Service Manual Eaton Transmissions TRSM0511 January 2018 ESO 14409 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....................................................................................................................................... 5 Model Information Serial Tag Information and Model Nomenclature ............................................................................................ 7 Model Number ................................................................................................................................................... 7 Serial Number ................................................................................................................................................... 8 Specifications Technical Data .................................................................................................................................................. 9 Torque Rating .................................................................................................................................................... 10 Gear End Floats ................................................................................................................................................ 12 Synchronizer Ring to Synchronizer Flange Clearance .................................................................................. 12 Lubrication Information Recommendations Lubrication ......................................................................................................................... 13 Europe specific information ............................................................................................................................ 14 Semi-synthetics / synthetic oil ........................................................................................................................ 15 Tool Information Recommended Tools ........................................................................................................................................ 16 Preventive Maintenance Preventive Maintenance.................................................................................................................................... 18 Checks Before Transmission Removal .......................................................................................................... 18 Checks With Drive Line Dropped ................................................................................................................... 18 Checks With Universal Joint Companion Flange or Yoke Removed ............................................................. 19 Rear Seal Maintenance .................................................................................................................................. 19 Table of Contents Power Flow Power Flow ........................................................................................................................................................ 20 General Features ............................................................................................................................................................ 21 The Epicyclic Reduction Gear .......................................................................................................................... 21 Transmission Installations ................................................................................................................................. 23 Air System System Theory .................................................................................................................................................. 24 Integrated Air System (IAS) Single H Electric .................................................................................................. 25 Filter Pressure Regulator .................................................................................................................................. 26 Integrated Air System (IAS) Operation ............................................................................................................. 27 Integrated Air System (IAS) Troubleshooting ................................................................................................... 28 Types of Integrated Air System (IAS) Unit- Operation ..................................................................................... 29 Air System ......................................................................................................................................................... 30 IAS Logics state ................................................................................................................................................ 32 IAS Horizontal “H” Electric ................................................................................................................................ 33 Remote Control Assembly Exploded View ................................................................................................................................................... 34 How to Disassemble Remote Control Assembly ............................................................................................. 35 How to Assemble Remote Control Assembly .................................................................................................. 38 Transmission Case Overhauling Exploded View ................................................................................................................................................... 42 How to Disassemble Transmission Case ...................................................................................................... 43 Exploded View ................................................................................................................................................... 51 How to Disassemble Rear Case .................................................................................................................... 52 Exploded View ................................................................................................................................................... 56 How to Disassemble Planet carrier Assembly ................................................................................................. 57 How to Assemble Planet Carrier Assembly ................................................................................................... 58 How to Assemble Rear Case ......................................................................................................................... 60 Table of Contents Mainshaft Assembly Exploded View ................................................................................................................................................... 66 End Float Check ................................................................................................................................................ 67 How to Disassemble Mainshaft Assembly ..................................................................................................... 68 Check Clearance between Synchronizer Ring and Flange ........................................................................... 72 How to Assemble Mainshaft ............................................................................................................................. 73 Layshaft Assembly Exploded View ................................................................................................................................................... 79 How to Disassemble Layshaft ........................................................................................................................ 80 How to Assemble Layshaft ............................................................................................................................... 81 Input Shaft Assembly Exploded View ................................................................................................................................................... 82 How to Disassemble Input Shaft Assembly ..................................................................................................... 83 How to Assemble Input Shaft Assembly ........................................................................................................ 85 Selector Assembly Exploded View ................................................................................................................................................... 87 Selector Assembly - Single H ......................................................................................................................... 88 How to Disassemble Selector Assembly 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