconds.
Note: The gear display will display “C1” on the gear display for 3 seconds indicating the transmission Primary Configuration settings have been
reselected.
15
Operation
Eaton Push Button
Note: Not all Eaton Push Button controllers have Configuration Switch capability.
1. Select Secondary Configuration Settings
•
Press and release the Configuration button on the Eaton Push Button
controller.
Note: The gear display will display “C2” on the gear display every 15 seconds
indicating the transmission is using the Secondary Configuration
settings.
2. Re-select Primary Configuration Settings
•
Press and release the Configuration button on the Eaton Push Button
controller.
Note: The gear display will display “C1” on the gear display for 3 seconds indicating the transmission Primary Configuration settings have been
reselected.
OEM Switch
Note: Not all vehicles have an OEM momentary Configuration Switch. There
may be a number of different OEM installed momentary Configuration
Switches depending on your vehicle make and model. Contact your vehicle manufacturer for specific details.
16
Operation
Transmission Power Take Off (PTO)
The ability to prevent a mode selection while the PTO is active is desired for
certain vocational applications such as a vehicle with a boom.
A PTO configuration is available that allows or prevents a non-neutral mode
selection when a PTO is active. The default setting for this configuration is
“Disabled”, which allows non-neutral mode selection and mobile operation
when the PTO is active. When set to “Enabled” and the PTO is active, non-neutral mode selections and mobile operation is not allowed.
Stationary PTO Operation
The transmission countershaft PTO is used in this application.To engage the
PTO for stationary operation, perform the following steps:
1.
Apply the parking brake.
2.
Depress the service brake.
3.
Select “D” on the Shift Control. (This stops countershaft rotation for
PTO engagement.)
4.
Select the transmission PTO switch.
5.
Select “N” on the Shift Control.
6.
Release the service brake to engage the clutch and the PTO.
7.
Raise engine speed as required to operate PTO.
Note: To disengage the PTO, deselect the transmission PTO switch.
17
Operation
Mobile PTO Operation
The transmission countershaft PTO is used in this application and provides
limited mobile operation in the start gears. To engage the PTO for mobile
operation, perform the following steps:
1.
Depress the service brake.
2.
Release the parking brake.
3.
Select “D” on the Shift Control. (This stops countershaft rotation for
PTO engagement.)
4.
Select the transmission PTO switch.
5.
Select “D,” MANUAL, “Neutral,” or “Reverse,” as required for vehicle
movement.
6.
Release the service brake to engage the clutch and the PTO.
7.
Raise engine speed as required to operate PTO.
Note: To disengage the PTO, deselect the transmission PTO switch.
Soft Soil Operation (Heavy-Duty Models Only)
•
The transmission system requires the ATC option to be enabled
when driving in soft soil/sand or snow/ice to prevent wheel slippage
and shifting issues. The ATC system has two modes, which are the
normal on mode for sand and loose road surface and the mud/snow
setting.
Normal Mode (Sand/Soft soil)
•
The normal ATC option will engage the brakes on the wheel or side
that the wheel slip is occurring to help the vehicle regain traction.
The point at which the traction control will actuate the braking system increases with throttle. Low throttle allows the system to brake
the wheels earlier and heavy/full throttle raises the point of the
acceptable wheel slip.
•
If using Drive mode in soft soil/sand - Maintain the engine rpm
between 1000-1300 rpm to prevent unnecessary upshifting.
•
If using MANUAL mode in soft soil/sand - Do not attempt an up-shift
and try to maintain the current gear.
•
If the vehicle comes to a stop in the sand it may be necessary to back
up prior to attempting forward movement.
18
Operation
Mud/Snow/Ice Mode
•
The mud/snow/ice ATC option can be selected by depressing the ATC
switch until the ATC lamp flashes. This mode raises the wheel slip
speed that is allowed before the traction control activates. The point
at which the traction control will actuate the braking system
increases with throttle. Low throttle allows the system to brake the
wheels earlier and heavy/full throttle raises the point of the acceptable wheel slip.
Snow/Ice Operation
•
The Fuller Advantage® Automated Transmission is designed to work
in coordination with the ATC system to ensure optimal operation.
However, if the driver observes low friction road conditions (snow,
rain, ice, etc.) and does not want the transmission to shift, risking
wheel slippage, the driver should select MANUAL mode. MANUAL
mode holds the current gear position under most operating conditions-the transmission will only shift when the driver uses the
upshift/downshift buttons. Once road conditions improve, the driver
should revert back to Drive mode.
Sliding Trailer Axle
•
Ensure axle rails and locks are properly maintained.
•
Follow proper procedure for unlocking and sliding the trailer axles.
•
Use Low mode (1st gear) for forward direction and Reverse (R1) for
reverse direction.
•
Avoid repeat attempts if the sliding axle is not moving.
Note: If repeat attempts are made and the automated clutch starts to
overheat, the display will indicate “CA” along with a warning tone.
Trailer Connecting
19
•
Prior to backing under the trailer, ensure proper trailer height.
•
Use Low mode (1st gear) for forward direction and Reverse (R1) for
reverse direction.
Operation
Operation with Paving Machine
1.
Back the vehicle to the paver.
2.
Move the shift lever to neutral. (“N” should appear in gear display.)
3.
Allow the paver to move the truck forward.
4.
When ready to pull away from the paving machine, the driver can
select “D” (if the vehicle is being pushed at or above 1 mph). The
engine will synchronize and put the UltraShift PLUS into the appropriate gear, allowing the vehicle to pull away from the paver.
Transfer Dump Application Power Down and Start-up
!
Warning: Only people trained in the use of Transfer Dump equipment and its
hazards should operate the vehicle.
!
Warning: Operator must ensure trailer connect and disconnect is completed
in a manner that is safe to themselves and others in the vicinity of the truck/
trailer.
!
Warning: Control of vehicle movement must be maintained at all times.
Power Down
1.
2.
3.
!
Position the vehicle in a safe area on level ground and safely come to
a complete stop.
Select "Neutral" on the driver interface device.
Confirm the transmission is in the desired mode indicated by a solid
"N" in the display.
Important: Neutral should always be selected before initiating a power down,
except in cases of emergency.
4.
5.
6.
Set the vehicle parking brake.
Turn ignition key to the "OFF" position and allow the engine to shut
down.
Within 3-5 seconds of engine shut down, turn the ignition key to the
"ON" position.
20
Operation
7.
8.
Depress and hold service brake.
Select the desired mode on the driver interface device.
!
Important: If the service brake is not depressed while selecting the desired
gear, the desired gear will not engage. Re-select Neutral, depress and hold
service brake and select the desired gear.
!
Warning: If the gear display is flashing the desired gear, the desired gear has
not yet been achieved. Confirm the transmission is in the desired gear indicated by a solid desired gear number in the display before proceeding to the
next step.
Gear Shift
Transition
Current Gear
Successful Gear
Shift
Solid
Solid
May Momentarily
Flash
9.
!
Slowly release service brake.
Warning: If vehicle movement occurs, immediately depress service brake and
repeat Power Down procedure.
10. Perform out-of-cab operation following the manufacturers' operating
instructions.
Start-up
1.
2.
Select "Neutral" on the driver interface device.
Confirm the transmission is in the desired mode indicated by a solid
"N" in the display.
Note: If the gear display does not indicate a solid "N", engine will not crank.
3.
4.
21
Start the engine.
Depress and hold service brake.
Operation
5.
Select the desired mode and start gear with the driver interface
device.
!
Important: If the service brake is not depressed while selecting the start gear,
the initial start gear will not engage. Re-select Neutral, depress and hold service brake, select the desired gear.
!
Important: The transmission will over-ride inappropriate start gear selections
to avoid driveline damage.
6.
Release the vehicle parking brake, transmission is ready for operation.
22
Operation
Features
Hill Start Aid Operation (HSA)
Hill Start Aid defaults to the “On” position. In heavy-duty Fuller Advantage®
Automated models, it can be turned “Off” by pressing and releasing the Hill
Start Aid switch, however, it will turn back on after the first successful launch.
If the switch is turned off, the lamp in the Hill Start switch will flash (Mediumduty Fuller Automated models do not have a HSA override switch).
The grade at which Hill Start Aid is active is defaulted to 1% but can be configured to activate on a 2% or 3% grade
A grade sensor is used to determine when to engage Hill Start Aide. The driver
can view the grade reading in the Gear Display by the following process:
•
Ignition is on with engine not running.
•
Shift Device is set to Neutral.
•
Depress the Accelerator Pedal (5) times within 10 seconds.
•
The grade will be displayed in 1% increments with Up or Down
arrows indicating slope direction.
Vehicle Facing Uphill - Forward Mode
•
Vehicle must be on incline greater than 1% and in a forward mode.
•
Bring vehicle to a stop and depress the service brakes then release
the service brakes.
Note: Vehicle will begin to move after 3 seconds, and the clutch will
perform partial engagements to slow the vehicle motion. You must
either step on the brake or apply the throttle.
Vehicle Facing Downhill - Reverse Mode
23
•
Vehicle must be on a decline greater than 1% and in Reverse mode.
•
Bring vehicle to a stop and depress the service brakes then release
the service brakes.
Operation
Note: Vehicle will begin to move after 3 seconds, and the clutch will
perform partial engagements to slow the vehicle motion. You must
either step on the brake or apply the throttle.
Clutch Abuse Protection
•
This vehicle uses an automated clutch for launching the vehicle;
however the clutch can still overheat and slip with improper use.
•
DO select the lowest possible start gear for the application. If moving
slowly is require, select 1st or R1.
•
DO use Creep mode when appropriate.
•
DO use the Service Brakes and let Hill Start Aid assist you when
launching on an incline.
•
DO minimize the time it takes to engage the clutch from rest.
•
Do NOT use the throttle to hold the vehicle on an incline. (Use Service Brakes).
•
Do NOT use the throttle to stop roll back on an incline after Hill Start
Aid disengages. (Use Service Brakes and then relaunch).
•
Do NOT continually start and stop, especially when loaded. (Use a
lower gear or Creep mode).
•
If the automated clutch does start to overheat, the display will show
“CA” along with a warning tone. Full clutch actuation must be completed quickly. If not, the system will either open the clutch if not on
the throttle or close the clutch if on the throttle. If the abuse continues, the system will open the clutch and take away throttle control
for a short period of time to allow the clutch to cool down.
Engine Over-Speed Protection
•
The transmission system will upshift if necessary to prevent engine
over-speed in Drive, MANUAL and LOW modes.
!
Warning: The Fuller Advantage® Automated Transmission initiates
upshifts from MANUAL and LOW for engine over speed protection.
Some engines do not use the Eaton engine overspeed protection.
24
Operation
Shuttle Shifting
•
Shuttle shifting from Reverse to any forward mode is only allowed if
the vehicle speed is approximately zero.
Auto Start Gear Selection
•
The transmission system uses various inputs to automatically select
the best start gear in Drive and MANUAL.
•
This selection can be changed using the up/down buttons, however,
if the selection requested could cause damage or engine lugging the
request will be denied and an audible tone will sound.
Skip Shifting
•
When appropriate, the transmission system may skip shift in Drive
mode.
•
Skip shifts can be performed in MANUAL by pressing the up/down
buttons providing the current conditions like load and grade allow
this condition.
Note: Multiple gear upshifts and downshifts may be allowed when
the shift buttons are pushed multiple times (Each button push equals
one gear change request).
Auto Neutral
25
•
The transmission system will automatically shift to neutral if the
vehicle is left in Drive and the parking brakes are set.
•
“AN” will appear in the gear display. Driver must select Neutral and
then select the desired forward or reverse mode with the service
brake applied.
Operation
Load Based Shifting
•
•
The transmission system will adapt to the conditions of the vehicle to
change the shift points based on the followings inputs:
•
Vehicle grade
•
Engine RPM
•
Throttle position
•
Vehicle load
After changing loads or powering up the transmission system needs
to relearn these inputs for the first few shifts to make the proper
adjustments.
Coast Mode
•
When coasting to a stop on level terrain the transmission system
may not downshift into the lower gears. It will select a gear after the
throttle is reapplied.
Cruise Control
•
This transmission system is compatible with cruise control.
Neutral Coast Mode
If equipped and enabled, Neutral Coast Mode allows the transmission to disengage the driveline by pulling out of gear on slight downhill grades, where
little to no engine power is required, when the vehicle is in cruise control and
the transmission is in Drive Mode.
•
When Neutral Coast Mode is active, the engine will drop to idle speed
and the transmission will disengage.
•
The gear display may flash a gear number or indicate Neutral when
Neutral Coast Mode is active, depending upon specific OEM implementation.
•
If a flashing number is indicated in the gear display, this represents
the gear that the transmission will select when it is necessary to
engage a gear.
26
Operation
•
•
The transmission will exit Neutral Coast Mode and reengage an
appropriate gear under any of the following conditions:
-
Vehicle brakes are applied
-
Driver depresses accelerator pedal
-
Cruise control is canceled
-
A mode other than Drive is selected
-
Cruise high or low set speeds are exceeded
-
Maximum vehicle grade is exceeded
-
Request by an adaptive cruise system
Various brand names may be used for Neutral Coast systems.
Automated Lube Schedule
•
The heavy-duty Fuller Advantage® Automated Transmission has an
optional prognostic feature that notifies the operator when the Clutch
Release Bearing needs greasing.
•
At the appropriate grease interval and shortly after each engine start,
“GI” will momentarily appear in the gear display, along with an audible tone. This will continue to occur at each engine start until clutch
service has been completed.
•
The operator can choose to follow this Automated Lube Schedule but
should not exceed the published lube guidelines in the Lubrication
MANUAL TCMT0021.
Note: “GI” stands for grease interval and may be misread as “G1” on
gear display.
27
Service & Maintenance
General Model Information
Nomenclature
Fuller Advantage® Automated 10-Speed Transmissions
F A O - 1X 8 1 0 S - E P 3
Generation 3 Electronics
Eaton / PACCAR
Fuller Advantage®
Ratio Set
Overdrive
Forward Speeds
Design Level
x 100 = Nominal
Torque Capacity
F A O M - 1X 8 1 0 S - E C 3
Generation 3 Electronics
Fuller Advantage®
Eaton / Cummins
Ratio Set
Overdrive
Forward Speeds
Multi-torque
Design Level
x 100 = Nominal
Torque Capacity
F A O M - 1X 8 1 0 S - E C 3
Generation 3 Electronics
Eaton / Cummins
Fuller Advantage®
Ratio Set
Overdrive
Forward Speeds
Multi-torque
Design Level
x 100 = Nominal
Torque Capacity
F A O M - 1X 8 1 0 S - E P 3
Generation 3 Electronics
Fuller Advantage®
Overdrive
Multi-torque
x 100 = Nominal
Torque Capacity
Eaton / PACCAR
Ratio Set
Forward Speeds
Design Level
28
Service & Maintenance
Tag Location
The blank spaces provided below are for recording transmission identification
data and part numbers of maintenance items. All Fuller transmissions are
identified by the model and serial number. This information is stamped on the
transmission identification tag and affixed to the case.
DO NOT REMOVE OR DESTROY THE TRANSMISSION IDENTIFICATION TAG.
The blank spaces provided below are for recording transmission identification
data. Have these reference numbers handy when ordering replacement parts
or requesting service information:
Transmission Model _____________________________________
Transmission Serial Number _______________________________
Model
Serial
Assembled In
Eaton ® Transmissions
Fuller ® Transmissions
29
Eaton Corporation
Kalamazoo, MI USA
Service & Maintenance
Troubleshooting
Diagnostics
In the event there is a problem with a Fuller Advantage® Automated transmission, there are three primary tasks the driver should perform:
1.
Note the driving condition under which the problem occurred.
2.
Note the condition of the transmission under which the problem
occurred (i.e. operation mode (Drive, MANUAL, LOW), current gear,
engine speed, etc).
3.
Reset system.
Transmission Reset Procedure
In some cases, proper transmission operation can be restored by “resetting”
the transmission Electronic Control Unit (ECU). Use the following procedure
to reset the ECU.
1.
!
Continue to drive the vehicle to a safe location before selecting “N”
NEUTRAL.
Important: Once “N” NEUTRAL is selected, a gear engagement may not be
allowed.
2.
Place the transmission shift lever in Neutral “N” and turn the ignition
key to the “off” position.
3.
Wait at least 2 minutes.
4.
Restart the engine.
5.
If the problem continues, contact a service facility to have the vehicle
and transmission system evaluated.
30
Service & Maintenance
Product Diagnostic Mode “PD”
In the event the transmission is put in Product Diagnostic mode, a “PD” will
be displayed on the gear display, and the truck will not start. Use the following procedure to exit Product Diagnostic mode:
1.
Select Neutral “N” and turn the key off.
2.
Wait at least 2 minutes.
3.
Turn the key on and power the system up.
4.
Verify there is an “N” on the gear display.
5.
Start the engine.
Locked in Gear
If the truck is shut down or stalls in gear, the Fuller Advantage® Automated
transmission may become locked in gear. The transmission will attempt to get
to Neutral during the next power up if the shifter is in Neutral. If Neutral is
achieved, a solid “N” appears on the Gear Display. If Neutral can not be
achieved, a “DASH” will appear on the display and the engine will not start. If a
dash appears during power up and the lever is in Neutral try the following:
31
1.
Select Neutral, “N.” Turn the key OFF and let the transmission power
down for at least 2 minutes.
2.
Depress the brake pedal.
3.
Release the parking brake.
4.
Select Neutral.
5.
Turn the key to the “ON” position.
6.
The transmission will attempt to shift into Neutral once you turn the
key ON, but you may have to slightly release the brake pedal to help
let the torque off the drive line.
7.
Once it reaches Neutral a solid “N” will appear on the Gear Display
and the truck will start. If a dash still appears after this procedure
take the vehicle to a local service center.
Service & Maintenance
Proper Clutch Lubrication
ECA Clutch Greasing Guidelines
Service Interval
•
Linehaul - 50,000 miles (80,000 Km) or 3 months
!
Important: It is highly important to follow proper ECA Clutch lube
intervals. Failure to do so may result in clutch failure and unnecessary repairs.
The heavy-duty ECA clutch housing has two grease fittings on the lower right
side. The upper port is marked “CS” for the upper Cross-Shaft Assembly,
while the lower port is marked “RB” for the Release Bearing.
For more detailed release bearing and cross-shaft greasing information, refer
to the following manuals:
-
TRSM0980 Fuller Advantage Automated Transmission Service
Manual (Release Yoke and Cross-shaft installation section)
-
CLSM0200 Clutch Service Manual (Release bearing greasing information)
-
TCMT0021 Lubrication Manual (Clutch greasing guidelines)
All Manuals can be found in the Literature Center section of Roadranger.com
Cross-Shaft Service Interval
•
At every chassis lubrication
32
Service & Maintenance
Proper Transmission Lubrication
Proper lubrication procedures are key to a good all-around maintenance program. If the lubricant is not doing its job or if the lubricant level is ignored, all
the maintenance procedures in the world are not going to keep the transmission running or assure long transmission life.
Heavy-duty Fuller Advantage® Automated Transmissions are designed so the
internal parts operate in an oil bath circulated by the motion of the gears and
shafts.
Thus, all parts are amply lubricated if these procedures are closely followed:
1.
Maintain lubricant level and inspect regularly.
2.
Follow maintenance interval chart.
3.
Use the correct grade and type of lubricant.
4.
Buy lubricant from an approved dealer.
Mixing of Oil Types
!
Caution: Never mix engine oils and gear oils in the same transmission.
Engine oils and gear oils may not be compatible; mixing can cause breakdown
of the lubricant and affect component performance. When switching between
types of lubricants, all areas of each affected component must be thoroughly
flushed.
Note: For a list of Eaton Approved Synthetic Lubricants, see TCMT0021 or call
1-800-826-HELP (4357).
Note: Additives and friction modifiers must not be introduced.
33
Service & Maintenance
Proper Transmission Lubrication Level
Make sure the transmission lubricant is level with the bottom of the fill opening. Being able to reach the lubricant with your finger does not mean the lubricant is at the proper level.
Hole
Improper Oil Level
Hole
Proper Oil Level
If the Transmission operating angle is more than 12° (or roughly a 21%
grade), improper lubrication will occur. The operating angle is the
Transmission mounting angle in the chassis plus the percent of upgrade
(expressed in degrees).
34
Service & Maintenance
To check the oil level with the sight glass (Heavy-Duty
Models Only)
1.
Vehicle engine must be stopped and parked on level ground.
2.
Wipe dirt from the oil level sight glass.
3.
Proper oil level is obtained when the oil level is at the middle of the
clear plastic bubble. If the oil level is below this level, add at the fill
plug the necessary amount of oil.
1
2
2
Lube Change Intervals
Lubricant changes should be based on a combination of the intervals shown
in TCMT0021 Lubrication Specification Manual, and user judgment based on
the application and operating environment. Extending drain intervals beyond
those shown in the tables is not recommended and will put warranties at risk.
35
Service & Maintenance
Vehicle Towing
When towing the vehicle, the output shaft of the transmission must not be
allowed to spin or turn. If the vehicle is towed with the drive wheels still in
contact with the road surface, the vehicle axle shafts or driveline must be
removed or disconnected.
!
Important: Serious Internal transmission damage can result from
improper vehicle towing.
Correct
Incorrect
36
Copyright Eaton, 2017.
Eaton hereby grant their customers,
vendors, or distributors permission
to freely copy, reproduce and/or
distribute this document in printed
format. It may be copied only in
its entirety without any changes or
modifications. THIS INFORMATION
IS NOT INTENDED FOR SALE OR
RESALE, AND THIS NOTICE MUST
REMAIN ON ALL COPIES.
Note: Features and specifications
listed in this document are subject to
change without notice and represent
the maximum capabilities of the
software and products with all options
installed. Although every attempt has
been made to ensure the accuracy of
information contained within, Eaton
makes no representation about the
completeness, correctness or accuracy
and assumes no responsibility for
any errors or omissions. Features and
functionality may vary depending on
selected options.
For spec’ing or service assistance,
call 1-800-826-HELP (4357) or visit
www.eaton.com/roadranger.
In Mexico, call 001-800-826-4357.
Roadranger: Eaton and trusted partners
providing the best products and services in the
industry, ensuring more time on the road.
Eaton
Vehicle Group
P.O. Box 4013
Kalamazoo, MI 49003 USA
800-826-HELP (4357)
www.eaton.com/roadranger
Printed in USA
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