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UltraShift PLUS Series
Eaton UltraShift PLUS Series User Manual
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Service Manual
Ul
t
r
aShift
P
L
US Automated
T
r
ansmis
si
o
ns
TRSM0940 EN-US
July
2019
Linehaul Active
Shift
ing
(LAS)
Vocational
A
ctive
S
hifting
(VAS)
Multipurpose Extreme Performance (MXP)
Multipurpose High Performance (MHP)
Vocational Construction Se
ries
(VCS)
Vocational High Performance (VHP)
Vocational Multipurpose
Series
(
VMS)
Vocational
Ext
reme Performance (VXP)
2
Table of Contents
General Information
2
Table of Contents
11
Warnings & Cautions
12
How to Use this Manual
13
Transmission Overview
14
Bill of Material or Customer Number
17
Model Number
17
Serial Number
17
Serial Tag Information and Model Nomenclature
17
Model Options
18
Shift Bar Housing
18
Torque Rating
18
Upper Countershaft
18
Front Section
19
Timing Procedures
19
Auxiliary Section Timing
20
Inspection before Transmission Removal
21
Preventive Maintenance
21
Assembly and Disassembly Precautions
22
Bearings
22
Gaskets
22
LAS/VAS Auxiliary Section Removal and Disassembly – in Chassis
23
Service Procedure
23
Component Identification
24
In Chassis
25
LAS/VAS Auxiliary Section Removal
25
LAS/VAS Auxiliary Section Removal and Disassembly
26
LAS/VAS Auxiliary Section Removal
27
Output Yoke Removal
27
LAS/VAS Auxiliary Section Removal and Disassembly
30
Range Synchronizer Disassembly
32
Range Synchronizer Assembly
34
LAS/VAS Auxiliary Section Assembly and Installation
36
LAS/VAS Auxiliary Section Assembly
37
LAS/VAS Auxiliary Counter Shaft Installation and Timing
39
Range Cylinder LAS/VAS Model Rebuild – in Chassis
47
Range Cylinder Disassembly
48
Range Cylinder Assembly
50
VCS/VMS Auxiliary Section Removal and Disassembly – in Chassis
53
In Chassis Auxiliary Section Removal
54
VCS/VMS Auxiliary Section Removal and Disassembly
55
Auxiliary Section Removal
57
VCS/VMS Auxiliary Section Assembly and Installation
66
Auxiliary Section Assembly
68
VCS/VMS Combination Cylinder Disassembly and Assembly
79
VCS/VMS Combination Cylinder Disassembly
81
Procedure – Combination Cylinder Assembly - VCS, VMS
83
VCS/VMS Combination Valve Removal and Installation
86
Combination Valve Installation
87
Combination Valve Removal
87
MHP/MXP/VHP/VXP Auxiliary Section Removal and Disassembly
88
Auxiliary Section Disassembly
93
MHP/MXP/VHP/VXP Range Cylinder Disassembly and Assembly
101
MHP/MXP/VHP/VXP Splitter Cylinder Disassembly and Assembly
107
Splitter Cylinder Removal
109
Splitter Cylinder Assembly
110
MHP/MXP/VHP/VXP Splitter Gear Bearing Disassembly and Assembly
113
Splitter Gear Bearing Assembly
115
MHP/MXP/VHP/VXP Auxiliary Section Assembly and Installation
117
Auxiliary Mainshaft Assembly
118
Synchronizer Assembly and Splitter Gear Installation
119
MHP/MXP/VHP/VXP Auxiliary Countershaft Installation
121
Auxiliary Countershaft Installation
122
Range Cylinder and Piston Installation
126
Splitter Cylinder Installation
127
Auxiliary Section Installation
129
Auxiliary Countershaft Shimming and Installation
130
Range and Splitter Cylinder Cover Installation
131
Range Synchronizer Disassembly and Assembly
133
Input Shaft Removal and Installation
137
Input Shaft Installation
139
Clutch Housing Removal and Installation
141
Clutch Housing Installation
142
Clutch Housing Removal
142
Shift Bar Housing Removal and Installation
143
Shift Bar Housing Disassembly and Assembly
145
2017 Eaton. All Rights Reserved
146
Shift Bar Housing Disassembly
146
2017 Eaton. All Rights Reserved
147
2017 Eaton. All Rights Reserved
148
2017 Eaton. All Rights Reserved
149
2017 Eaton. All Rights Reserved
150
Main Case Disassembly and Lubrication Tube Removal
151
Oil Pump and Lube Tube Installation
160
Lubrication Tubes Installation
161
Oil Pump Installation
161
Main Case Gear Timing and Assembly
162
Main Case Counter Shaft Installation
163
Main Case Main Shaft Disassembly with Low Force Gearing
175
Main Case Main Shaft Assembly with Low Force Gearing
181
Main Case Main Shaft Without Low Force Gearing Disassembly
187
Main Case Main Shaft Disassembly
188
Main Case Main Shaft Assembly
192
Reverse Switch Testing, Removal and Installation
197
Electronic Clutch Actuator (ECA) Removal and Installation
199
And Installation
200
ECA Removal
200
ECA Installation
201
Low Capacity Inertia Brake (LCIB) Removal and Installation
203
And Installation
204
Release Yoke and Cross-Shaft(S) Removal and Installation
205
And Installation
206
Release Yoke and Cross-Shaft(S) Removal
206
Release Yoke and Cross-Shaft(S) Installation
207
Cobra Lever Removal and Installation
210
Eaton Push Button Shift Control Device (PBSC) Removal and Installation
212
Transmission Harness Removal and Installation
214
Transmission Electronic Control Unit (TECU) Removal and Installation
216
TECU Removal
217
TECU Installation
218
ECA Calibration
219
Grade Sensor Calibration
219
X-Y Shifter Removal and Installation
220
X-Y Shifter Removal
221
X-Y Shifter Installation
222
Range Valve Removal and Installation
224
Range Valve Removal
225
Range Valve Installation
226
Output Shaft Speed Sensor Removal and Installation
227
Output Shaft Speed Sensor Removal
228
Output Shaft Speed Sensor Installation
229
Input Shaft Speed Sensor Removal and Installation
230
Input Shaft Speed Sensor Removal
231
Input Shaft Speed Sensor Installation
232
Main Shaft Speed Sensor Removal and Installation
233
Main Shaft Speed Sensor Removal
234
Main Shaft Speed Sensor Installation
235
Electronic Clutch Actuator (ECA) Speed Sensor Removal and Installation
236
ECA Speed Sensor Installation
237
ECA Speed Sensor Removal
237
Rail Position Sensor Removal and Installation
239
Rail Position Sensor Removal
240
Rail Position Sensor Installation
241
Gear Position Sensor Removal and Installation
242
Gear Position Sensor Removal
243
Gear Position Sensor Installation
244
General Tools
245
Tool Specifications
245
Appendix
245
Oil Leak Inspection Process
249
Inspection Procedure
250
Bearing Covers
250
Clutch Release Parts
250
Gear Shift Lever Housing Assembly
250
Sliding Clutches
251
Splines
251
Synchronizer Assembly
251
Washers
251
Power Flow
252
Front Section Power Flow - Reverse Gear
253
Auxiliary Section Power Flow - Low Range
253
Auxiliary Section Power Flow - High Range
253
Torque Specifications
256
Torque Specifications LAS/VAS
258
Lubrication Specifications
260
Transmission Operating Angles
260
Operating Temperatures
260
Maintenance and Lubricant Change Intervals
260
Clutch Greasing Guidelines
261
Recommended Lubrication
261
Lubrication Interval
261
Serviceranger Procedure
262
Operator-Triggered Procedure
262
Grade Sensor Calibration
262
5
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Eaton UltraShift PLUS Series Specifications
General
Brand
Eaton
Model
UltraShift PLUS Series
Category
Microphone system
Language
English
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