Eaton FS-4005A Manuel utilisateur

Service Manual

Fuller Mid-Range Transmissions

TRSM0130

October 2007

FS-4005A

FS-4005B

FS-4005C

FS-4205A

FS-4205B

FS-4205C

FS-5005A

FS-5005B

FS-5005C

A WARNING

Before starting a vehicle always be

seated

the drivers seat, place the

transmission

neutral, set the park-

ing brakes and disengage the clutch.

Before working

a vehicle place the

transmission

neutral, set the park-

ing brakes and block the wheels.

Before towing the vehicle place the

transmission

neutral, and lift the

rear wheels off the ground or discon-

nect the driveline to avoid damage to

the transmission during towing.

TABLE

CONTENTS

FOREWORD

................................................................

MODEL DESIGNATIONS AND SPECIFICATIONS

..................................

LUBRICATION

...............................................................

OPERATION

................................................................

POWER FLOW

...............................................................

TORQUE RECOMMENDATIONS

................................................

PREVENTIVE MAINTENANCE

.................................................

PRECAUTIONS

DISASSEMBLY

............................................................

INSPECTION

..............................................................

REASSEMBLY

.............................................................

DISASSEMBLY AND REASSEMBLY -SHIFTING CONTROLS

GEARSHIFT LEVER HOUSING ASSEMBLY

.......................................

SHIFT BAR HOUSING ASSEMBLY

..............................................

REMOVAL -YOKE AND CLUTCH HOUSING

.....................................

DISASSEMBLY -TRANSMISSION

..............................................

REASSEMBLY -TRANSMISSION

..............................................

INSTALLATION-

CLUTCH HOUSING

...........................................

INSTALLATION -SHIFTING CONTROLS

........................................

OPTIONS

..................................................................

FOREWORD

This manual is designed to provide detailed information

necessary to service and repair the

Eaton@

Fuller@

Transmission listed

the cover.

As outlined

the Table of Contents, the manual

divided into 3 main sections:

Technical information and reference

Removal, disassembly, reassembly, and

installation

Options

The format of the manual is designed to be followed

its entirety if complete disassembly and reassembly of

the transmission is necessary. But if only one compo-

nent of the transmission needs to be repaired, see the

Table of Contents for the page numbers showing that

component. For example, if you need to work

the

Shifting Controls, you will find instructions for removal,

disassembly, and reassembly

page 15. Instructions

for installation are

page 58. Service Manuals,

Illustrated Parts Lists, Drivers Instructions, and other

forms of product service information for these and other

Eaton Fuller Transmissions are available upon re-

quest. A Product Literature Order Form, Service

Bulletins (detailing information

product improve-

ments), repair procedures, and other service-related

subjects can be obtained by writing to the following

address:

EATON CORPORATION

TRANSMISSION DIVISION

Technical Service Department

P.O. Box 4013

Kalamazoo, Michigan 49003

(616) 342-3344

Every effort has been made to ensure the accuracy of all information

this brochure. However, Eaton Transmis-

sion Division makes no expressed or implied warranty or representation based on the enclosed information.

Any errors or omissions may be reported to Training and Publications, Eaton Transmission Division, P.O. Box 4013,

Kalamazoo, Ml 49003.

MODEL DESIGNATIONS

AND SPECIFICATIONS

Nomenclature:

S-

Fuller"' I

Letter Designations

Synchronized----------""""'

Specifications:

GearRat'os

Ne.

Model

Speecs

·a

4th

FS-5005A 5 7.52 2.54 2.54 1.52

FS-50058

5 6.82 2.15 2.15 1.28

FS-5005C 5 6.82 1.99 1.99 1.17

5005A

Number

Designations

Ratio Group

'.1

1.00

Forward Speeds

Design Level

x 100 =Nominal Torque

Capacity

IMPORTANT: All Eaton Fuller Transmissions are

identified by the model and serial number. This

information

stamped

the transmission identifi-

cation tag and affixed to the case.

NOT REMOVE OR DESTROY THE TRANSMIS-

SION IDENTIFICATION TAG.

Reial

Soeed

No:c

· 2

Note

PTO

3ear:::

_e-g111

l//eo':

Q,I

Caoaci:y

lnpc:

ir.

Los.

Pi-ts

Rf:'ver:;e

Rig

Li:/t

'"1:'1)

:Kg)

1Uersi

6.27 .460 .435 21.9 280 10.5

(556.0) (127.0) (5.0}

5.30 .543 .515 21.9 280 10.5

(556.0) (127.0} (5.0)

5.30 .543 .515 21.9 280 10.5

(556.0) (127.0) (5.0}

Lengths measured from clutch housing face to speedo gear rear.

Weights include shift bar housing, clutch housing, less tower assembly, and clutch release parts. For more

information on available clutch housings, see the transmission's Illustrated Parts List or the Super Parts Book.

All weights are approximate.

3. Oil capacities are approximate, depending

inclination of engine and transmission. Always fill transmission,

with proper grade and type of lubricant, to level of filler opening. See LUBRICATION.

LUBRICATION

Proper

Lubrication.

the Key to long

transmission life

Proper lubrication procedures are the key to a good all-

around maintenance program.

the oil is not doing its

job, or if the oil level

ignored, all the maintenance

procedures

the world are not going to keep the

transmission running or assure long transmission life.

Eaton Fuller Transmissions are designed so that the

internal parts operate

an oil circulating bath by the

motion of the gears and shafts.

Thus, all parts are amply lubricated if these procedures

are closely followed:

Maintain oil level. Inspect regularly.

2. Change oil regularly.

3. Use the correct grade and type of oil.

Buy from a reputable dealer.

Lubrication Change and Inspection

Eaton® Roadranger®

CDSO

Transmission Fluid

HIGHWAY USE

Firs'

3,000

5,000

miles

Factory

fill

{4827

8045

Km!

1rn:ia

o·ai:-:.

Every

0,000

miles

Check

flukl

level.

(;6090

Ker)

Check

::::r

iea;.;s.

Every

250,000

m•les

Craoge

t•ans'.'1•sso1

(402336

Krr)

llu·d.

OFF-HIGHWAY USE

hour_;

Factory

f I

initial

d·ain.

Every

hours

lnspec:

fluic

eve!.

Creek

fa•

leaks.

Every

500

hours

Criange

tra."sriission

71uic

where

severe

dirt

:::onditions

exist.

Every

.:O·J

oours

Cra1ge

trans11·ss.0°

lluid

(Norrra:

off-h

ahway

cse."

Heavy Duty Engine Lubricant or

Mineral Gear Lubricant

HIGHWAY USE

First

3.000

5,COO

riiles

Fac:oryiill

4827

8045

Krr

imtial.

Every

10,000

-;iles

l'isoec:

lubrica'lt

level.

(t6090

C1eck

:or

·eal{s.

Every

50.000

les

Cha1ge

tra:isr:i1ss1on

(80450)

lubr•car:.

OFF-HIGHWAY USE

First

3·J

oours

Cnange

transrr:issio-;

lubricant

new

:.inits.

Every

1purs

lr.soect

lubricaPt

Chee!\

1eaks.

Every

500

rours

transmissior.

lubr:cant

where

sevee

condit:ons

exist.

Every

1,00C

hoers

Change

'ransmission

lubricant

(Norma:

off-h:ghway

t.se.]

Recommended Lubricants

Grade

Fahrenheit

(Celsius)

Type

Ambient

(SAE)

Temperature

Eaton@Roadranger(<,

CDSO

Transmission

All

Fluid

Heavy

Duly

.gine

MIL-L-21048,

Dor

Above

10' F(-t2'C)

APl-SF

AP:-CD

Above

10"F

(·12"C;

(Pr9ViOJS

API

Below

10'F

:-12''C)

acceotab

neral

Gear

OI'

'.h

rust

Abo'e 1

'.2'·C)

and

i'":hibitor

sew

Below

'O'F i-"2'C)

ft.Pl-GL-'.

The use of mild EP gear oil or multi-purpose gear oil

is not recommended, but

ifthesegearoilsare

used,

be sure to adhere to the following limitations.

not use mild EP gear oil or multi-purpose gear oil

when operating temperatures are above 230° F (110"

C). Many of these gear oils, particularly 85W140,

break down above 230° F and coat seals, bearings, and

gears with deposits that can cause premature failures.

these deposits are observed (especially a coating on

seal areas causing oil leakage), change

Eaton

Roadranger CD50 transmission fluid, heavy duty en-

gine oil, or mineral gear oil to assure maximum compo-

nent life and to maintain your warranty with Eaton.

(Also see "Operating Temperatures".)

Additives and friction modifiers are not recommended

for use

Eaton Fuller Transmissions.

Proper Oil Level

Make sure oil is level with the filler opening. Because you

can reach oil with your finger does not mean oil is at

proper

level. (One inch of oil level is about one gallon

oil.)

Draining Oil

Drain transmission while oil is warm. To drain oil remove

the drain plug at case bottom. Clean the drain plug

before re-installing.

Refilling

Clean case around filler plug and remove plug from case

side. Fill the transmission to the level of the filler opening.

the transmission has two filler openings, fill to the level

of both openings.

The exact amount of oil depends on the transmission

inclination and model. Do not over

fill-this

causes oil to

be forced out of the case through the front bearing cover.

When adding oil, types and brands of oil should not

be mixed because of possible incompatibility.

LUBRICATION

Operating Temperatures

-With

Eaton Roadranger

CDSO

Transmission Fluid

Heavy Duty Engine Oil

and Mineral Oil

The transmission should not be operated consistently

at temperatures above 250° F (120° C}. However,

intermittent operating temperatures to 300° F (149°

do not harm the transmission. Operating temperatures

above 250° F increase the lubricant's oxidation rate

and shorten its effective life. When the average oper-

ating temperature

above 250°

the transmission

can require more frequent oil changes or external

cooling.

The following conditions

any combination can cause

operating temperatures of over 250°

)operating

consistently at slow speeds,

(2)

high ambient tempera-

tures,

(3)

restricted air flow around transmission,

(4)

exhaust system too close to transmission,

(5)

high

horsepower, overdrive operation.

External oil coolers are available to reduce operating

temperatures when the above conditions are encoun-

tered.

Transmission

Oil

Coolers

are:

Recommended

-With

engines of 350 H.P. and above with

overdrive transmissions

Required

-With

engines 399 H.P. and above with over

drive transmissions and GCW's over

90,000 lbs.

-With

engines 399 H.P. and above and 1400

lbs-ft or greater torque

-With

engines 450 H.P. and above

With

Multipurpose Gear Oil

Mild

gear oil and multipurpose gear oil are not

recommended when lubricant operating temperatures

are above 230° F (110°

C).

addition, transmission oil

coolers are not recommended with these gear oils

since the oil cooler materials can

attacked by these

gear oils. The

lower

temperature

limit

and

oil

cooler

restriction

with

these

gear

oils

generally

limit

their

success

milder

applications.

Proper Lubrication Levels

as Related

Transmission

Operating Angles

If the transmission operating angle

more than 12

degrees, improper lubrication can occur. The operat-

ing angle

the transmission mounting angle

the

chassis plus the percent of upgrade (expressed

degrees).

The chart below illustrates the safe percent of upgrade

which the transmission can be used with various

chassis mounting angles. For example: if you have a

4 degree transmission mounting angle, then 8 degrees

(or 14 percent of grade)

equal to the limit of 12

degrees. If you have a 0 degree mounting angle, the

transmission can be operated on a 12 degree

(21

percent} grade.

Anytime the transmission operating angle or 12 de-

grees

exceeded for

extended period of time the

transmission should

equpped with

oil

pump or

cooler kit to insure proper lubrication.

Note

the chart the effect

low

oil

levels can have on

safe operating angles. Allowing the oil level to fall 1/2"

below the filler plug hole reduces the degree of grade

by approximately 3 degrees (5.5 percent}.

Proper Lubrication Levels are Essential!

t---+--l--+--+--l---1---1

1 8'

0 0

0 2 3 4 5

Transmission Mounting Angle

Dotted line showing "2 Quarts Low"

for

reference only. Not recommended

OPERATION

Gear Shift Lever Pattern and

Shifting Instructions

Follow the simple 5-speed shift pattern.

Simple progressive

shift pattern

-,\

(--

R 2 4

"-·-1

) I

I \ j

/ ,

____

I Neutral ]

___

I ( \

1 3 5

J j \

____

··--"

Adobe 0001-2/88

General Information

R 2H• 4H

2L i 4L ,

<__;

\...

--j

-1H

.,,

1(-

-,i

,--

-,I

1L , 3L ·

)

"·-

: <_

FS-SOOSB

with "soft"

fourth and 2-speed axle.

(--\

R I

2H.

4H'

I 2L : 4L

\,__)

\.._.)

""-

Neutral

-1

(--

: -..\

(,,.-

·-,,

, 1H , 3H , ,

1L 3L

\,_

__/

___

,__

FS-5005C with "short"

fourth and 2-speed axle.

FS-5005 transmissions have five forward speeds and one reverse, and are shifted as you would shift any synchro-

nized manual transmission, following the simple 5-speed shift pattern.

Driving Tips

• Always use the clutch when making upshifts or downshifts. Premature synchronizer failure can result from not

using the clutch.

• Always select a starting gear that provides sufficient reduction for the load and terrian.

• Never downshift at road speed too high.

• Never slam or jerk the shift lever to complete gear engagement.

• Never coast with the transmission

neutral and the clutch dis-engaged.

POWER FLOW

The transmission must efficiently transfer the engine's power, in terms of torque, to the vehicle's rear wheels. Knowl-

edge of whattakes place

the transmission during torque transfer is essential when troubleshooting and making repairs.

1. Power (torque) from the engine is transferred to the input shaft and drive gear.

Torque is transferred to the countershaft drive gear.

Torque is delivered along the countershaft to all countershaft gears.

Torque

transferred to "engaged" mainshaft gear. The cross section illustrates 1st speed gear position.

Engaged mainshaft gear internal clutching teeth transfers torque to mainshaft through synchronizer assembly.

6. Mainshaft transfers torque directly to driveshaft through rear yoke.

TORQUE RECOMMENDATIONS

Correct torque application is important to assure long transmission life. Over or under tightening of fasteners can

resul1

a loose installation and,

many instances, can eventually cause damage to the transmission. Use a torque wrench

obtain recommended torque ratings. Do not torque capscrews dry.

4 FRONT BEARING

COVER CAPSCREWS

15-20 LBS.-FT.

5/16-18 THREAD

2 HAND HOLE

COVER CAPSCREWS

5 LBS.-FT.

1/4-12 THREAD

Adobe 0002-2/88

4 SHIFT LEVER HOUSING

CAPSCREWS

20-25 LBS.-FT.

3/8-16 THREAD

9 SHIFT RAIL RETAINER

CAPSCREWS

20-25 LBS.-FT.

3/8-16 THREAD

17 SHIFT

BAR

HOUSING

CAPSCREWS

20-25 LBS.-FT.

3/8-16 THREAD

4 CLUTCH HOUSING

CAPSCREWS

145-155 LBS.-FT.

5/8-16 THREAD

OUTPUT SHAFT NUT

300-350 LBS.-FT.

11/4-18 THREAD WITH

NYLON LOCKING INSERT

(OILED

VEHICLE

INSTALLATION)

Ce manuel convient aux modèles suivants

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