Eaton Roadranger TRSM4106 Bedienungsanleitung

Service Manual

Fuller Mid Range Transmissions

TRSM4106

October 2007

For parts or service call us

Pro Gear & Transmission, Inc.

1 (877) 776-4600

(407) 872-1901

[email protected]

906 W. Gore St.

Orlando, FL 32805

Service Manual

(4106 / 5206)

Eaton 6-Speed Synchromesh Transmission

Truck Components Operations Europe

PO Box 11 Worsley

Manchester M28 5GJ

England

5/01

Section 1 General

1/1 Letter and Model Designation

1/2 Technical Data

1/3 Lubrication

1/4 Recommended Lubricants

1/5 Torque Tightening Recommendations

1/7 Disassembly Precautions and Inspection of Expendable Parts

1/9 Reassembly Precautions

1/10 Gear End Floats

1/11 Special Tools

1/14 Locally Made Tools

Section 2 General Discription

2/1 Features

2/2 Gear Change Pattern

2/2 Power Flow Diagrams

Section 3 Shifting Controls

3/2 Remote Control - Exploded View

3/3 Remote Control Disassembly

3/4 Remote Control Reassembly

3/7 Direct Control - Exploded View

3/8 Direct Control Disassembly

3/9 Direct Control Reassembly

Section 4 Transmission Overhaul

4/2 Transmission Case - Exploded View

4/3 Transmission Case Disassembly

4/9 Layshaft Disassembly

4/10 Layshaft Reassembly

4/11 Synchroniser Flange Removal / Fitment

4/12 Maninshaft Disassembly (New Type)

4/13 Maninshaft Reassembly (New Type)

4/17 Mainshaft Assembly - Exploded View (NewType)

4/31 Mainshaft Disassembly (Old Type)

4/32 Mainshaft Assembly - Exploded View (Old Type)

4/35 Mainshaft Reassembly (Old Type)

4/41 Selector Shaft Disassembly

4/42 Selector Shaft Reassembly

4/44 Transmission Case Reassembly

5/01

Section 2 General

5/01

1/1

General

Model Designation

Example: FSO-4106A

FS Standard prefix

O Overdrive

4 Nominal torque in 00 lbs ft

1 Series 1

06 Number of forward gears

A Standard ratio set

B, C Alternative ratio sets

Transmission Identification

All transmissions are fitted with an identification plate on the left hand side of the front case showing

1. Transmission serial number.

2. Transmission model.

3. Manufacturing data code.

4. Transmission specification number.

The transmission specification number is unique to each customer and gives precise details of the trans-

mission design level. This number must be quoted when ordering replacement parts.

There are currently two design levels of the 4106 transmission. Each level is identified by the specifica-

tion number.

Y 0400

Y 04100

The middle digit denotes the design level.

5/011/2

General

Technical Data

Models FS-4106A, FS-4106B, FS-5206A, FS(O)-5206B

640 Nm

650 Nm

700 Nm

115 kg

520 mm

7,5 lit

6,5 lit

SAE Standard

Left side (vertical installation), bottom right

(horizontal installation): 2 SAE 6 bolt facings

plus extended layshaft for Eaton PTO

Rotation to Engine

engine speed x

0,226 Same

0,271

0,336

engine speed x

0,434 Opposite

0,519

0,644

1) including output coupling, low remote control; less clutch housing

2) front face of transmission case to rear face of output flange

3) recommended backlash is from 0.15 to 0.25mm.

Gear

Reverse

FS-4106A

FS-5206A

1.00

1.38

2.00

3.10

5.25

9.03

8.07

Step

FS-4106B

FS-5206B

1.00

1.29

1.86

2.80

4.38

7.54

6.74

Step

FS(O)-4106B

FS(O)-5206B

1.00

1.37

2.12

3.56

6.08

9.03

5.43

Step

Nominal Input Torque

FS-4106A

FS-4106B

FS-5206A

FS(O)-5206B

Weight 1)

Length 2)

Oil capacity

Vertical

Horizontal

Clutch Housing

Power Take-off Openings

PTO Drive Gears 3)

driven from the reverse idler gear at:

FS-4106A, FS-5206A

FS-4106B, FS-5206B

FS-4106B, FS(O)-5206B

driven from layshaft front gear at:

FS-4106A, FS-5206A

FS-4106B, FS-5206B

FS-4106B, FS(O)-5206B

5/01

1/3

General

Lubrication

Proper Oil Level

Before checking the oil level or refilling, vehicle should

be on level ground.

Make sure that the oil is level with the filler opening.

Draining Oil

Drain transmission while oil is warn. To drain oil remove

the drain plug at the bottom if case. Clean the drain plug

before re-installing.

Refilling

Clean area round filler plug.

Fill transmission to the level of the filler opening.

The exact amount of oil depends on the

transmission inclination. In every instance, fill to the

level of the filler opening. Do not overfill this causes

oil to be forced out of the case past the mainshaft and

input shaft seals.

Adding Oil

It is recommended that different types and brands of oil

are not intermixed because of possible incompatibility.

Operating Temprature

It is important that the transmission operating tempera-

ture 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 trans-

mission 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.

Towing

When towing the vehicle, the propeller shaft between the

axle and transmission must be disconnected.

5/011/4

Only use recommended lubricants to ensure smooth running.

Highway Use

First 5000 to 8000 km (3000 to

5000 miles)

Every 16000 km (10000 miles)*

Every 80000 km (50000 miles)+

Off Highway

First 30 hours

Every 40 hours *

Every 500 hours

Every 1000 hours +

Change transmission oil on new units

Inspect oil level. Check for leaks

Change transmission oil

Change transmission oil on new units

Inspect oil level. Check for leaks

Change transmission oil when severe dirt condi-

tions exist

Change transmission oil (normal off- highway use)

General

Recommended Lubricants

Models Temprature RangeGrade

Mild EP Gear Oil

to Specification

MIL-L-2105 or

API-GL-4

Heavy Duty Engine Oil

to Specification

MIL-L-2104C or

MIL-L-46152 or

API-CD

-26¡C to 21¡C

-12¡C to 37¡C

-26¡C to 38¡C

above -12¡C

below -12¡C

SAE 80 W

SAE 90 W

SAE 80 W/90

SAE 50

SAE 40

SAE 30

Lubrication Change and Inspection

Remove and clean oil strainer at each oil change.

Transmissions fitted with an oil cooler may additionally be fitted with a filter in the cooler line,

Renew the filter at every oil change.

* Or 2 months, whichever occurs first.

+ Or 12 months, whichever occurs first.

DO NOT use oil additives, friction modifiers or synthetic lubricants.

Service Intervals

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