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TMS800E SERVICE MANUAL POWER TRAIN
Published 01-29-2014, Control # 496-00
Removal
1. Shift the transmission to neutral. Bleed the air reservoirs
and tag and disconnect the nylon tubing at the range
shift valve on the gearshift lever. Tag and disconnect the
tubing at the splitter valve.
NOTE: The range shift valve may be removed from the
gearshift lever without disconnecting the nylon
tubing from the valve, if so desired.
This is recommended if no service is to be
performed on the air shift piping or valves.
2. Loosen the bolts and washers in the universal joints on
the shift control shaft (at both ends of the shaft) and
remove the shift control shaft.
3. Remove the capscrews securing the master control unit
to the bracket.
4. Loosen the locknuts on the slave control unit mounting
flange studs. Loosen the hex nuts on the mounting
studs, remove all nuts, and lift off the slave control unit.
Installation
1. Route the shift control tower up through the cut out in the
cab floor. Apply Loctite to bolts. Install bolts and washers
and secure the slave unit to the plate.
2. Install the slave unit onto the studs in the transmission
shift bar cover, ensuring the shift fingers engage
properly with the shift bars inside the transmission.
3. Position the gearshift lever to the neutral (perpendicular)
position and install the shift control shaft, being careful to
maintain the exact position of the slave unit input shaft
and the gearshift lever.
4. After installing the shift control shaft and ensuring the
master and slave unit are synchronized in the exact
neutral position, tighten the setscrews on the shift
control shaft universal joint yokes. There are two
setscrews on each yoke mounted at 90 degrees to each
other. Lockwire these setscrews after tightening.
5. Lubricate the U-joints with chassis grease.
6. Connect the nylon tubing to the range shift valve if
disconnected.
7. Connect the nylon tubing to the splitter valve.
MANUAL TRANSMISSION
Description
The transmission provides 11 forward speeds and three
reverse, consisting of a five speed front section and a three
speed auxiliary section. The auxiliary section contains the
LO and HI range ratios, plus the three deep reduction gears.
The range button is used once during an upshift sequence
and once during a downshift sequence. Deep reduction
ratios are selected using the deep reduction button on the
control knob.
Theory of Operation
One ratio in the front section is used only in low range as a
starting gear. The remaining four ratios in the front section
are used once through the reduction (low) gear in the range
section and once through direct (high) in the range section.
The twin countershaft design splits torque evenly between
two countershafts, reducing gear tooth pressure and wear.
The floating mainshaft gears of this design eliminate gear
bushings and sleeves as gears float between mating gears
on the countershafts.
Maintenance
Troubleshooting
Before attempting to determine a cause of transmission
noise or trouble, note what position the gearshift lever is in
when the trouble occurs. If the noise is evident in only one
gear position, the cause of the trouble is generally traceable
to the gears in operation. There are times, however, due to
abnormal conditions in other parts of the crane, when noises
are transmitted from the engine, power train, frame, or body
to the transmission and will appear to originate there. All
such sources should be checked out before removing and
disassembling the transmission.
Another source of trouble could be a faulty air system or in
the actuating parts of the shifting bar housing. This will be
noticed when the transmission fails to make a range shift, or
shifts too slowly.
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