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Eaton FS-4205A, Installation Manual

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Eaton FS-4205A Installation Manual Download Page 75

 

 

 

 

Drawing shows inertia brake with 
angle adaptor.  Please see 
instructions above for installation 
without angle adaptor. 

Inertia Brake mounting to 6-bolt 
Angle Adapter as viewed from 
rear of transmission 
 

Note orientation of hose connection 
end of Inertia Brake when mounted to 
a PTO Angle Adapter 

72

Inertia Brake

Ine
rtia Brake

Summary of Contents for FS-4205A

Page 1: ...Installation Guide Eaton PTOInformationGuide TRIG2600 EN US August 2017...

Page 2: ...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...

Page 3: ...raShift PLUS and FA PTO Inputs and Configurations 35 Countershaft Thru Shaft and Split Shaft PTOs 35 PTO Configurations 36 UltraShift PLUS Auto Neutral Feature 36 Endurant PTO Inputs and Configuration...

Page 4: ...quirements Thru Shaft Thru Shaft design for Fuller transmissions Three speed ratios available Two shift options available Direct mount pump flanges or driveshaft output options Note Thru Shaft is a PT...

Page 5: ...additional PTO openings Several 6 Bolt and Reversible PTOs will fit on the 912 Series Three 8 Bolt openings that allow you to operate a variety of auxiliary equipment Wide variety of 6 Bolt 8 Bolt Po...

Page 6: ...c mounts Air shift operation Suitable for stationary or mobile applications Precision ground gearing for quiet operation Split shaft PTOs can be used on all heavy duty Fuller manual UltraShift PLUS an...

Page 7: ...ears as the 442 and 489 Series Uses the same mounting hardware and spacers used to mount a 442 Series to a specific application 628 Series Mounts a 6 Bolt PTO to a 6 Bolt transmission opening Moves th...

Page 8: ...ng is needed for PTO usage this 30 adapter allows the movement of the high capacity inertia brake from the 8 Bolt opening to the 6 Bolt opening and rotates the high capacity inertia brake to eliminate...

Page 9: ...flange outward away from the transmission Angular Adapters Various angles available 55 adapter available for relocating high capacity inertia brake on heavy duty Fuller UltraShift transmis sions 8 Bol...

Page 10: ...7 PTO Adapters Angular Offset Gear Adapter Offered in multiple gearing configurations All adapters offered with a 10 offset...

Page 11: ...eth 6 35P N A N A N A 26 Teeth 52 FS 6305A N A N A Right Left 39 Teeth 6 35P N A N A N A 26 Teeth 46 FS 6305B N A N A Right Left 41 Teeth 6 5P N A N A N A 26 Teeth 46 FS 6406A N A N A Right Left 38T 6...

Page 12: ...Yes 47T 6 0P 20DEG PA Yes4 45T 6 0P 20DEG PA Lower Left 32T 0 5P 30DEG PA N A N A 79 RTX 13609B Yes 47T 6 0P 20DEG PA Yes4 45T 6 0P 20DEG PA Lower Left 32T 0 5P 30DEG PA N A N A 79 RTX 14609B Yes 47T...

Page 13: ...T 0 5P 30DEG PA N A N A 94 RTO 14909ALL Yes 47T 6 0P 20DEG PA Yes4 45T 6 0P 20DEG PA Lower Left2 32T 0 5P 30DEG PA N A N A 79 RTO 14915 Yes 47T 6 0P 20DEG PA Yes4 45T 6 0P 20DEG PA N A 32T 0 5P 30DEG...

Page 14: ...es4 45T 6 0P 20DEG PA N A N A N A N A 79 RTLO 20918B Yes 47T 6 0P 20DEG PA Yes4 45T 6 0P 20DEG PA N A N A N A N A 79 RTLO 22918B Yes 47T 6 0P 20DEG PA Yes4 45T 6 0P 20DEG PA N A N A N A N A 79 5006 RT...

Page 15: ...G PA N A N A 79 FAOM 16810C Yes 47T 6 0P 20DEG PA Yes4 45T 6 0P 20DEG PA 32T 0 5P 30DEG PA N A N A 79 FAO 11810C Yes 47T 6 0P 20DEG PA Yes4 45T 6 0P 20DEG PA 32T 0 5P 30DEG PA N A N A 79 FAO 12810C Ye...

Page 16: ...65 FRW 15210B Yes 47T 6 0P 20DEG PA Yes9 45T 6 0P 20DEG PA LL UR 32T 0 5P 30DEG PA N A N A 65 FRM 15210B Yes 47T 6 0P 20DEG PA Yes9 45T 6 0P 20DEG PA LL UR 32T 0 5P 30DEG PA N A N A 87 FR 9210B Yes 47...

Page 17: ...T 0 5P 30DEG PA N A N A 87 FRO 15210C Yes 47T 6 0P 20DEG PA Yes9 45T 6 0P 20DEG PA LL UR 32T 0 5P 30DEG PA N A N A 84 FRO 16210B Yes 47T 6 0P 20DEG PA Yes9 45T 6 0P 20DEG PA LL UR 32T 0 5P 30DEG PA N...

Page 18: ...xt Aux Counter shaft PTO Ext Spline Info of Engine Speed Transmission TorqueLimitfor PTO use lb ft AT 1202 Yes 30T 5 0P 20DEG PA Yes 30T 5 0P 20DEG PA N A N A N A N A 93 5006 2A 92 No N A No N A N A N...

Page 19: ...able Default UltraShift HV N A Available Default N A AutoShift Available Available Default N A UltraShift DM3 N A Available Default N A Fuller Advantage Available Available Default Available Default U...

Page 20: ...N A N A Left or Right2 48T 7 00P 26DEG R H HELIX N A N A Yes 26T 45DEG PA 67 FO 6506B DM3 N A N A Left or Right2 48T 7 00P 26DEG R H HELIX N A N A Yes 26T 45DEG PA 67 FO 6406A ASX N A N A Right Only 4...

Page 21: ...7 EDCO 6F107A N A L 23T LH Helix 5 64P 20DEG PA R 47T RH Helix 8 975P 17DEG PA Left or Right 45T 6 0P 20DEG PA N A N A Yes 400mm 12T 20DEG PA L 39 R 82 500 EDCO 6F107A P N A Left or Right 45T 6 0P 20...

Page 22: ...26DEG R H HELIX N A N A Yes 26T 45DEG PA 67 EH 8E406A P N A N A Left or Right 48T7 00P 26DEG R H HELIX N A N A Yes 26T 45DEG PA 67 EH 8FA0406A PSB N A N A Left or Right 48T7 00P 26DEG R H HELIX N A N...

Page 23: ...r Left 32T 0 5P 30DEG PA N A N A 79 5006 FO 14E310C LAS Yes 47T 6 0P 20DEG PA Yes4 45T 6 0P 20DEG PA Lower Left 32T 0 5P 30DEG PA N A N A 79 FOM 14E310C LAS Yes 47T 6 0P 20DEG PA Yes4 45T 6 0P 20DEG P...

Page 24: ...32T 0 5P 30DEG PA N A N A 79 FOM 16E310C LAS Yes 47T 6 0P 20DEG PA Yes4 45T 6 0P 20DEG PA Lower Left 32T 0 5P 30DEG PA N A N A 79 FOM 16E310C VAS Yes 47T 6 0P 20DEG PA Yes4 45T 6 0P 20DEG PA Lower Le...

Page 25: ...5P 30DEG PA N A N A 79 FAOM 15810C EA3 Yes 47T 6 0P 20DEG PA Yes4 45T 6 0P 20DEG PA Lower Left 32T 0 5P 30DEG PA N A N A 79 FAOM 16810C EA3 Yes 47T 6 0P 20DEG PA Yes4 45T 6 0P 20DEG PA Lower Left 32T...

Page 26: ...6 0P 20DEG PA Yes4 45T 6 0P 20DEG PA Lower Left 32T 0 5P 30DEG PA N A N A 79 FAOM 15810S EN3 Yes 47T 6 0P 20DEG PA Yes4 45T 6 0P 20DEG PA Lower Left 32T 0 5P 30DEG PA N A N A 79 FAO 16810S EN3 Yes 47T...

Page 27: ...N A N A 94 FO 17E308LL VCS Yes 47T 6 0P 20DEG PA Yes4 45T 6 0P 20DEG PA Lower Left 32T 0 5P 30DEG PA N A N A 94 FO 10E309ALL VMS Yes 47T 6 0P 20DEG PA Yes4 45T 6 0P 20DEG PA Lower Left 32T 0 5P 30DEG...

Page 28: ...18B MXP Yes 47T 6 0P 20DEG PA Yes4 45T 6 0P 20DEG PA N A N A N A N A 79 FO 16E318B VXP Yes 47T 6 0P 20DEG PA Yes4 45T 6 0P 20DEG PA N A N A N A N A 79 RTLO M 16913L DM3 N A3 47T 6 0P 20DEG PA Yes4 45T...

Page 29: ...0P 20DEG PA N A N A N A N A 79 350 FO 20E313A MHP Yes 47T 6 0P 20DEG PA Yes4 45T 6 0P 20DEG PA N A N A N A N A 79 5006 FO 20E313A VHP Yes 47T 6 0P 20DEG PA Yes4 45T 6 0P 20DEG PA N A N A N A N A 79 F...

Page 30: ...ed Transmission Power Limit for PTO Use HP EEO 14F112C Yes1 42T 3 156 MODULE 20DEG PA 28 9747 DEG H A LEFT HAND 137 Opposite of Engine 95 HP 950 RPM min EEO 15F112C EEO 16F112C EEO 17F112C EEO 18F112C...

Page 31: ...AE J1455 Convoluted Conduit shall have a service temperature of at least 257 F 125 C Braided Loom shall have a service temperature of at least 280 F 138 C Coverage A minimum of 10 maximum of 12 picks...

Page 32: ...le R 69246 round Convo luted Tubing Size 13 mm 500 125 C or higher temperature rating 29 Cable Configuration Note Eaton recommended component Recommended Bend Radius 6 X Hardness Diameter Inch Metric...

Page 33: ...gn compound shall be applied to the connector jackscrew threads The use of such compounds may affect jackscrew torque and prevent proper sealing of the connector The recommended minimum material volum...

Page 34: ...ve the transmission main box countershaft Incorrect or no PTO interface signal to the transmission will result in no clutch activation and therefore no PTO operation The active signal will illuminate...

Page 35: ...icle is stopped i e stationary PTO operation and a transmission gear engagement cannot be selected When disengaged switch opened normal transmission gear engagement can be selected The Fuller AutoShif...

Page 36: ...no enabling of the countershaft PTO feature is required unless the push button console change to TECU was previously programmed for split shaft PTO operation The input signal wire for the PTO must be...

Page 37: ...witch closed this feature causes the transmission to neutralize when the vehicle is stopped i e stationary PTO operation and a transmission gear engagement cannot be selected When disengaged switch op...

Page 38: ...for correct wire and terminal pin sizes for communication and control wires PTO input shall be a normally open switch The switch shall close to the PTO return line pin 34 whenever the PTO is activated...

Page 39: ...to reflect Split Shaft PTO The Eaton ServiceRanger tool is the recommended interface for changing the configuration setting UltraShift PLUS Auto Neutral Feature An auto neutral feature is provided wi...

Page 40: ...eration Examples of the three different types of integration are shown below PTO System Engagement Sequence Note This is not an operator sequence 1 The TCM will receive a PTO request from the vehicle...

Page 41: ...O 11 12 J1939 PTO Installation with Hardwire Confirm Module 2 OEM ECU sends the Request message via J1939 to the TCM J 1939 Battery Voltage Ground Switched Ground Solenoid Driver Air Supply J1939 PTO...

Page 42: ...to the TCM J 1939 Battery Voltage Ground Switched Ground Solenoid Driver Air Supply 6 J1939 Confirm message from OEM ECU to TCM to operate PTO 5 PTO Confirm to OEM ECU J1939 PTO Control From To Descri...

Page 43: ...posistion PTO with Confirm Switched to Chassis From To Description Notes TCM B 14 DPST SW01 PTO Request DPST SW02 TCM B 15 PTO Request Vbatt DPST SW03 PTO Power Vbatt should be fused to protect wirin...

Page 44: ...5 5 14 4 13 3 12 2 11 1 16 15 14 2 5 PTO with Confirm Switched to Power From To Description Notes TCM B 14 DPST SW01 PTO Request DPST SW02 TCM B 15 PTO Request TCM B 5 PTO Engage Relay 86 PTO Engage P...

Page 45: ...2 ePTO selection input comes from the Push Button Shift Control which is sent from the TECU over J1939 to the HCM The transmission will go to neutral and then the HCM will activate PTO pins 21 and 22...

Page 46: ...us HCM 34 ePTO 18 PTO Power Minus HCM 6 ePTO 18 ePTO HCM J1939 Controlled Description From Pin To Pin AWG J1939 Low CAN HCM 2 J1939 Backbone 2 18 J1939 High CAN HCM 3 J1939 Backbone 3 18 mPTO HCM Cont...

Page 47: ...on TCM has the functionality to support two PTOs at the same time one direct wire control and one over the J 1939 network PTO operation requires a single pole double throw switch Consult PTO manufactu...

Page 48: ...active posistion PTO with Confirm Switched to Chassis From To Description Notes TCM B 14 DPST SW01 PTO Request DPST SW02 TCM B 15 PTO Request Vbatt DPST SW03 PTO Power Vbatt should be fused to pro tec...

Page 49: ...D B 5 RTN_1 CHASSIS GROUND PTO w Confirm Switched to Power 30 87A 87 86 85 30 87 A 87 86 85 PTO Confirm Relay PTO Inside or on Dashboard TCM SW02 SW04 SW03 SW01 DPST L L PTO Power PTO Ground PTO Confi...

Page 50: ...PTO and PTO DPST SW04 PTO Engage Relay 30 PTO Engage PTO Engage Relay 87 PTO PTO Power PTO Engage PTO PTO Ground Chassis GND PTO Ground PTO PTO Confirm PTO Confirm Relay 85 PTO Confirm Splice PTO Lam...

Page 51: ...the PTO Active Switch It can be a mechanical ball switch or air switch Relay Isolated PTO Application 30 X Protected Power Battery or VIGN r Indicator Lamp Transmission ECU 38 Way Connector Vehicle I...

Page 52: ...or Lamp PTO Switch Input Vehicle 30 87a 87 86 85 30 87a 87 86 85 Transmission ECU 38 Way Connector Vehicle Interface PTO Active Switch 1 Battery Negative or Frame Ground 18 PTO Switch 19 Auto Neutral...

Page 53: ...t rotation for PTO engagement 4 Engage the PTO 5 Release clutch pedal 6 Raise engine speed up to operate the PTO Mobile PTO Operation The Transmission countershaft PTO is used in this application and...

Page 54: ...t Control 6 Release the service brake 7 Raise engine speed up minimum of 1000 RPM for heavy duty transmissions to operate the PTO Remote throttle controls are not approved for use with UltraShift ASW...

Page 55: ...he engine speed as required to move vehicle operate PTO Split Shaft PTO Operation The drive line split shaft or transfer case PTO is used in this application and provides stationary operation only 1 W...

Page 56: ...on the Shift Control this stops countershaft rotation for PTO engagement 4 Engage the PTO 5 Select D MANUAL Neutral or Reverse as required for vehicle movement 6 Release the service brake to engage t...

Page 57: ...orage position 2 Push ePTO button on shift console once to shut down electric power take off 3 Turn key to off position to shutdown vehicle or turn key to start position to start engine for driving No...

Page 58: ...engage the clutch and power the PTO Mobile PTO Operation The Transmission countershaft PTO is used in this application and provides limited mobile operation in 2nd R2 only To engage the PTO for mobil...

Page 59: ...ie to clear frame and suspension components Both Chelsea and Muncie have produced adapters to rotate the HCIB away from potential vehicle interferences The Chelsea adapter kit is 630 2 30 degree The M...

Page 60: ...on the inertia brake casting If the transmission does not already have this style inertia brake a different kit containing the correct inertia brake needs to be ordered The correct inertia brake is r...

Page 61: ...e residual oil in the inertia brake 4 Remove the inertia brake spacer plate and gaskets from the transmission Note Clean and remove all old gasket material from the mating surfaces of the inertia brak...

Page 62: ...Some transmission models do not use a spacer with the inertia brake 2 Remove the Speed Sensor Adapter 3 Remove hex socket plug 4 Apply thread adhesive to the speed sensor adapter threads 5 Install the...

Page 63: ...nnector Note Gently guide wires back into the Inertia Brake Housing Align connector screw holes with housing screw holes and insert connector into mounting hole Note orientation of Connector Use cauti...

Page 64: ...of the transmission case Torque to 45 55 lb ft 61 75 Nm 2 Apply thread sealant to the 90 fitting Install into filter fitting Torque to 25 lb ft 34 Nm minimum then continue to rotate to position and o...

Page 65: ...y for electrical contacts 2 Route the jumper harness over the transmission with the correct connectors on the right side for the inertia brake and the correct connectors on the left side for the harne...

Page 66: ...ure all connectors 2 on the right side 2 on the left side are fully mated and latches are locked 5 Tie down jumper harness with ty raps as shown below Note Do not over tighten ty raps Ty raps Ty raps...

Page 67: ...sure harness is connected and properly secured 5 Look for leaks and repair as necessary 6 Check the inertia brake for significant clearance to prevent contacting tanks brackets frame rails exhaust or...

Page 68: ...the six 6 mounting bolts from the 6 bolt PTO cover 8 Remove and discard the 6 bolt PTO cover and gasket from the transmission Note Clean and remove all old gasket material from the mating surfaces of...

Page 69: ...ertia Brake also requires a new lubrication hose Eaton part number 5588209 4 Using the six 6 3 8 mounting bolts install the Inertia Brake and gasket being careful to align the Inertia Brake gear with...

Page 70: ...rake housing Install tie wraps every 6 10 inches The harness should not have sharp bends or be under tension 7 Install the PTO to the 8 bolt PTO opening following the manufacturers instructions Note F...

Page 71: ...ke when mounted to a PTO Angle Adapter Mate inertia brake connector and insert push in harness anchor into threaded hole as shown Route the harness up along side of the transmission case as indicated...

Page 72: ...er plate and gasket from the transmission 7 Remove the six 6 mounting bolts from the 6 bolt PTO cover 8 Remove and discard the 6 bolt PTO cover and gasket from the transmission Note Clean and remove a...

Page 73: ...ote When mounted directly orient the inertia brake housing with hose connection forward electrical connection rearward as shown in the Final Check section same orientation as 8 bolt When mounted to a...

Page 74: ...bolt PTO opening following the manufacturers instructions Note Fill the transmission with lubricant Final Check Make sure the mounting bolts are properly tightened Make sure the lubricant supply line...

Page 75: ...tructions above for installation without angle adaptor Inertia Brake mounting to 6 bolt Angle Adapter as viewed from rear of transmission Note orientation of hose connection end of Inertia Brake when...

Page 76: ...over end of terminal Fold package length wise Before starting inspect mating connector pins on transmission for damage or dirt If pins need cleaning use clean shop air or an approved spray cleaner spe...

Page 77: ...he harness up along side of the transmission case as indicated With any installation scheme use tie wraps at the top and side of transmission to remove excess slack 3 Push in Anchor 1 2 3 1 2 Route th...

Page 78: ...nufacturers Contact Information Chelsea Products Division 8225 Hacks Cross Road Olive Branch MS 38654 662 895 1011 www parker com chelsea Muncie Power Products Inc P O Box 548 Muncie IN 47308 0548 765...

Page 79: ...smission RT Linehaul Heavy Duty Manual Transmission RT Vocational Heavy Duty Manual Transmission RT Performance Heavy Duty Manual Transmission FR Series Heavy Duty Manual Transmission Auxiliary Transm...

Page 80: ...s by adding 34 UltraShift PLUS to each of the grounds Medium Duty and Heavy Duty Automated PTO Operating Instructions section AutoShift Countershaft and Split Shaft PTO Operation section Changed Item...

Page 81: ...po in call the model name for Heavy Duty Automated 13 18 Speed table for Model FO 16E318B MXP Added to Heavy Duty Automated UltraShift PLUS VCS and VMS table the following Models FO 18E313A VHP FO 20E...

Page 82: ...ducts with all options installed Although every attempt has been made to ensure the accuracy of information contained within Eaton makes no representation about the completeness correctness or accurac...

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