Eaton Roadranger TRSM4106 User manual

Service Manual
Fuller Mid Range Transmissions
TRSM4106
October 2007

For parts or service call us
Pro Gear & Transmission, Inc.
1 [phone]
[phone]
[email protected]
906 W. Gore St.
Orlando, FL 32805

Service Manual
(4106 / 5206)
Eaton 6-Speed Synchromesh Transmission
Truck Components Operations Europe
PO Box 11 Worsley
Manchester M28 5GJ
England

5/01
Section 1 General
1/1 Letter and Model Designation
1/2 Technical Data
1/3 Lubrication
1/4 Recommended Lubricants
1/5 Torque Tightening Recommendations
1/7 Disassembly Precautions and Inspection of Expendable Parts
1/9 Reassembly Precautions
1/10 Gear End Floats
1/11 Special Tools
1/14 Locally Made Tools
Section 2 General Discription
2/1 Features
2/2 Gear Change Pattern
2/2 Power Flow Diagrams
Section 3 Shifting Controls
3/2 Remote Control - Exploded View
3/3 Remote Control Disassembly
3/4 Remote Control Reassembly
3/7 Direct Control - Exploded View
3/8 Direct Control Disassembly
3/9 Direct Control Reassembly
Section 4 Transmission Overhaul
4/2 Transmission Case - Exploded View
4/3 Transmission Case Disassembly
4/9 Layshaft Disassembly
4/10 Layshaft Reassembly
4/11 Synchroniser Flange Removal / Fitment
4/12 Maninshaft Disassembly (New Type)
4/13 Maninshaft Reassembly (New Type)
4/17 Mainshaft Assembly - Exploded View (NewType)
4/31 Mainshaft Disassembly (Old Type)
4/32 Mainshaft Assembly - Exploded View (Old Type)
4/35 Mainshaft Reassembly (Old Type)
4/41 Selector Shaft Disassembly
4/42 Selector Shaft Reassembly
4/44 Transmission Case Reassembly

5/01
Section 2 General

5/01
1/1
General
Model Designation
Example: FSO-4106A
FS Standard prefix
O Overdrive
4 Nominal torque in 00 lbs ft
1 Series 1
06 Number of forward gears
A Standard ratio set
B, C Alternative ratio sets
Transmission Identification
All transmissions are fitted with an identification plate on the left hand side of the front case showing
1. Transmission serial number.
2. Transmission model.
3. Manufacturing data code.
4. Transmission specification number.
The transmission specification number is unique to each customer and gives precise details of the trans-
mission design level. This number must be quoted when ordering replacement parts.
There are currently two design levels of the 4106 transmission. Each level is identified by the specifica-
tion number.
Y 0400
Y 04100
The middle digit denotes the design level.

5/011/2
General
Technical Data
Models FS-4106A, FS-4106B, FS-5206A, FS(O)-5206B
640 Nm
650 Nm
700 Nm
700 Nm
115 kg
520 mm
7,5 lit
6,5 lit
SAE Standard
Left side (vertical installation), bottom right
(horizontal installation): 2 SAE 6 bolt facings
plus extended layshaft for Eaton PTO
Rotation to Engine
engine speed x
0,226 Same
0,271
0,336
engine speed x
0,434 Opposite
0,519
0,644
1) including output coupling, low remote control; less clutch housing
2) front face of transmission case to rear face of output flange
3) recommended backlash is from 0.15 to 0.25mm.
Gear
6
5
4
3
2
1
Reverse
FS-4106A
FS-5206A
1.00
__
1.38
__
2.00
__
3.10
__
5.25
__
9.03
__
8.07
%
Step
38
45
55
69
72
FS-4106B
FS-5206B
1.00
__
1.29
__
1.86
__
2.80
__
4.38
__
7.54
__
6.74
%
Step
26
43
50
57
72
FS(O)-4106B
FS(O)-5206B
1.00
__
1.37
__
2.12
__
3.56
__
6.08
__
9.03
__
5.43
%
Step
26
37
55
69
72
Nominal Input Torque
FS-4106A
FS-4106B
FS-5206A
FS(O)-5206B
Weight 1)
Length 2)
Oil capacity
Vertical
Horizontal
Clutch Housing
Power Take-off Openings
PTO Drive Gears 3)
driven from the reverse idler gear at:
FS-4106A, FS-5206A
FS-4106B, FS-5206B
FS-4106B, FS(O)-5206B
driven from layshaft front gear at:
FS-4106A, FS-5206A
FS-4106B, FS-5206B
FS-4106B, FS(O)-5206B

5/01
1/3
General
Lubrication
Proper Oil Level
Before checking the oil level or refilling, vehicle should
be on level ground.
Make sure that the oil is level with the filler opening.
Draining Oil
Drain transmission while oil is warn. To drain oil remove
the drain plug at the bottom if case. Clean the drain plug
before re-installing.
Refilling
Clean area round filler plug.
Fill transmission to the level of the filler opening.
The exact amount of oil depends on the
transmission inclination. In every instance, fill to the
level of the filler opening. Do not overfill this causes
oil to be forced out of the case past the mainshaft and
input shaft seals.
Adding Oil
It is recommended that different types and brands of oil
are not intermixed because of possible incompatibility.
Operating Temprature
It is important that the transmission operating tempera-
ture does not exceed 120¡C (250¡F) for an extended
period of time. Operating temperatures above 120¡C
(250¡F) cause breakdown of the oil and shorten trans-
mission life.
The following conditions in any combination can cause
operating temperatures of over 120¡C (250¡F):
1. Operating consistently at road speeds
under 32 km/h (20m.p.h.)
2. High engine RPM
3. High ambient temperature
4. Restricted air flow around transmission
5. Exhaust system too close to transmission
6. High horsepower, over-drive operation
7. High power PTO operation for
extensive periods while stationary
High operating temperatures may require more frequent
oil change.
Towing
When towing the vehicle, the propeller shaft between the
axle and transmission must be disconnected.

5/011/4
Only use recommended lubricants to ensure smooth running.
Highway Use
First 5000 to 8000 km (3000 to
5000 miles)
Every 16000 km (10000 miles)*
Every 80000 km (50000 miles)+
Off Highway
First 30 hours
Every 40 hours *
Every 500 hours
Every 1000 hours +
Change transmission oil on new units
Inspect oil level. Check for leaks
Change transmission oil
Change transmission oil on new units
Inspect oil level. Check for leaks
Change transmission oil when severe dirt condi-
tions exist
Change transmission oil (normal off- highway use)
General
Recommended Lubricants
Models Temprature RangeGrade
Mild EP Gear Oil
to Specification
MIL-L-2105 or
API-GL-4
Heavy Duty Engine Oil
to Specification
MIL-L-2104C or
MIL-L-46152 or
API-CD
-26¡C to 21¡C
-12¡C to 37¡C
-26¡C to 38¡C
above -12¡C
above -12¡C
below -12¡C
SAE 80 W
SAE 90 W
SAE 80 W/90
SAE 50
SAE 40
SAE 30
Lubrication Change and Inspection
Remove and clean oil strainer at each oil change.
Transmissions fitted with an oil cooler may additionally be fitted with a filter in the cooler line,
Renew the filter at every oil change.
* Or 2 months, whichever occurs first.
+ Or 12 months, whichever occurs first.
DO NOT use oil additives, friction modifiers or synthetic lubricants.
Service Intervals