Eaton Fuller 9 Speed Gearbox Transmission FS 6109 / 6209 / 6309 / 8209 / 8309 Service Manual

Service Manual Eaton Transmissions TRSM0060 FS(O)-6109 FS(O)-6209 FS(O)-6309 FS(O)-8209 FS(O)-8309 December 2009

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 ...............................................................................................................................................14 Gear End Floats ............................................................................................................................................16 Synchroniser Ring to Synchroniser Flange Clearance ..................................................................................16 Lubrication Information Lubrication ....................................................................................................................................................17 Recommended Lubricants.............................................................................................................................18 Tool Information Recommended Tools ...................................................................................................................................20 Special Tools Manufacturers .........................................................................................................................21 Locally Made Tools........................................................................................................................................22 Preventive Maintenance Preventive Maintenance ...............................................................................................................................23 Checks Before Transmission Removal .........................................................................................................23 Checks With Drive Line Dropped ..................................................................................................................23 Checks With Universal Joint Companion Flange or Yoke Removed.............................................................24 Rear Seal Maintenance .................................................................................................................................24

Table of Contents Power Flow Power Flow ...................................................................................................................................................25 General Features .......................................................................................................................................................26 The Epicyclic Reduction Gear .......................................................................................................................26 Transmission Installations .............................................................................................................................28 Air System System Theory .............................................................................................................................................29 Range Change Shift Air Lines .......................................................................................................................30 Filter Pressure Regulator...............................................................................................................................31 Mecman Regulator ........................................................................................................................................32 Selector Valve ...............................................................................................................................................33 Slave Valve....................................................................................................................................................35 Range Change Shift Cylinder .......................................................................................................................37 Raneg Change Air Circuit Diagram - Double H .............................................................................................38 Raneg Change Air Circuit Diagram - Single H .............................................................................................39 Exhaust Control Valve ...................................................................................................................................41 Raneg Change Shift Air Circuit Diagram with Exhaust Control Valve ..........................................................42 Raneg Change Shift Air Circuit Diagram with Range Inhibitor ......................................................................44 Mecman Valve ..............................................................................................................................................45 Raneg Change Shift Air Circuit Diagram with Mecman Valve .......................................................................46 Range Inhibition System................................................................................................................................50 Integrated AIr System (IAS) ..........................................................................................................................51 Type of IAS Unit ............................................................................................................................................52 Range Change Shift Air Lines ......................................................................................................................54 Raneg Change Shift Air Circuit Diagram - Double H .....................................................................................55 Raneg Change Shift Air Circuit Diagram - Single H ......................................................................................58 Remote Control Assembly Exploded View ..............................................................................................................................................63 How to Disassemble Remote Control Assembly ..........................................................................................64 How to Assemble Remote Control Assembly ................................................................................................68 Transmission Case Overhauling Exploded View ..............................................................................................................................................72 How to Disassemble Transmission Case .....................................................................................................73 Exploded View ..............................................................................................................................................82 How to Disassemble Rear Case....................................................................................................................83

Table of Contents Exploded View ..............................................................................................................................................87 How to Disassemble Palnet carrier Assembly ...............................................................................................88 How to Assemble Planet Carrier Assembly ...................................................................................................89 How to Assemble Rear Case ........................................................................................................................91 Mainshaft Assembly Exploded View ..............................................................................................................................................97 End Float Check ...........................................................................................................................................98 How to Disassemble Mainshaft .....................................................................................................................99 Check Clearance between Synchroniser Ring and Flange ...........................................................................102 How to Assemble Mainshaft ..........................................................................................................................103 Layshaft Assembly Exploded View ..............................................................................................................................................109 How to Disassemble Layshaft ......................................................................................................................110 How to Assemble Layshaft ............................................................................................................................111 Input Shaft Assembly Exploded View ..............................................................................................................................................112 How to Disassemble Input Shaft Assembly ...................................................................................................113 How to Assemble Input Shaft Assembly........................................................................................................114 Selector Assembly Exploded View ..............................................................................................................................................116 Selector Assembly - Single H ........................................................................................................................117 How to Disassemble Selector Assembly ......................................................................................................117 How to Assemble Selector Assembly ............................................................................................................118 Selector Assembly - Double H.......................................................................................................................119 How to Disassemble Selector Assembly ......................................................................................................119 How to Assemble Selector Assembly ............................................................................................................119 Transmission Case Assembly Exploded View ...............................................................................................................................................121 How to Assemble Transmission Case ...........................................................................................................122

Table of Contents Clutch Housing Exploded View ...............................................................................................................................................133 How to Disassemble Clutch Housing ............................................................................................................134 How to Assemble Clutch Housing .................................................................................................................136

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, or 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 specifications at any time without notice. Any reference to brand name in this publication is made as an example of the types of tools and materials recommended for use and should not be considered an endorsement. Equivalents may be used. This symbol is used throughout this manual to call attention to procedures where carelessness or failure to follow specific instructions may result in personal injury and/or component damage. Departure from the instructions, choice of tools, materials and recommended parts mentioned in this publication may jeopardize the personal safety of the service technician or vehicle operator. Warning: Failure to follow indicated procedures creates a high risk of personal injury to the servicing technician. Caution: Failure to follow indicated procedures may cause component damage or malfunction. Note: Additional service information not covered in the service procedures. Tip: Helpful removal and installation procedures to aid in the service of this unit. Always use genuine Eaton replacement parts. 1

Introduction Introduction Purpose and Scope of Manual This manual is designed to provide detailed information necessary to service and repair the Eaton® transmissions listed on the front. How to use this Manual The procedure sections are laid out with a general heading at the top outside edge of each page followed by more specific headings and the procedures. To find the information you need in these sections, first go to the section that contains the procedure you need. Then look at the heading at the top and outside edge of each page until you find the one that contains the procedure you need. Transmission Overhaul Procedures follow the general steps for complete disassembly and then assembly of the transmission. Note: In some instances the transmission appearance may be different from the illustrations, but the procedure is the same. Disassembly Precautions It is assumed in the detailed disassembly instructions that the lubricant has been drained and the necessary linkage and air lines (if fitted) have been removed from the chassis. Removal of the gear shift remote control housing assembly is included in the detailed instructions; how- ever, this assembly may also be removed from the transmission before removing unit from vehicle. Follow each procedure closely in each section, making use of both the text and the pictures. Cleanliness Provide a clean place to work. It is important that no dirt or foreign material enters the unit during repairs. The outside of the unit should be carefully cleaned before starting the disassembly. Dirt is abrasive and can damage bearings. Assemblies When disassembling the various assemblies, such as the mainshaft, range change epycyclic, layshaft and remote control housing, lay all parts on a clean bench in the same sequence as removed. This procedure will simplify reassembly and reduce the possibility of losing parts. When pulling off synchroniser hubs follow the procedures detailed in ‘Disassembly’ using a suitable puller of adequate capacity. Failure to adhere to the recommended procedures may cause irreparable damage. Snap rings Remove snap rings with pliers designed for this purpose. New selective fit snap rings must be fitted as specified in ‘Reassembly’. Input shaft The input shaft on direct drive transmission can be removed without removing the front case. Take care not to misplace or lose the mainshaft spigot bearing. Bearings Carefully wash and relubricate all bearings as removed and protectively wrap until ready for use. Remove bearings with pullers designed for this purpose. When Pressing Apply force to shafts, housings etc. with restraint. Movement of some parts is restricted. Do not apply force after the part being driven stops solidly. Use soft hammers for all disassembly work. 2

Introduction Do not use pry bars or chisels to separate casing halves and housings or irreparable damage may be caused. Inspection Precautions Before reassembling the transmission, the individual parts should be carefully checked to eliminate those damaged. They should be renewed. This inspection procedure should be carefully followed to ensure the maximum wear life from the rebuilt unit. The cost of a new part is generally a small fraction of the total cost of downtime and labour, should the use of a questionable part make additional repairs necessary before the next regularly scheduled overhaul. Recommended inspection procedures are set forth in the following check list. Bearings • Wash all bearings in clean solvent. Check rollers and races for pits and spalled areas. Renew damaged bearings. • Lubricate undamaged bearings and check for axial and radial clearances. Renew bearings with excessive clearances. • Check fits of bearings in housing bores. If outer races turn too freely in the bores, the housing should be renewed. Check housing bores for signs of wear prior to taking this action. Only replace housing if wear is seen as a result of bearing spin. Gears • Check gear teeth for pitting of the tooth faces. Gears with pitted teeth should be renewed. Check the reverse gear dog engagement teeth for freedom from damage. • Check the internal bearing surfaces for wear of the effects of overheating. • Check axial clearances of gears. Where excessive clearance is found, check gear and hub for excessive wear. • Maintain the specified axial clearance on all mainshaft gears. Bearing Sleeve — Mainshaft • Sleeves with groove formation, pits or which have either been overheated or worn out must be renewed. 3

Introduction Introduction Synchroniser Assemblies • Check to ensure all splines are free from excessive wear. • Check that the engagement dog teeth on the sliding sleeves, synchroniser rings are free from chipping and burring. • Check that the synchroniser ring cones are not excessively worn or showing the effects of overheating. Check the clearance between the synchroniser ring and the synchroniser flange is between 3.01 mm maximum and 0.50 mm minimum. • Renew the springs, plungers and rollers. Splines • Check splines on all shafts for wear. If synchroniser hubs, output drive flange or clutch hub have worn into the sides of the splines, the shafts in this condition must be renewed. Thrust Washers • Check surfaces of all thrust washers. Washers scored or reduced in thickness should be renewed. Range Change Planet Gears, Spindles and Needle Roller Bearings • It is found neccessary to dismantle the planet gears, retain each gear, spindle, rollers, spac- ers and washersin their respective set for reassembly in the same relative position. • If uneven wear is found in the planet gears, check lubrication holes for blockage and renew all rollers. • Renew planet spindle grubscrews on reassembly. Reverse Idler Gear • Check bearings and shaft for wear from action of roller bearings. Clutch Release Parts • Check clutch release parts, yokes and bearing carrier. Check pedal shafts. Renew worn shafts and bearings. Gear Selector Shaft Assembly • Check forks and keys for wear at contact points. Renew worn parts. • Check forks for alignment. • Check forks for excessive and uneven wear, renew worn forks. • Check lockscrew in selector block. A lockscrew with worn taper must be renewed. • Check condition and fit of selector key and interlock key in shift shaft. Worn or damaged keys must be renewed. Gear Shift Remote Control • Check spring tension on cross shaft. Renew tension springs if shaft moves too freely. • If housing is dismantled, check cross shaft and inner lever and the bearing bushes for wear. Renew worn parts. • Check all seals and locating journals. Renew worn parts. Bearing Covers • Check covers for wear from thrust. Renew covers worn or grooved from thrust of bearing outer race. • Check bores of covers for wear. Renew those worn oversize. Oil Return Seals • Check oil seal in front bearing cover for damage and wear, renew if necessary. • Check oil seal in speedometer housing for damage or wear, renew if necessary. Renew grit shield if worn or loose on flange. • Check oil seal tracks for wear and renew if worn or grooved. • Check the oil sealing ring in the muff ring for wear or breakage. O-Rings • Renew all O-rings. 4

Introduction Oil Pump • Check the oil pump rotors and covers for scor- ing and wear. The complete pump assembly must be renewed if scored or excessively worn, or its serviceability is suspect in any way. Assembly Precautions Make sure that interiors of all housings are clean. It is important that dirt be kept out of transmission during reassembly. Dirt is abrasive and can damage polished surfaces of bearings and washers. Use certain precautions, as listed below, during reassembly. Gaskets Use new gaskets where detailed only (neutral detent cover and remote control housing covers). All other locations ensure mating faces are clean and undamaged and apply a continuous bead of Loctite 5900 Flange Sealant to one face only. Do not apply excessive sealant or allow it to penetrate into the bearings. Capscrews Use thread sealant on all capscrews. Refer section ‘Specification’ for torque ratings. ‘O’ Rings Lubricate all ‘O’ rings lightly with silicone lubricant. Initial Lubrication Lubricate bearings with gearbox oil during reassembly. Axial Clearances Refer section ‘Specification’ to maintain the end float of mainshaft gears. Bearings Use of the correct special tools and bearing drivers is recommended for the installation of bearings. Heating the bearing inner tracks will aid installation. Output Shaft Drive Flange Tighten the nut to the correct torque. Do not under any circumstances use an impact wrench to tighten the flange/yoke nut. Use only a hand oper- ated torque wrench or a stall torque motor. Failure to carry out these instructions can cause damage to the locking medium of the nut. During disassembly and again during reassembly prior to tightening the new nut, it is important to ensure that the output shaft does not slide through the bearing, or the assembled range change synchroniser roller, plungers and springs may be displaced. A suitable spacer should be temporarily assembled under the nut to allow for the thickness of the nut locking insert to ensure the shaft is firmly held in the bearing until the nut can be torque tightened. 5

Eaton Fuller 9 Speed Gearbox Transmission FS 6109 / 6209 / 6309 / 8209 / 8309 Service Manual

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