DOCSLIB.ORG

FC Service Manual

Total Page：16

File Type：pdf, Size：1020Kb

Download full-text PDF Read full-text
FC Service Manual Service Manual Eaton Transmissions TRSM0080 March 2015 FS-4106A FS-4206B FSO-4206B FS-5206A FS-5206B FS-5206F FSO-5206B Table of Contents Introduction Warnings and Precautions ...........................................................................................................................1 Purpose and Scope of Manual .....................................................................................................................2 How to use this Manual .................................................................................................................................2 Disassemble Precautions ..............................................................................................................................2 Inspection Precautions ..................................................................................................................................3 Assembly Precautions ...................................................................................................................................4 Model Information Serial Tag Information and Model Nomenclature .........................................................................................5 Model Number ..............................................................................................................................................5 Serial Number................................................................................................................................................5 Specifications Technical Data...............................................................................................................................................6 Torque Rating ...............................................................................................................................................7 Gear End Floats ............................................................................................................................................8 Synchroniser Ring to Synchroniser Flange Clearance .................................................................................8 Lubrication Information Lubrication ....................................................................................................................................................9 Recommended Lubricants.............................................................................................................................10 Tool Information Recommended Tools ...................................................................................................................................13 Special Tools Manufacturers .........................................................................................................................14 Locally Made Tools........................................................................................................................................15 Preventive Maintenance Preventive Maintenance ...............................................................................................................................16 Checks Before Transmission Removal .........................................................................................................16 Checks With Drive Line Dropped ..................................................................................................................17 Checks With Universal Joint Companion Flange or Yoke Removed.............................................................17 Rear Seal Maintenance .................................................................................................................................17 Table of Contents Power Flow Power Flow ...................................................................................................................................................18 Direct Control Assembly Exploded View ..............................................................................................................................................19 How to Disassemble Direct Control Assembly .............................................................................................20 How to Assemble Direct Control Assembly ...................................................................................................22 Remote Control Assembly Exploded View ..............................................................................................................................................24 How to Disassemble Remote Control Assembly ..........................................................................................25 How to Assemble Remote Control Assembly................................................................................................27 Pneumatic Power Assist (PPA) Assembly Exploded View ..............................................................................................................................................30 How to Disassemble PPA Assembly ............................................................................................................31 How to Assemble PPA Assembly..................................................................................................................31 Transmission Case Disassembly Exploded View ..............................................................................................................................................32 How to Disassemble Transmission Case .....................................................................................................33 Layshaft Assembly Exploded View ..............................................................................................................................................39 How to Disassemble Layshaft ......................................................................................................................40 How to Assemble Layshaft ............................................................................................................................41 Mainshaft Assembly - W/O 1st-2nd Double Cone Synch. Exploded View ..............................................................................................................................................42 End Float Check ...........................................................................................................................................43 How to Disassemble Mainshaft .....................................................................................................................44 Check Clearance between Synchroniser Ring and Flange ...........................................................................46 How to Assemble Mainshaft ..........................................................................................................................47 Table of Contents Mainshaft Assembly - With 1st-2nd Double Cone Synch. Exploded View ..............................................................................................................................................53 End Float Check ...........................................................................................................................................54 How to Disassemble Mainshaft .....................................................................................................................55 Check Clearance between Synchroniser Ring and Flange ..........................................................................58 Check Clearance between Synchroniser Ring and Flange ..........................................................................59 How to Disassemble 1st and 2nd Double Cone Synchroniser Assembly .....................................................61 How to Assemble 1st and 2nd Double Cone Synchroniser Assembly ..........................................................63 How to Assemble Mainshaft ..........................................................................................................................66 Selector Assembly Exploded View ..............................................................................................................................................72 How to Disassemble Selector Assembly ......................................................................................................73 How to Assemble Selector Assembly............................................................................................................74 Transmission Case Assembly How to Assemble Transmission Case ..........................................................................................................75 Introduction Warnings and Precautions Before starting a ve hicle always be s eated in the driver’s seat, place the transmission in ne utral, set the parking brakes and disengage the clutch. Before working on a vehicle place the transmission in neutral, set the parking brakes and block the wheels. 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. The description and specifications contained in this service publication are current at the time of printing. Eaton Corporation reserves the right to discontinue or modify its models and/or procedures and to change specifi- cations at any time without notice. Any reference to brand name in this publication is made as an example of the types of tools
Load more

Recommended publications
  • The Effect of Vehicle Electrification on Transmissions and The
    MAG 2016 # December The AutomotiveCTI TM, HEV & EV Drives magazine by CTI A New Automatic Trans mission The Effect of Vehicle Approach – a Suitable MT Electrification on Replacement? Transmissions and the Transmission Market Interview with John Juriga Director Powertrain, What Chinese Customer Hyundai America Technical Center is Expecting Innovations in motion Experience the powertrain technology of tomorrow. Be inspired by modern designs that bring together dynamics, comfort and highest effi ciency to offer superior performance. Learn more about our perfect solutions for powertrain systems and discover a whole world of fascinating ideas for the mobility of the future. Visit us at the CTI Symposium in Berlin and meet our experts! www.magna.com CTIMAG Contents 6 The Effect of Vehicle Electrification on 45 Software-based Load and Lifetime Transmissions and the Transmission Monitoring for Automotive Components Market TU Darmstadt & compredict IHS Automotive 49 “Knowledge-Based Data is the Key” 10 What Chinese Customer is Expecting Interview with Prof. Dr-Ing. Stephan Rinderknecht, AVL TU Darmstadt 13 HEV P2 Module Concepts for Different 50 Efficient Development Process from Transmission Architectures Supplier Point of View BorgWarner VOIT Automotive 17 Modular P2–P3 Dedicated Hybrid 53 Synchronisers and Hydraulics Become Transmission for 48V and HV applications Redundant for Hybrid and EV with Oerlikon Graziano Innovative Actuation and Control Methods Vocis 20 eTWINSTER – the First New-Generation Electric Axle System 56 Moving Towards Higher
    [Show full text]
  • Limited Slip Differentials, Performance Gearkits and Gearboxes, Uprated Halfshafts and Much More
    Performance > Transmission > Driveline Components > Motorsport Driven by Precision PRODUCT CATALOGUE UK designed & manufactured 2019 We are 3J Driveline Ltd is one of the UK’s leading drivetrain specialists. Producing Limited Slip Differentials, Performance Gearkits and Gearboxes, uprated Halfshafts and much more. All of our products are proudly designed, produced and manufactured right here in the UK, so you can buy with confidence that we will not compromise on quality. Made in UK 3J Driveline Ltd was launched in 2012 and deliver very happy and satisfied customers. quickly established itself as one of the UK’s From classic and fast road enthusiasts leading drivetrain authorities. Designing to club and international racing drivers and producing a wide range of limited slip across the UK, Europe, USA and the rest differentials, gearboxes and gear kits, and of the world. half-shaft sets for road and competition use. We always have time to talk. So if you have Our reputation for engineering and the a product enquiry, technical query, require quality of our products make us a aftercare or have any other questions first-choice purchase for thousands of relating to our product range both present car enthusiasts and competitors, with and future, be sure to get in touch. You our ever-growing catalogue of product can be assured of the same high quality of applications further strengthening our service whatever the nature of your contact position within the market place. with us, as we value each and every client. If we can help, we will help. All of our products are designed, manufactured, produced, and built right Getting in touch has never been easier: You here in the UK.
    [Show full text]
  • Automobile Engineering 1 Vehicle Introduction & Clutches
    Automobile Engineering 1 Vehicle Introduction & Clutches By: PULKIT AGRAWAL Assistant professor Mechanical Engg. Dept. MODULE I (14 HOURS) Introduction Main units of automobile chassis and body, different systems of the automobile, description of the main parts of the engine, motor vehicle act. Power for Propulsion Resistance to motion, rolling resistance, air resistance, gradient resistance, power required for propulsion, tractive effort and traction, road performance curves. Breaking systems Hydraulic breaking system, breaking of vehicles when applied 6 to rear, front and all four wheel, theory of internal shoe Page 7 brake, design of brake lining and brake drum, different arrangement of brake shoes, servo and power brakes. MODULE II (12 HOURS) Transmission Systems Layout of the transmission system, main function of the different components of the transmission system, transmission system for two wheel and four wheel drives. Hotchkiss and torque tube drives. Gear box : Sliding mesh, constant mesh and synchromesh gearbox, design of 3 speed and 4 speed gear box, over drive, torque converter, semi and fully automatic transmission. Hookes joint, propeller shaft, differential, rear axles, types of rear axles, semi floating, there quarter floating and full floating types. MODULE III (14 HOURS) Front wheel Geometry and steering systems : Camber, castor, kingpin inclination, toe-in and toe- out, centre point steering condition for true rolling, components of steering mechanism, power steering. Electrical system of an automobile : Starting system, charging system, ignition system, other electrical system. Electrical vehicles: History, electrical vehicles and the environment pollution, description of electric vehicle, operational advantages, present EV performance and applications, battery for EV, Battery types and fuel cells, Solar powered vehicles, hybrid vehicles.
    [Show full text]
  • 1152 Longitudinal Sportscar Transaxle Gearbox Manual
    1152 Longitudinal Sportscar Transaxle Gearbox Manual Issue 2.0 – 10/12/15 - 1152 Longitudinal Transaxle Sportscar Gearbox Manual © 2015 - Xtrac Limited, Gables Way, Kennet Park, Thatcham, Berkshire. RG19 4ZA. 1 Xtrac Inc, 6183 W. 80th Street, Indianapolis, IN 46278. United States Contents 1. Summary of Lubricants and Greases .................................................................. 4 2. Operating requirements ...................................................................................... 5 3. Specification ........................................................................................................ 7 3.1. General Items .............................................................................................. 7 3.2. Standard Options (no cost) .......................................................................... 9 3.3. Optional Extras (cost options) ...................................................................... 9 3.4. Excluded Items ............................................................................................ 9 4. Gearbox Operation ............................................................................................ 10 4.1. Gearchange Description ............................................................................ 10 4.2. Oil System .................................................................................................. 10 4.2.1. Description ............................................................................................ 10 4.2.2. Dedicated Oil
    [Show full text]
  • Machine Design Lab: Using Automotive Transmission Examples to Reinforce Understanding of Gear Train Analysis
    AC 2011-838: MACHINE DESIGN LAB: USING AUTOMOTIVE TRANS- MISSION EXAMPLES TO REINFORCE UNDERSTANDING OF GEAR TRAIN ANALYSIS Roger A Beardsley, Central Washington University Roger Beardsley is an Assistant Professor in the Mechanical Engineering Technology program at Central Washington University in Ellensburg, WA. He teaches courses in energy related topics (thermodynamics, fluids & heat transfer), along with the second course in the undergraduate sequence in mechanical de- sign. Some of his technical interests include renewable energy, appropriate technology and related design issues. Charles O. Pringle, Central Washington University Charles Pringle is an Assistant Professor in the Mechanical Engineering Technology program at Central Washington University in Ellensburg, WA. He teaches courses in statics, mechanics of materials, and systems simulation, along with the first course in the undergraduate sequence in mechanical design at CWU. Some of his technical interests include systems, renewable energy, and the related design issues. c American Society for Engineering Education, 2011 Machine Design Lab: Using Automotive Transmission Examples to Reinforce Understanding of Gear Train Analysis Abstract: In studying mechanical gear train analysis, some students struggle with relatively simple gear design concepts, and virtually all have difficulty with the complexities of planetary gear sets. This paper describes two labs developed for an undergraduate senior level machine design course. One lab uses a three-speed manual synchromesh transmission with parts of the case cut away to demonstrate the operation of the gears, shifting mechanism, bearings, and other aspects of the design. Students then count teeth and analyze the gear ratios using standard gear train analysis methods. The other lab uses a 1924 Ford Model T planetary transmission to observe how planetary gears can create two forward speeds and reverse from constant rotation of the engine.
    [Show full text]
  • Presented by Tire Rack 2019 Solo Rules 2019 SOLO RULES
    On orders over $50 FAST FREE SHIPPING tirerack.com/freeshipping 200 TREADWEAR STREET AND ST-CLASS TIRES Tire Rack Presented by 2019 Solo Rules 2019 SOLO RULES g-Force Rival S Potenza RE-71R Direzza ZIII Azenis RT615K+ PRESENTED BY: g-Force Rival S 1.5 3-rib/4-rib Ventus R-S4 Ecsta V720 N FERA SUR4G Proxes R1R ADVAN Neova AD08R Visit www.tirerack.com throughout the year for the latest tire selection! R-COMPOUND TIRES BFGoodrich g-Force R1 / R1 S Hankook Ventus Z214 C51 Medium Hankook Ventus Z214 C71 So Hoosier A7 / R7 Hoosier D.O.T. Radial Wet H2O Toyo Proxes RR Competition Tire Prep Services Include Tire Shaving & Heat Cycling www.SCCA.com ©2018 Tire Rack 888-380-8473 On orders over $50 FAST FREE SHIPPING tirerack.com/freeshipping 200 TREADWEAR STREET AND ST-CLASS TIRES Tire Rack Presented by 2019 Solo Rules 2019 SOLO RULES g-Force Rival S Potenza RE-71R Direzza ZIII Azenis RT615K+ PRESENTED BY: g-Force Rival S 1.5 3-rib/4-rib Ventus R-S4 Ecsta V720 N FERA SUR4G Proxes R1R ADVAN Neova AD08R Visit www.tirerack.com throughout the year for the latest tire selection! R-COMPOUND TIRES BFGoodrich g-Force R1 / R1 S Hankook Ventus Z214 C51 Medium Hankook Ventus Z214 C71 So Hoosier A7 / R7 Hoosier D.O.T. Radial Wet H2O Toyo Proxes RR Competition Tire Prep Services Include Tire Shaving & Heat Cycling www.SCCA.com ©2018 Tire Rack 888-380-8473 SCCA® National Solo® Rules 2019 EDITION Sports Car Club of America® Solo® Department 6620 SE Dwight St.
    [Show full text]
  • The Hybridised Layshaft Transmission
    The Hybridised layshaft transmission Ben Chiswick, Senior Design Engineer, Drive System Design Miriam Lorenzo, Principal Engineer, Drive System Design Matthew Hole, Head of Design, Drive System Design Drive System Design, Leamington Spa, United Kingdom Abstract: Layshaft transmission designs have been 1. Introduction modified to integrate electrical motors for hybrid vehicles for many years although it is typical for Global CO2 reduction is currently one of the major designers to couple conventional electric motors that tasks for OEMs, due to the short-term mandated CO2 are developed in isolation from the transmission emission targets for new passenger cars and light- system. The integration and optimization of the two commercial vehicles. components together leads to lighter, more compact and efficient hybrid solutions. Further benefits are realised if the electrical machine can be used to perform multiple powertrain functions such as input shaft synchronisation and electric creep alongside the normal hybrid functions: regenerative braking and torque support. By using the electrical machine to displace existing components such as shift elements in the transmission, some of the additional cost and weight of these hybrid systems can be offset by savings in the mechanical components. This can lead to Figure1: Global CO2 targets (Source ICCT [9]) significant savings in package, weight and efficiency. To achieve the best integration the electric motor Significant global reductions in emissions cannot be must be designed to support specific transmission achieved solely through the delivery of high-tech functionality and the transmission adapted to better ultra-efficient hybrid and electric vehicles if they only support the needs of the motor.
    [Show full text]
  • Edmt for Commercial Vehicle Applications an Innovative Concept
    December 2019 December INTERVIEW Oliver Blume, Porsche “We need Exciting Cars – and just as Important, a Fast Charging Infrastructure” PUNCH Powerglide An Innovative Concept for an eKontrol Optimized DHT in Terms of eDMT for Commercial Vehicle Efficiency, Cost and Packaging Applications A zero-emission future is only impossible until it isn’t. The future of mobility is electric. Most agree, but few know how to get there. Until now. With our etelligentDRIVE™ solutions, Magna is making it possible. From 48 volt and pure electric drives, to eAWD and plug-in hybrids, we’re electrifying powertrains, improving fuel effi ciency, reducing the environmental impact of vehicles - and moving the industry into the future. Science fi ction thinking. Automotive reality. Dear reader, welcome to the thirteenth issue of CTI Magazine. Inside, major suppliers describe the latest developments in transmissions and drives, where two factors – the diversity of electrified drives and digitization – continue to fuel R&D activities. In addition to DHT and add-on hybrid drives for passenger cars and multispeed BEV transmissions for commercial vehicles, we also explore component-related topics such as pumps, lubricants, controllers and software methods. For developers, the primary aims are to increase efficiency and performance while simultaneously reducing costs and weight. To complement these specialist articles, we interview top automotive managers and experts including Dr Oliver Blume, CEO Porsche, who describes Porsches electrification strategy and how the digitization changes the automotive industry. Top drive expert Stephan Tarnutzer, AVL, reflects on how electrification affects the work content of OEMs, suppliers and engineering service providers, while automotive specialist Prof Giorgio Rizzoni, Ohio State University, examines the ‘drive mix’ for commercial vehicles.
    [Show full text]
  • DRIVETRAIN 7.0 Introduction Drivetrain Is the Assembly of All The
    DRIVETRAIN 7.0 Introduction Drivetrain is the assembly of all the components that are involved in the transmission of the power from the engine of the vehicle to its wheels. 7.1 Drivetrain configurations The layout of the automotive drivetrain varies according to the position of the engine and the drive axle: 7.2 Drivetrain elements The elements of the drive train must perform the following functions: remaining stationary even with the engine running, achieving the transition from a stationary to a mobile state, converting torque and rotational speed, providing for forward and reverse motion, compensating for wheel-speed variations in curves, ensuring that the power unit remains within a range on the operating curve commensurate with minimum fuel consumption and exhaust emissions. 7.3 Clutch Operation Stationary idle, transition to motion and interruption of the power flow are all made possible by the clutch. The clutch slips to compensate for the difference in the rotational speeds of engine and drivetrain when the vehicle is being set in motion. When different conditions demand a change of gear, the clutch disengages the engine from the transmission while the gear shift operation takes place. With automatic transmissions, the hydrodynamic torque converter is responsible for the take-up of power. The transmission (gearbox) modifies the engine's torque and revolution per minute to adapt them to the vehicle's momentary tractive requirements. The overall conversion of the drivetrain is the product of the constant transmission ratio of the axle differential and the variable transmission ratio of the gearbox – assuming there are no other transmission stages involved.
    [Show full text]
  • Range Rover Classic 1995 Workshop Manual
    Workshop manual 01 04 RANGE ROVER 05 06 07 09 10 This manual covers vehicles from 1995 model year 12 01 INTRODUCTION 17 04 GENERAL SPECIFICATION DATA 19 05 ENGINE TUNING DATA 06 TORQUE WRENCH SETTINGS 07 GENERAL FITTING REMINDERS 09 LUBRICANTS, FLUIDS AND CAPACITIES 26 10 MAINTENANCE 12 ENGINE Tdi 12 ENGINE 3.9 V8 17 EMISSION CONTROL 30 19 FUEL SYSTEM Tdi 19 FUEL SYSTEM MFI 19 CRUISE CONTROL 26 COOLING SYSTEM Tdi 33 26 COOLING SYSTEM V8 30 MANIFOLD AND EXHAUST SYSTEM 33 CLUTCH 37 MANUAL GEARBOX 37 41 41 TRANSFER GEARBOX 44 44 AUTOMATIC GEARBOX 47 PROPELLER SHAFTS 51 REAR AXLE AND FINAL DRIVE 47 54 FRONT AXLE AND FINAL DRIVE 51 54 57 STEERING 60 FRONT SUSPENSION 64 REAR SUSPENSION 68 AIR SUSPENSION 57 70 BRAKES NON ABS 70 BRAKES ABS 70 BRAKES ELECTRONIC TRACTION 60 CONTROL 64 68 74 WHEELS AND TYRES 74 76 SUPPLEMENTARY RESTRAINT SYSTEM 76 CHASSIS AND BODY 80 HEATING AND VENTILATION 70 82 AIR CONDITIONING 84 WIPERS AND WASHERS 86 ELECTRICAL 76 Published by Rover Technical Communication 80 Rover Group Limited 1995 82 Publication Part No. LRL0030ENG (2nd Edition) 84 86 INTRODUCTION INTRODUCTION REFERENCES This workshop manual covers vehicles from 1995 References to the left or right hand side in the manual model year onwards. Amendments and additional are made when viewing the vehicle from the rear. pages will be issued to ensure that the manual With the engine and gearbox assembly removed, the covers latest models. Amendments and additions water pump end of the engine is referred to as the will be identified by the addition of a dated footer front.
    [Show full text]
  • THE BEAULIEU SALE Collectors’ Motor Cars, Motorcycles and Automobilia Saturday 2 September 2017 the National Motor Museum Beaulieu, Hampshire
    THE BEAULIEU SALE Collectors’ Motor Cars, Motorcycles and Automobilia Saturday 2 September 2017 The National Motor Museum Beaulieu, Hampshire AUTOMOBILIA | 1 2 | THE BEAULIEU SALE THE BEAULIEU SALE Collectors’ Motor Cars, Motorcycles and Automobilia Saturday 2 September 2017 The National Motor Museum Beaulieu, Hampshire VIEWING Please note that bids should be ENQUIRIES CUSTOMER SERVICES submitted no later than 16:00 on Monday to Friday 08:30 - 18:00 Friday 1 September Motor Cars Friday 1 September. Thereafter +44 (0) 20 7447 7447 10:00 to 17:00 +44 (0) 20 7468 5801 bids should be sent directly to the Saturday 2 September +44 (0) 20 7468 5802 fax Bonhams office at the sale venue. Please see page 2 for bidder 09:00 event exhibitors [email protected] +44 (0) 8700 270 089 fax or information including after-sale 10.00 general admission [email protected] collection and shipment Motorcycles +44 (0) 20 8963 2817 SALE TIMES We regret that we are unable to [email protected] Please see back of catalogue Automobilia 11:00 accept telephone bids for lots with for important notice to bidders a low estimate below £500. Motorcycles 14:00 Automobilia Absentee bids will be accepted. Motor Cars 14:30 +44 (0) 8700 273 619 ILLUSTRATIONS New bidders must also provide [email protected] Front cover: Lot 558 SALE NUMBER proof of identity when submitting Back cover: Lot 414 & Lot 222 bids. Failure to do so may result 24121 in your bids not being processed. ENQUIRIES ON VIEW AND SALE DAYS IMPORTANT INFORMATION CATALOGUE The United States Government Live online bidding is +44 (0) 8700 270 090 has banned the import of ivory £25.00 + p&p available for this sale +44 (0) 8700 270 089 fax into the USA.
    [Show full text]
  • Development of a Testing Assembly for Powertrain Speed Sensors
    DEGREE PROJECT IN ELECTRICAL ENGINEERING, SECOND CYCLE, 30 CREDITS STOCKHOLM, SWEDEN 2016 Development of a Testing Assembly for Powertrain Speed Sensors ZACHARIAS ZAFIRAKIS KTH ROYAL INSTITUTE OF TECHNOLOGY SCHOOL OF ELECTRICAL ENGINEERING Development of a Testing Assembly for Powertrain Speed Sensors Zacharias Zafirakis zacharias.zafi[email protected] [email protected] Examiner and Supervisor: Jonas Mårtensson Department of Automatic Control KTH - Royal Institute of Technology Stockholm, Sweden July 12, 2016 Development of a Testing Assembly for Powertrain Speed Sensors Zacharias Zafirakis zacharias.zafi[email protected] [email protected] Manager: Fredrik Strååt Supervisors: Andrey Gromov Johan Thornblad Powertrain Control System Development Scania CV AB Södertälje, Sweden July 12, 2016 Abstract Knowledge about the speed and the direction of the different shafts in the gearbox and the engine of trucks is becoming more and more important, especially as the industry moves towards autonomous vehicles. The most common way to measure these parame- ters today is by using inductive or Hall sensors. Testing and benchmarking these sensors has a large significance for heavy truck manufacturers such as Scania. In order to test these components, a rig assembly was constructed. In this project a LabVIEW program was developed for controlling the rig and gathering the required data. The aim of the rig was to try and simulate the behaviour of the components that are commonly measured in the gearbox or the engine, as well as use it for testing and benchmarking new rotational speed sensors. In order to achieve this, different processes were studied that cover certain working conditions in a Scania truck. The rig’s ability to follow these processes was then studied.
    [Show full text]