Driver Instructions. Eaton 9-Speed Synchronized Transmissions Single H Shift Control Configuration. TRDR0072 January 2016

Transcription

1 1 Driver Instructions Eaton 9-Speed Synchronized Transmissions Single H Shift Control Configuration TRDR0072 January 2016

2 2 SAFETY - ALERT SYMBOL AND TERMS This Safety Alert Symbol means ATTENTION! BE ALERT! YOUR SAFETY IS INVOLVED! Why is SAFETY important to you? *ACCIDENTS DISABLE AND KILL * ACCIDENTS CAN BE AVOIDED * ACCIDENTS ARE COSTLY Remember that YOU are the key to safety. Good safety practices not only protect you, but also the people around you. Study the features in this manual and make them a working part of your safety program. Keep in mind that this safety section is written only for this manual. Practice all other usual and customary safe working precautions, and above all - REMEMBER SAFETY IS YOUR RESPONSIBILITY. YOU CAN PREVENT SERIOUS INJURY OR DEATH. SAFETY SYMBOLS: DANGER, WARNING and CAUTION Whenever you see the words and symbols shown below, used in this book and on decals, you MUST take note of their instructions. The safety alert symbol identifies important safety messages on machines, safety signs, in manuals, or elsewhere. When you see this symbol, be alert to the possibility of personal injury or death. Follow the instructions given in the safety messages. DANGER: The symbol and the word DANGER indicates an imminently hazardous situation which, if not avoided, will result in DEATH OR SERIOUS INJURY. WARNING: The symbol and the word WARNING indicates a potentially hazardous situation. If the instructions or procedures are not correctly followed it could result in PERSONAL INJURY, OR LOSS OF LIFE. CAUTION: The symbol and the word CAUTION identifies special instructions or procedure which if not strictly observed, could result in DAMAGE, DESTRUCTION OF EQUIPMENT, OR PERSONAL INJURY. Note: The word NOTE indicates additional detail that will aid in the diagnosis or repair of a component/system for more efficient and convenient repair or operation. Work Safely Follow these Rules 1. Always wear safety glasses when using a hammer, chisel or other tools that may cause chips to fly. 2. Use proper tools to make repairs; using hammers and chisels or punches instead of pullers increases the probability of injury. 3. Keep work area organized and clean. Wipe up oil or spills of any kind. Do not keep tools and parts on the floor. Eliminate the possibility of a fall which could result in a serious injury. 4. Be sure to reinstall safety devices, guards or shields after adjusting and/or servicing the machine. 5. After servicing, be sure all tools, parts, or servicing equipment are removed from the vehicle. 6. Use a safety catch on all hoist hooks. Do not take a chance; the load could slip off the hook. 7. Batteries give off explosive hydrogen gas when charging and continue to do so for some time after receiving a steady charge. Do not under any circumstances allow an electric spark or an open flame near the battery. Always disconnect a battery cable before working on the electrical system. Always wear safety goggles when servicing batteries. 8. Be careful when using compressed air to dry parts. Use approved air blow guns, do not exceed 2.5 bar, wear safety glass or goggles and use proper shielding to protect everyone in the work area. 9. Do not wear rings, wrist watches or loose fitting clothing when working on machinery because they could catch on moving parts causing serious injury. Wear sturdy, rough soled work shoes. Never carry out repairs and/or service with bare feet or while wearing sandals or sneakers. 10. Exhaust gases are highly poisonous! Therefore, do not start the engine in closed rooms unless adequate ventilation is ensured. 11. Before starting a vehicle always be seated in the driver s seat, place the transmission in neutral, set the parking brakes and disengage the clutch. 12. Anytime you will be working on a vehicle, parking a vehicle, or leaving the cab with the engine running, place the transmission in neutral, set the parking brakes, and block the wheels. 13. For safety reasons, always engage the service brakes prior to selecting gear positions from N. 14. Before working on a vehicle or leaving the cab while the engine is running you must place the shift lever in N, set the parking brake, and block the wheels. 15. When parking the vehicle or leaving it you must place the shift lever in N and set the parking brake. 16. If the engine cranks in any gear other than Neutral, service your vehicle immediately. 17. Before towing the vehicle place the transmission in neutral, and lift the rear wheels off the ground, remove the axle shafts, or disconnect the driveline to avoid damage to the transmission during towing. 18. Always use genuine Eaton replacement parts. 19. Read this manual carefully and keep it in a convenient place for future reference. 20. The description and specifications contained in this service publication are current at the time of printing. 21. Eaton Corporation reserves the right to discontinue or modify its models and/or procedures and to change specifications at any time without notice. 22. Any reference to brand name in this publication is made as an example of the types of tools and materials recommended for use and should not be considered an endorsement. Equivalents may be used. 23. Departure from the instructions, choice of tools, materials and recommended parts mentioned in this publication may jeopardize the personal safety of the service technician or vehicle operator.

3 3 Table of Contents Warnings & Cautions...04 Introduction...05 Tag Information...05 Operation...06 Nomenclature...06 Shift Pattern...06 General Information...07 High to Low Range Shifting...07 Driving Tips...08 Initial Start-Up...08 Upshift...09 Downshift...09 Quick Tips...10 Driving Instruction...11 Service & Maintenance...12 Proper Lubrication..12 Mixing Oil Types..12 Proper Transmission Lubrication Levels.13 Lubricant Change Intervals...13 Operating Temperatures...14 Lubricant Change 15 Maintenance Checks..16 Towing of a truck stuck in mud.17

4 4 Warnings and Cautions Read the entire driver instructions before operating this transmission. Set the parking brakes before starting a vehicle, always be seated in the driver s seat, move the shift level to neutral, and depress the clutch fully. If engine cranks in any gear other than neutral or without the clutch depressed, service your vehicle neutral safety start circuit immediately. Before working on a vehicle or when leaving the cab with the engine running, place the transmission in neutral and set the parking brakes. Do not release the parking brake or attempt to select a gear until the air pressure is at the correct level. When parking the vehicle or leaving the cab, always place the shift lever in neutral and set the parking brakes. Towing: To avoid damage to the transmission during towing, disconnect the driveline.

5 5 Introduction Tag Information Transmission model designation and other transmission identification information are stamped on the transmission tag. To identify the transmission model designation and serial number, locate the tag on the transmission and then locate the numbers as shown. IMPORTANT: DO NOT REMOVE OR DESTROY THE TRANSMISSION IDENTIFICATION TAG. Record the Transmission Model and Serial Number below. Have these reference numbers handy when ordering replacement parts or requesting service information: Transmission Model: Transmission Serial Number: Every effort has been made to ensure the accuracy of all information in this manual. However, Eaton Truck Components Operations makes no expressed or implied warranty or representation based on the enclosed information. Any errors or omissions may be reported to Eaton Corporation, Truck Components, Global Marketing Services, P.O. Box 4013, Kalamazoo, Michigan,

6 6 Operation Nomenclature Shift pattern Note: The shift lever is cross gate biased and will rest naturally in either the 1st / 2nd or 3rd / 4th gate position depending on the vehicle manufacturer. Ensure you are familiar with this before driving the vehicle. With the gear shift lever at neutral 3/4 as the driver presses the range switch UP for High Range and DOWN for Low Range compressed air changes the range. Range changes only when the transmission is in NEUTRAL.

7 7 General Information 9-Speed Single H Models in this series provide nine forward speeds and two reverse speeds, consisting of a five-speed front section and a two-speed auxiliary range section. Crawler gear (C) in the front section is used only as a starting gear. The other four ratios are used once in LOW range and once again in HIGH range. After shifting out of Crawler gear, use the repeat 'H' shift pattern. LOW range and HIGH range are selected with the range switch. The switch is used once during the upshift sequence and once during the downshift sequence. Always pre-select the range shift while in gear. After pre-selection, the transmission will automatically make the synchronized range shift as the shift lever passed through neutral. High to Low Range Shifting Never attempt to shift down at too high a vehicle speed as this will result in major damage to the driveline. Note: Some vehicles are fitted with a range shift over-speed protection device in conjunction with the vehicle manufacturer. Never assume a range over-speed device is fitted. As a guide never shift from HIGH range to LOW range above 30 kph - not even if the vehicle is in neutral and the clutch pedal is depressed. Note: This speed will vary based on the overall driveline configuration.

8 8 Shift Pattern Diagrams A shift pattern diagram / etched shift knob should be in your vehicle (depending on vehicle manufacture). Driving Tips Always use the clutch when making up shifts or down shifts. Premature synchronizer failure can result from not using the clutch. Always select an initial starting gear that provides sufficient reduction for load and terrain. Never slam or jerk the shift lever to complete gear engagement. Never coast with the shift lever in the neutral position. Never downshift at too high of a road speed. Never shift to crawler gear (C) while the vehicle is moving. Never select reverse gear while the vehicle is moving. Initial Start Up Make sure you understand the shift pattern correctly. Before starting the vehicle, be seated in the driver s seat. 1. Make sure the parking brakes are applied, shift lever is in ¾ neutral, and the range is DOWN. 2. Press the clutch pedal and start the engine, release the clutch pedal. 3. Build up the air pressure fully. 4. Depress the clutch pedal completely. 5. Move the shift lever to the appropriate starting gear. 6. Release the parking brakes, press the service brake pedal. 7. Slowly and smoothly release the clutch pedal and gradually press the accelerator. In the (unlikely) case the vehicle was parked with range switch UP (7/8 Neutral), the Step-1 above takes care. After pressing the range button DOWN, range will change to LOW only if air pressure is sufficient. You would wait anyway for air pressure to build up before launching the vehicle.

9 Upshift You will see the LOW range indicator ON. 1. Release the accelerator 2. Fully depress the clutch pedal, move the shift lever to the appropriate starting gear. 3. Release the clutch pedal. 4. Accelerate the vehicle. 5. Continue upshifting till 4th gear Range shift LOW to HIGH (4th to 5th) When in the 4th gear - and ready for the next upshift; press the range switch UP. 6. Release the accelerator 7. Fully depress the clutch pedal, move the shift lever to neutral. This changes range to HIGH. You will also hear the air release noise. You will see HIGH Range indicator ON. 8. Move the shift lever to LEFT. 9. With the clutch still depressed, shift to 5th gear 10. Release the clutch and press the accelerator. 11. Continue upshifting till 8th gear Downshift 1. Release the accelerator 2. Fully depress the clutch pedal, move the shift lever to the next gear. 3. Release the clutch pedal. 4. Continue downshifting till 5th gear Range shift HIGH to LOW (5th to 4th) When in the 5th gear and ready for the next downshift; 5. Press the range switch DOWN. 6. Release the accelerator 7. Fully depress the clutch pedal, move the shift lever to neutral. This changes the range to LOW. You will also hear the air release noise. 8. Move the shift lever towards LEFT. You will see LOW range indicator ON. 9. With the clutch still depressed, shift into 4th gear. 10. Release the clutch. 9

10 As the vehicle slows down continue downshifting as required but only up to 1 st gear, NOT Low/Crawler). Note: Never shift into LOW range at vehicle speed more than km/h. Never shift to Low gear (L) while the vehicle is still moving. IMPORTANT: 1. LOW range must NOT be engaged from HIGH range so long as the vehicle speed is above km/h 2. Coasting (transmission in neutral) must be avoided at all costs. 3. Special attention must be paid to avoid any over-revving of the engine, as the latter is damaging for the synchronizers. 4. To ensure that the transmission functions without problems and has a long life, the compressed air reservoirs on the vehicle must be drained regularly as per recommendation. 5. The compressed air pressure in the system must be min 6 bar. Quick Tips 1. Vehicle should be parked in neutral in low range (range switch press DOWN) with parking brake applied. 2. Always select an initial starting gear that provides sufficient pull for the load and terrain. 3. Loaded vehicle must always be marched off in the lowest gear. This will ensure maximum life of clutch and transmission. 4. Always shift gears depressing the clutch pedal fully. 5. Premature synchronizer failure can result from not using the clutch apart from increasing the shift effort. 6. Do not rest foot on clutch pedal. It causes clutch wear and may lead to gear jump-out. 7. Never release the clutch suddenly nor too slowly; it may damage the clutch and transmission. 8. Never downshift at too high a road speed. 9. Never slam or jerk the shift lever to complete gear engagements. 10. The gear lever must not be used as hand support. 11. Avoid coasting. It causes rapid wear of transmission components apart from being a safety hazard. 12. Engine must not be switched off in a running vehicle because of power steering and compressed air requirements. 13. Never tow a vehicle with propeller shaft still connected to the transmission. 14. Do not tow another vehicle, stuck in mud or sand. It may damage clutch and gear box. Crane should be used in such situations. 15. Never try to extricate the stuck in vehicle by a quick succession of forward and reverse movements of the vehicle with manipulation of clutch and accelerator.

11 11 Operation Driving instructions 1. Vehicle should be parked in neutral with parking brake applied. 2. Always select an initial starting gear that provides sufficient pull for the load and terrain. 3. Loaded vehicle must always be marched off in the lowest gear. This will ensure maximum life of clutch and transmission. 4. Always shift gears depressing the clutch pedal fully. 5. Premature synchronizer failure can result from not using the clutch apart from increasing the shift effort. 6. Do not rest foot on clutch pedal. It causes clutch wear and may lead to gear jump-out. 7. Never release the clutch suddenly nor too slowly; it may damage the clutch and transmission. 8. Never downshift at too high a road speed. 9. Never slam or jerk the shift lever to complete gear engagements. 10. The gear lever must not be used as hand support. 11. Avoid coasting. It causes rapid wear of transmission components apart from being a safety hazard. 12. Engine must not be switched off in a running vehicle because of power steering and compressed air requirements. 13. Never tow a vehicle with propeller shaft still connected to the transmission. 14. Do not tow another vehicle, stuck in mud or sand. It may damage clutch and gear box. Crane should be used in such situations. 15. Never try to extricate the stuck in vehicle by a quick succession of forward and reverse movements of the vehicle with manipulation of clutch and accelerator.

12 12 Service & Maintenance Proper Lubrication Proper lubrication procedures are key to a good all-around maintenance program. 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. Eaton transmissions are designed so that the internal parts operate in an oil circulating bath created by the motion of the gears and shafts. All parts will be lubricated if these procedures are closely followed: Maintain oil level and inspect regularly. Follow maintenance plan. Use correct grade and type of oil. Prolonged oil change will cause internal damage. Do not overfill as this causes overheating and effects fuel economy. Buy from a reputable dealer. Mixing Oil Types Never mix engine oils and gear oils in the same transmission. Note: Additives and friction modifiers must not be introduced. 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.

13 13 Proper Transmission Lubrication Levels Make sure oil is level with the filler opening. Being able to reach oil with your finger does not mean oil is at proper level. Lubricant Change Intervals Lubricant change intervals will be included in the vehicle operating handbook and will be defined based on the type of oil used and the operating conditions. As a base rule the following should be followed: Mineral Oils * On Highway Use Every 20,000 km - Inspect oil level and check for leaks Every 100,000 km (or annually) - Change oil (see Note below) Note: Whichever comes first. * Off Highway Use Every 40 hours - Inspect oil level and check for leaks Every 500 hours - Change oil (see Note 1 below) Every 1000 hours - Change oil (see Note 2 below) Note 1: Oil change - where severe dirt conditions exist. Note 2: Oil change - where normal conditions exist.

14 14 Synthetic / Semi-Synthetic Oils * On Highway Use Every 20,000 km - Inspect oil level and check for leaks Every 300,000 km to 500,000 km - Change oil (see Note below) OR Every 3 years - Change oil. Note: Mileage will depend on type of oil used. * Off Highway Use Every 40 hours - Inspect oil level and check for leaks Every 500 hours - Change oil (see Note below) Every 1000 hours - Change oil (Normal operation) Note: Change oil where severe dirt conditions exist. Operating Temperature It is important that the transmission operating temperature does not exceed 120 C (250 F) for an extended period of time. Operating temperatures above 120 C (250 F) cause breakdown of the oil and shorten transmission life. The following conditions in any combination can cause operating temperatures of over 120 C (250 F): 1. Operating consistently at road speeds under 32 km/h (20m.p.h.) 2. High engine RPM 3. High ambient temperature 4. Restricted air flow around transmission 5. Exhaust system too close to transmission 6. High horsepower, over-drive operation 7. High power PTO operation for extensive periods while stationary High operating temperatures may require more frequent oil change.

15 15 Lubrication change Oil Level Before checking the oil level or refilling, ensure vehicle is on level ground. Make sure that the oil is level with the filler opening. Draining Oil Before draining the oil, ensure that oil is warm and the vehicle is on level ground. To drain the oil, remove the drain plug from the left hand side bottom of the intermediate case. Clean the drain plug before refitting. Before refilling the transmission: 1. Clean the oil strainer in kerosene (paraffin) or suitable solvent and dry thoroughly. 2. Dry the strainer thoroughly. 3. Clean the drain plug. 4. Inspect the washer and replace if necessary 5. Refit the drain plug and tighten to Nm. Do not overfill. This causes the oil to be forced out of the front and rear seals and also overheating and loss of fuel economy. Do not mix different types of oil. While adding the oil, different types and brands of oil must not be mixed. It is important that the transmission operating temperature does not exceed 120 C for an extended period of time. Operating temperatures above 120 C cause breakdown of the oil and shorten the transmission life.

16 16 Remember It is your responsibility to be thoroughly familiar with transmission shift patterns and shifting procedures. We recommend that you study the truck manufacturer s operating manual. When you start to move, put the vehicle in the lowest appropriate gear. Do not shock-load the drive line by abruptly releasing the clutch pedal. Apply power gradually when moving heavy loads uphill. Do not allow the clutch to slip excessively, since this can overheat the clutch and cause premature failure. Remember: Co-ordinated clutch operation and smooth transmission shifting will prolong the life of any vehicle. Putting vehicle in motion When starting to move, gradually release the clutch and at the same time release the hand control valve or parking brake. At the same time, the engine must be speeded up gradually on some vehicles to prevent stalling. Check the brakes immediately after you have the vehicle underway, within 15 meters. Service & Maintenance Maintenance Checks Conduct regular maintenance checks where possible regarding: Clutch mechanism - General operation Lubricant - Correct level Filler and Drain plug - Correct tightness / damage to washers Cap screws and Gaskets - Loose / oil leaks LRC / Shift Tower - Secure / free play / wear

17 17 Towing of a truck stuck in mud When towing the vehicle, the propeller shaft between the axle and transmission must be disconnected. How to pull out a truck stuck in the mud If your truck gets stuck in the mud, it can be very trying to get it unstuck. Mud tends to suck tires in and trap axles from forward or backward movement. Simply spinning the tires for long periods of time in an attempt to get free will only sink the truck further into the mud and make the situation worse. Never try to extricate the stuck in vehicle by a quick succession of forward and reverse movements of the vehicle and manipulation of clutch and engine speed. Instructions 1. Look under the stuck truck to see if the vehicle is "high centered" on any rocks or obstacles; high centered means the truck is on top of an object that is causing the wheels to not fully touch the ground. If the truck is high centered, dig out any mud or sediment around the truck's wheels and place wood or mats by the tires and add sand to any icy areas. Use the wire grate to walk on if the ground is slippery or icy. 2. Decide if the truck would have an easier time going forward or backward out of the mud & dig out under the tires in that direction as well as possible. Once the tires are visible and free, place plywood, or the truck's interior floor mats down in the mud in the direction the truck is to travel as a traction aid. 3. Place the hi-lift jack under a wheel well or solid object under the truck body. Plant the base of the jack on a level surface. Lift the truck up with the jack enough to push the shovel under the truck and push the object out of the truck's underside. Do not attempt to crawl under the jacked up truck to get the obstacle. Push it out with the shovel or other long pole. 4. Lower the truck and remove the jack. Have an assistant back the towing vehicle to the stuck truck as close as possible to within 2 or 3 m. Attach the tow chain to one of the stuck trucks tow loops. Look for these under the truck bed. Attach the other tow chain hook to the tow vehicle's tow loop.

18 18 5. Put the stuck truck into neutral & make sure the parking brakes are released. Assign a "watcher" to oversee a coordinated removal of the truck. Have another person drive the tow vehicle. Coordinate hand signals for go, stop or slow. 6. Have the tow vehicle slowly begin to inch forward until the tow chain is tight. Gradually accelerate the tow vehicle, let the tow chain slowly tighten. Once tight, put the tow vehicle into a low gear and begin to pull the stuck truck up and out of the predicament. Tow it up to flat and level ground and away from the snarl. WARNING: Coasting is dangerous and damaging to the transmission. NEVER COAST VEHICLE. Never let the vehicle cruise in neutral (or in gear with clutch pedal pressed). This dangerous practice can lead to loss of vehicle control and surely damages the transmission. The following are the associated risks: 1. If the vehicle speed becomes too great or if the brakes are used during a descent that may overheat and become incapable of even slowing, let alone stopping the vehicle. 2. It may not be possible to re-engage a gear when needed, especially if vehicle speed has increased excessively. 3. Engaging the clutch while coasting may damage it. It can also damage the transmission, over rev the engine or lock up the drive wheels. 4. With the engine just idling during coasting, the compressor may not be able to maintain air pressure leading to loss of the brakes. If the engine stalls while coasting it may be impossible to engage any gear and the brakes may become ineffective or completely fail due to loss of air pressure. You will also lose power steering. Eaton transmission requires rotation of the countershaft to provide adequate lubrication. It does not rotate when the vehicle is being towed with the rear wheels on the ground and the drive train connected. The mainshaft however is driven at a high speed by the rear wheels. Coasting with the transmission in neutral will cause friction between the mainshaft and the needle rollers resting on it, due to lack of lubrication and the extreme difference in rotational speeds, severely damage the transmission..

19 19 To prevent this: 1. Never coast with the transmission in neutral 2. Never coast with the clutch depressed 3. When towing a vehicle a) Remove the propshaft Or b) Remove the halfshafts Or c) Lift the drive wheels off the ground