PDF Service Manual Eaton Gem III Automated RTLO-18918A-AS3 Transmission - 3 MB
This service manual provides in-depth information for the Eaton Gem III Automated RTLO-18918A-AS3 transmission.
It is an essential resource for transmission specialists and heavy-duty mechanics.
The guide covers troubleshooting, fault codes, removal, disassembly, inspection, and reassembly procedures.
Keep your automated transmission shifting smoothly with this factory-approved service document.
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Service Manual
Eaton Gen III Automated
Transmissions
TRSM0930 EN-US
May 2013
UltraShift®
AutoShift®
UltraShift® PLUS Linehaul Active Shifting (LAS)
UltraShift® PLUS Linehaul Small Step Efficiency (LSE)
UltraShift® PLUS Multipurpose Extreme Performance (MXP)
UltraShift® PLUS Multipurpose High Performance (MHP)
UltraShift® PLUS Vocational Active Shifting (VAS)
UltraShift® PLUS Vocational Construction Series (VCS)
UltraShift® PLUS Vocational High Performance (VHP)
UltraShift® PLUS Vocational Multipurpose Series (VMS)
UltraShift® PLUS Vocational Extreme Performance (VXP)
UltraShift® PLUS Passenger Vehicle (PV)
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Transmission Overview | General Information TRSM0930
Heavy-Duty 13-Speed MHP/VHP, 16-Speed LSE
& 18-Speed VXP/MXP
Input Shaft Speed Sensor
Electric Shifter
Gear Select Sensor
Mainshaft Rail Select Sensor
Speed Sensor
Splitter Valve Range Valve Solenoid
Solenoid Air Filter Regulator
Output Shaft
Speed Sensor
Flywheel Speed Sensor
Transmission Harness
(Shipping Location)
Transmission ECU
7 © 2013 Eaton. All rights reserved 2013.05.30
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Serial Tag Information and Model Nomenclature | General Information TRSM0930
6-Speed E O - 1 X E 4 0 6 B P V
Passenger
Brand - Eaton Vehicle
Overdrive
Ratio Set
X 100 + 50
Nominal Torque Lb. Ft. Number of Speeds
Configuration
Design Level
Mechicanical & Electronic
10-Speed F O - 1 X E 3 0 8 L L - V C S
Construction
Brand - Fuller Series
Overdrive UltraShift
X 100 + 50 Vocational
Nominal Torque Lb. Ft.
Ratio Set
Starting Device
(Clutch Type) Number of Speeds
Design Level
Mechicanical & Electronic
10-Speed F O M 1 X E 3 1 0 C - L A S
Active
Brand - Fuller Shifting
Overdrive UltraShift
Line Haul
Multi-Torque
Ratio Set
X 100 + 50
Nominal Torque Lb. Ft. Number of Speeds
Starting Device
(Clutch Type)
Design Level
Mechicanical & Electronic
10-Speed F O M 1 X E 3 1 0 C - V A S
Active
Brand - Fuller Shifting
Overdrive UltraShift
Vocational
Multi-Torque
Ratio Set
X 100 + 50
Nominal Torque Lb. Ft. Number of Speeds
Starting Device
(Clutch Type)
Design Level
Mechicanical & Electronic
11-Speed F O - 1 X E 3 0 9 A L L - V M S
Mixer
Brand - Fuller Series
Overdrive UltraShift
X 100 + 50 Vocational
Nominal Torque Lb. Ft.
Ratio Set
Starting Device
(Clutch Type) Number of Speeds
Design Level
Mechicanical & Electronic
13-Speed F O - 1 X E 3 1 3 A - M H P
Brand - Fuller High Performance
Overdrive UltraShift
X 100 + 50 Multipurpose
Nominal Torque Lb. Ft. Ratio Set
Starting Device
(Clutch Type) Number of Speeds
Design Level
Mechicanical & Electronic
17 © 2013 Eaton. All rights reserved 2013.05.30
--- Page 5 ---
Electronic Clutch Actuator (ECA) | Service Procedure TRSM0930
Procedure - Installation
1. Install the ECA into the clutch housing bore. Align it 3. If applicable, install the 4 cap screws for the ECA
with the lower cross-shaft. shield. Tighten them to 35-45 lb-ft. (47-61 Nm).
Note: The ECA will have to be rotated to align with the
slot in the Clutch Housing.
Note: Ensure you rotate the Release Yoke as close to
the Case Dowel in the Clutch Housing prior to
mating with the cross-shaft. This allows the
Release Yoke to clear the Release Bearing during
installation.
4. Apply NyoGel to terminals and reconnect the 8-way
and 3-way connectors to the ECA.
Note: Apply just enough material to cover the end of
the terminal.
Note: Use only Eaton lubricant part number 5564527
(Nye Lubricants NYOGEL 760G. For MSDS safety
or other information see www.nyelubri-
2. Install the 4 cap screws from the ECA Mounting Flange. cants.com.)
Tighten them to 35-45 lb-ft. (47-61 Nm).
Note: Medium-duty models are mounted with 3 cap
screws and 1 lock nut. Tighten to 35-45 lb-ft. (47-61
Nm).
Note: The cap screws for the ECA are longer than the
ECA Bracket cap screws.
Note: Ensure the ECA does not bind on the cross-shaft
by snugging all cap screws before tightening to
the specified torque.
5. Reconnect the negative 12-volt battery cable.
6. If previously removed, install the 8-bolt PTO after ECA
installation. Follow the PTO manufacturer’s guidelines
for installation instructions.
29 © 2013 Eaton. All rights reserved 2013.05.30
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Release Yoke and Cross-shaft(s) | Service Procedure TRSM0930
5. Slide yoke onto upper Cross-shaft assembly and install 8. Grease upper Cross-shaft assembly until grease
1 cap screw and lock washer by hand. purges from the bleed hole in the upper Cross-shaft
boss.
6. Install lower Cross-shaft assembly and install 1 cap
screw and lock washer by hand.
7. Tighten the 2 Yoke cap screws to 35-45 lb-ft. (47-61
Nm).
39 © 2013 Eaton. All rights reserved 2013.05.30
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Medium-Duty Transmission Harness | Service Procedure TRSM0930
Medium-Duty Transmission Harness
Special Instructions Special Tools
None Basic hand tools
Component Identification
Medium-Duty
2 9
3
4
8
1
7
5
6
1. Transmission ECU 38-way Connector
2. Gear Sensor Connector
3. Rail Sensor Connector
4. Future position of 4-way Transmission Diagnostic Connector
5. Input Shaft Speed Sensor Connector
6. Inertia Brake Connector
7. Wet Clutch Solenoid Connector (AW3 only)
8. Output Shaft Speed Sensor Connector
9. Electric Shifter Connector
49 © 2013 Eaton. All rights reserved 2013.05.30
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Medium-Duty Transmission Electronic Control Unit (TECU) | Service Procedure TRSM0930
Procedure - Installation
Caution: Battery negative must remain disconnected until 3. Reconnect the following connectors:
! the TECU 38-way connectors are installed.
Caution: Do not exceed the torque on the Transmission
Caution: Do not allow contamination into the TECU or con- ! Harness or Vehicle Harness Connector or bolt
! nectors. failure will occur.
1. Position the Transmission Controller on the locating • Using a 5/32” wrench, reconnect the Transmission
studs. Harness 38-way Connector and tighten to 25 +/- 3
lb-in. (2.82 +/- 0.33 Nm).
• Using a 5/32” wrench, reconnect the Vehicle Inter-
face 38-way Connector and tighten to 25 +/- 3 lb-in.
(2.82 +/- 0.33 Nm).
• Reconnect the negative battery cable.
2. Using a 7/16” socket, install the 3 Transmission Con-
troller mounting bolts and tighten to 7-9 lb-ft.
(9.5-12.2 Nm).
4. To operate properly, the system must be calibrated as
follows:
Important: The Electric Shifter must be calibrated
! before the vehicle is placed in operation.
• Turn ignition switch on. Allow the transmission to
power up.
• Turn ignition off and wait 2 minutes.
Note: UltraShift AW3- Perform clutch calibration:
“Clutch Calibration” on page 143.
5. Connect ServiceRanger to vehicle and compare
recorded configuration settings (step 1 in removal pro-
cess) to the replacement TECU. Update and save all
configurations that are different. (Refer to “Ser-
viceRanger User Guide” TCMT-0071 for more informa-
tion.)
59 © 2013 Eaton. All rights reserved 2013.05.30
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Medium-Duty Inertia Brake | Service Procedure TRSM0930
Medium-Duty Inertia Brake
Special Instructions Special Tools
None Basic hand tools
Component Identification
5
4
3
2
1
1. Cap Screw
2. Inertia Brake
3. Gasket
4. Spacer (Used on all Medium-Duty ratios except the “N”)
5. Gasket (Used on all Medium-Duty ratios except the “N”)
69 © 2013 Eaton. All rights reserved 2013.05.30
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Heavy-Duty Inertia Brake | Service Procedure TRSM0930
Heavy-Duty Inertia Brake
Special Instructions Special Tools
None Basic hand tools
Component Identification
3
2
1
1. Cap Screw
2. Inertia Brake
3. Gasket
79 © 2013 Eaton. All rights reserved 2013.05.30
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Range Valve | Service Procedure TRSM0930
Procedure - Installation
Important: Lubricate o-rings with Eaton Fuller silicone 3. Reconnect the Transmission Harness to the Range
! 71214 or equivalent. Valve and close all air tanks drains.
Important: The valve is keyed to fit its mounting location. Note: Install the Range Harness back into the tie-down
! Take care to align the key with the notch in the on the Range Valve.
housing.
1. Install and push the Range Valve down into the hous-
ing.
4. If equipped, install the Protective Cover. Push the cover
down by hand until it snaps into place.
2. Using a 5/16” socket, install the 4 Range Valve mount-
ing cap screws and tighten to 21-27 lb-in. (2.3-3.0 Nm)
using a cross pattern.
89 © 2013 Eaton. All rights reserved 2013.05.30
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Park Actuator Assembly | Service Procedure TRSM0930
Park Actuator Assembly
Special Instructions Special Tools
None Basic hand tools
Component Identification
1
2
3
6 5 4
1. Shift Lever connection for OEM supplied Shift Cable
2. Park Actuator Assembly
3. Actuator Gasket
4. Sensor Fasteners (2)
5. Park Sensor
6. Actuator Fasteners (6)
99 © 2013 Eaton. All rights reserved 2013.05.30
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Medium-Duty Output Shaft Speed Sensor | Service Procedure TRSM0930
Procedure - Removal
1. Disconnect the Transmission Harness from the Output 3. Remove the Output Shaft Speed Sensor, with o-ring,
Shaft Speed Sensor or Pigtail Connector, if equipped. from the transmission housing.
2. Using a 3/8” socket, remove the sensor retaining bolt.
109 © 2013 Eaton. All rights reserved 2013.05.30
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Medium-Duty Input Shaft Speed Sensor | Service Procedure TRSM0930
Medium-Duty Input Shaft Speed Sensor
Special Instructions Special Tools
Input Shaft Speed Sensor location varies as follows: Basic hand tools
• Medium-Duty: Top of Inertia Brake
• Heavy-Duty: Right front of Shift Bar Housing
Component Identification
1. Cap Screw
2. Sensor
3. O-ring
119 © 2013 Eaton. All rights reserved 2013.05.30
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Rail Select Sensor | Service Procedure TRSM0930
Procedure - Installation
1. Align sensor tabs with the slot in the Electric Shifter 3. Reconnect the Transmission Harness to the Rail Select
rail. Then, insert the Rail Select Sensor, with gasket, Sensor.
into its mounting location.
Note: Install the sensor, so connector opening faces
right side of the transmission. (As viewed from
the rear of the transmission)
2. Using a 5/32” hex key wrench, install the 2 hex key
mounting screws and tighten to 21-27 lb-in. (2.3-3.0
Nm).
Caution: Carefully hold sensor in position while install-
! ing the hex key mounting screws, or sensor
can snap.
129 © 2013 Eaton. All rights reserved 2013.05.30
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Operation and Basic Troubleshooting | Appendix TRSM0930
Operation and Basic Troubleshooting
Operation
For more detailed information on transmission operation
and shifting, go to the Roadranger Literature Center
(www.roadranger.com) and look for the “Driver’s Manual”
on your transmission model.
- Generation 3 UltraShift Driver Instructions -
TRDR0940
- Generation 3 AutoShift Driver Instructions -
TRDR0930
- Driver Instructions for Fuller® UltraShift® PLUS
models - TRDR1110
Basic Troubleshooting
For all Basic Troubleshooting questions refer to the appro-
priate service manual covering the base box procedures.
These manuals can be found on Roadranger.com under the
Literature Center.
Air System Operation and Troubleshooting
For all air system operation and troubleshooting questions
refer to the “Eaton Gen III Automated Transmissions Trou-
bleshooting Guide” TRTS0930, which is found on Road-
ranger.com under the Literature Center.
139 © 2013 Eaton. All rights reserved 2013.05.30
--- Page 18 ---
Torque Specifications | Appendix TRSM0930
Description Torque Value lb-ft. [N•m] Thread size Additional Comments
2 Rail Sensor Cap Screws 21–27 lb-in.
[2.4–3.1 N•m]
2 Gear Sensor Cap Screws 21–27 lb-in.
[2.4–3.1 N•m]
2 Air Filter Regulator Cap 8–12 lb-ft. 1/4"-20 Apply Loctite 242 to
Screws [10.8–16.02 N•m] threads.
1 Lubricant fill plug 45–55 lb-ft. 3/4-14 NPT
(6-Speed) [61–75 N•m]
1 Lubricant fill plug 60–75 lb-ft. 1¼-NPT
(13,10,18-speed) [81–102 N•m]
1 Cross-shaft Plug 34–48 lb-ft. 1.3125 - 12
[46–65 N•m]
2 Lifting Bracket Cap 35–45 lb-ft. 3/8"-16 Apply Loctite 242 to
Screws [47–61 N•m] threads.
1 Output Yoke Nut 500 ± 25 lb-ft.
(6-Speed) [678 ±34 N•m]
1 Output Yoke Nut 450–500 lb-ft.
(13,10,18-Speed) [610–678 N•m]
2 Output Yoke Cap Screws 70–85 lb-ft. M12 x 1.25 Spiralock ThreadsTM: No
(ECA) [95–115 N•m] thread adhesive neces-
sary.
4 Rear Bearing Cover Cap 60–70 lb-ft. 1/2-20 Apply Loctite 242 to
Screws (6-Speed) [81–95 N•m] threads.
Transmission Nodal Refer to OEM for Apply Loctite 242 to
Mount Cap Screws Specification threads.
4 Rear Bearing Cover Cap 35–45 lb-ft. 3/8-16 Apply Loctite 242 to
Screws (13,10,18-Speed) [47–61 N•m] threads.
Transmission Rear Mount Refer to OEM for
Nuts/Cap Screws Specification
6-Speed AW3 Specific
Oil cooler line fitting 50–60 lb-ft.
[68–81 N•m]
Oil cooler line nut 50–60 lb-ft.
[68–81 N•m]
2 Dipstick tube fitting 60–70 lb-ft. 1 5/8"-12
[81–95 N•m]
1 Wet clutch drain plug 34–48 lb-ft.
[46–65 N•m]
149 © 2013 Eaton. All rights reserved 2013.05.30