Eaton FS-6105 Manuel utilisateur

Service Manual

Fuller Mid Range Transmissions

TRSM0140

October 2007

TABLE

CONTENTS

FOREWORD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . • . • • . • • • • • . • . • • . • • • • . . • . . . . . . . 2

MODEL DESIGNATIONS AND SPECIFICATIONS .

. .

. . . . .

. . . .

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

...

. 3

LUBRICATION . • . . • . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . • . • • • • • . • . . • . . . . •• • • . . . . . . • . . . 4

OPERATION . . . . . . • . • • . • • . • . . • . • • . . • . • • . • • . • . . • . . . . . . . . . . • . . • • . • . . • . . . . . . . . • . . . 6

POWER FLOW . . . . . . . . . . . . . . . . . . . . . . . . . . • • . • • . • • • • . • • . • • . • • . • • . • • • • • . • • . • . . • . . . 7

TORQUE RECOMMENDATIONS

.......

...

....

. . .

.....

PREVENTIVE MAINTENANCE

....

.•••••.••.

••

. •

•••

• . .

•.••

•.

....

•..

..•••..

PRECAUTIONS

DISASSEMBLY.

....

•

.............•..•.•

•.••

.••.•••••.••.

•

•.

• . . •

•

• . . •

...

INSP

ECT

ION

...

.•

•..

..............•.•

••

...

..••.••.••.

•

•.

••

...

•

• . . . 12

REASSEMBLY

.....

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

. . .

...

. • . . •

•.

. . . •

..•..•...

DISASSEMBLY

AND

REASSEMBLY-SHI FTING CONTROLS

IFT LEVER HOUSI

ASSEMBLY .

.....

...........••.••.••

. • .

...

..•

SHIFT BAR HOUSING ASSEMBLY

.......

...

•..••••.••.••.••.•••••.••

...

REMOVAL-YOKE

AND

CLUTCH HOUSING . . . . . . • • . • • . • • . • . • • . . • . . . . . . . . . . . . . . . . .

DISASSEMBLY

-TR

ANSMISSION

.......

.....

. • .

. . •

.....

•

...

•

•.

. • .

.•...

REASSEMBLY-TRANSMISSION

......

.....

... ...

.........

...

••.•.

......

INSTALLATION-CLUTCH HOUSING AND

YOKE

........

. . . .

....

...........

......

INSTALLATION -SHIFTING CONTROLS

SHIFT BAR HOUSI

ASSE

. . . . .

. . .

• • . . • . . • . . • . . . . . .

. .

. . . . . .

GEAR

T LEVER HOUSI

ASSEMBLY .

.....

.......

.....

......

OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . • . . . . . . . . . . . . . . . . . . . . . . • . . . . . . 53

lll

l!!i

MODEL

DESIGNATIONS

AND

SPECIFICATIONS

FS-6105

letter

Designations II ' I' Number Ooslgnalions

FuUe

rCI

---

---------'

Forward Speeds

Synchronized

---------'·

Design

leve

Specifications:

Gt•

hln

••

.....

S;•(lolf

...

fl-

15 ' '" '"

see

Char

Not

CHART NOTES:

100

=Nominal

torque

Capac:ity

IMPORTANT: A

Fuller Tra

nsmissions

are

ldenll·

tied

mOdel

and serlal number. This Information

is stamped on !he trans

mis

sion Identification tag

and

affixed

10 the case.

NOT

REMOVE

DESTROY

THE

TRANS-

MISS

ION

IDENTIFICATION

TAG.

fltu!W

SjlHO

.....

!1111

, _,

1'10

UMt

N l•llJ!ll

.....

°'

Gal'«llt

1111111

ltf'M

...

,.,

'"'"!

\ICi

:u1t11"!

"" ,,,

,,.

...

",.

''"

•

1. Lenglhs measured trom face ot clutch housing to cent

lin

e ot yoke.

2. Weights Inclu

ift

bar

hous

g and end yoke, less

c1u

housing,

tower

assembty and c

tch

release

parts. For more lntormatton on available clutch housings, refer

pub

ca1

lon FUL·

140

lutch Hous

Chart."

All

weights

are

approximate.

011

capacities aro approximate, depending

inclin

ation

engine and 1rans

s.s

ion. A

ays

tr8l'lsmis·

sion

with

proper grade

and

lype

lubricant

level

ill

er opening. See LUBRICATION.

LUBRICATION

Operating Temperatures

-With Heavy Duty Engine O

and Mineral Oil

The

ans

ssion

ould

not

opera

con·

sis

ently

at temper

atures

f!bO\le 2so•F (120,.C}.

However,

in1e

rmi1tent opera.ting temperatures

300•F

(149"C) w i

not

arm

the

transrni5"

slon.

OpefaJ

lernperatures above 2so•F

Increase

lhe

icant's

rette

oxidation

11t1d

shor

ten

its

ective

te. When

the

average

operating temperature

above

2so•F,

tra

smission

may

requlre

ore

frequent

oll

changes or

ternal cooling.

The

following

condi

tions

any combina-

tion

can

cause

ope

rating temperatures

over

250"F:

{1}

ope

ating

consistently

al sl

speeds,

(2)

high

ambient temperatures.

(3}

re·

str

cted

flow

around

(4)

sys

O tr

ansmission

(5)

high hor

power,

overdrive

ope

ation

Ex ternal

coa

ers

are available

reduce

oper

ating tempera.l

ures

when

the

above

cond

i·

lio

ns ere enoountered.

Tran

ission

011

Coo

lers are:

Re<:o

mended

Wilh

engines

350 H.P.

and

abOve

wllh

overd

raflsm

ions

Required

With

engines 399

H.P.

and above wl1h

overdrive

transmiss

ons

and

GCW

over

,000 lbs.

th engines 399 H

.P.

and

above and

1400 lb&.·FI. or greater

torq

With

engines

41.SO

.P.

and

above

-With

Multipurpose Gear Oil

Mllct EP geetr

oil

and

multipu

rpo5e

gear

oil

at e

nol

reoom

ended

lubrican

ope

rat

temperatures are above 230•F

10 •1 In addl·

lion, transmission o

cooters

a.re

not recom·

mended

with

these gear

0115

since

lle

oil

coole

ter

ials

may

tacked

these

gear

o11s

. The l

ower

temperature

lim

and

oll

coo

res1rictlon

with

these

gear

y l

i t

their

success

milde

ations

•

Proper Lubrication Levels

as Related to Operating Angles

the

transm

ssion

operating

ang

le la

than

12 degree:&,

Imp

oper

bricaJlon

can

occur.

Th<1

operating

angle is the

ansm

lss

mounting

ang

lhe

cha

ssis

plus

per

cen1

o f

upgrade

(express.ad In

deg

rees).

The

cnar1

below

lllus

the

safe

perc;:ent

upgrade

which

the t

tansm

issio n

can

used

with

var

ous

chassis

mounting

ang

For

examp

le:

u have a 4

degree

trans

mis-

mounUng angle,

then

degrees

(or

percent

grade)

equal to

lhe

Omit

degrees

. If

you

have a 0

mounting

angte, 1he t

ransmission

can

operated

degree

(21

percent) grade.

Anytime

the

transmission

opera

ng angle

degrees

ex.ceoded

for

extended

period

o f

lime

the

transmlssfon

sho

equipped

with

oil

pump

o r

coo

101

kJI

insure

proper

lubrication.

No le

charl

cUect

low

oil

levels

can

have

safe

operating

ang

Allowing

the

oil

level

10 fall

lh"

fille

plug

hole

reduces i he

degree

grade

by approxi-

mately

degrees

(5.5 percent).

Proper Lub,

lcatlon

eve

ts are

Esun

tla

,,.

::..,.,.

I'!!!

(

10·13

•

.....

, !

....

•

.s···

· u

•.

• •

o·

1•

2·

a·

•'

.s·

e· 1·

ltllfl•mlt..rc.i

An;

I•

00t

1t1

all0

111l

t19

"2 Ou

•n•

l.o

• "

llllf

tt-t1t

11-n.:Nd

•

OPERATION

Lev

Pattern

Shifting

tru

tlon

Follow the simple 5-speed

shift

pattern

...

Fulle

r®

6105

R 0

eutr•I

1 0

w.ni.

•

General lnfo

rm•t

FS..6105

1tansm1ss1ons

h8\le

five

rward speeds

and

one

reverse,

and

are

shifted

you

would

s"ltl

any

aynchroniz&d manual ltansmlsslon, followrng the sim-

ple shifl pattern.

Driving

Tips

• A

Jway3

U1'C

tho

<;lutc:h

when

making

up.shlfl3

downshlfts

. P

mature synchronizer failure can re·

sull

from

no1

using the clutc;ih.

• Always

select

a starting gear

tlial

will

provide

suffl

cien1

reduction

lor

the load and terrain.

• Never downshlft al too high

a road speed.

•

Never

slam

the

shift

lever

comple1e

geru-

engagemenL

• Never coast with the transmission in neutral

and

the cf

ulch

dis-a.ngaged.

•

5 -

•

POWER

FLOW

-Tht

lr•nsmls.slon musl etflclenUy transfer l

engine's

power

, In

term•

torque, to

lht

vehlc1e·s rear wheels.

Knowledge

whal lakes place

tranamlealon d

ing torque transfer

es.senHal

when trouble-shoollng

making repairs, becomes

neces.sary

1 Power (IOtque)

lrom

the

engtne

ttantftrred

the

Input at'lafl and

dtfve

gear

Torque

transferred

the countaral'IAlfl

drive

geat.

Torque

dafivered

along

countershatt

111

cou.nteishalt gears

Torque rs transferred

"enoaved" maJnahalt gear. r ·l'\e cro11 section Ulustr411et 111 speed gear position

ln1

erna.

1clutching

IHlh

engaged m•lnahatt

gea.r

transfers torque

inshalt lhrougn synchronizer

II·

aemb

ly.

Malnstialt t

nsrera 1orque

ectly

drlveshaft through rear yoke.

TORQUE

RECOMMENDATIONS

Correct 1orquo application

important

assure tong transmission

life

. Over

undor

lightening

fastener&f

can result

a loose

slallatlon and,

many

insta

nces,

ccul

even1ually causo

dam.age

the transmission. Use

a torque wrench

obtain

recommended torque rat

gs.

not

torque capscrews

dry.

6 FRONT

8EARING

COVER

CA.P

SCREWS

l!.•2!0

l.8$.-FT..

tlie-18 THREAD

9 SHIFT

RAi

AETAJNER

CAPSCRE'W$

4 SHIFT

LEVE

HOUSING

CAJ>SCAEWS

l8S

.·

20·25 l8S,·FT.

lilt·16

Tl1

EAD

HAtfO

HOLE

COYIER

CAP'SCREWS

l8$.-Ft

••

12 Tl-lflEAD

THREAD

4 C:lUTCH HOUSIHG CAPSCR

£W$

14$-155

S.·FT.

,.·16

THR

EAO

(::.

(

$HIFT

BAR HOUSING

CAP$CAEWS

2().25

L8$.

•

F'T

..,_,&

TitAEAO

OUTPUT SHAFT NUT

300·360

LBS

THREAD

WITH

H't'lON

ING

INSERT.

(OILED AT VEHICLE

INSTAUATION)

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