Eaton EEV-7202, Service Manual

Page 1: ...1 Service Manual 2 Speed Transmission EEV 7202 Feb 14 ...

Page 2: ...ndable parts 13 11 Assembly precautions 15 12 Lubrication recommendations 16 13 Maintenance Interval Chart 17 14 Lubrication checking procedure 18 15 Operating Temperature 19 16 Power Flow 20 17 Air System 21 18 Tightening Torques 22 19 Exploded Views 23 20 Loctite locations 29 Section 2 Main Transmission Overhaul 1 Transmission Case Dis assembly 31 2 Front Cover dis Dis assembly 37 3 Intermediate...

Page 3: ...3 Section 1 General ...

Page 4: ... from the vehicle 6 Use a safety catch on all hoist hooks Do not take a chance the load could slip off the hook 7 Batteries give off explosive hydrogen gas when charging and continue to do so for some time after receiving a steady charge Do not under any circumstances allow an electric spark or an open flame near the battery Always disconnect a battery cable before working on the electrical system...

Page 5: ... to Use This Manual The manual describes Transmission Overhaul Procedures Bench Service 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 Images are representative ...

Page 6: ...on the transmission tag To identify the transmission model designation and serial number locate the tag on the transmission and then locate the numbers as shown below When calling for service assistance or parts have the model and serial numbers ready Do not remove or destroy the transmission identification tag Transmission Tag and Location ...

Page 7: ...lained below This number and TA number both are necessary when calling for service assistance or replacement parts Serial SERIAL NUMBER The serial number is the sequential identification number of the transmission Before calling for service assistance write the number down It may be needed Specification Number This number is written below the Serial It is the reference number used by Eaton and is ...

Page 8: ...smission no clutch Gear change will be done by air pressure Neutral is default position If there is no air pressure in system bias spring will shift to neutral Gear disengage would be possible with torque of traction motor reduced to zero Note Air valves and filter pressure regulator to be fitted by Customer Epicyclic Reduction Gear Epicyclic reduction gear consists of three main components An ann...

Page 9: ...nge synchronizer sleeve attached to the annulus is in mesh with synchro flange fixed to rear case the annulus is locked and the output shaft rotates in the same direction as input shaft but at a slower speed High When the range sliding sleeve is in mesh with the synchro flange fixed to the planet carrier the annulus and planet carrier output shaft are locked together Now the planet gears can no lo...

Page 10: ...Neutral Gear position sensor L low H high N neutral Max input torque 700 Nm Max Input speed 6000 rpm Weight 81 kg without Oil Oil Capacity 4 6 liters with transmission installed in vehicle at 9 75 input end up Gear Ratios Low 3 529 1 High direct gear Overall Dimensions ...

Page 11: ...11 Features Description ...

Page 12: ...ronizer Ring Flange Clearances mm Range Minimum 0 50 Maximum for ref 2 16 Oil Pump Oil Muff Sealing Rings Clearances mm Minimum 0 2 Oil Pump Clearances mm Outer Rotor to Pump Body 0 50 maximum Inner to Outer Rotor 0 50 maximum ...

Page 13: ... 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 Do not use pry bars or chisels to separate casing halves and housings or irreparable damage may be caused Before assembling the transmission the individual parts should be carefully checked and any th...

Page 14: ...1 Check surfaces of all thrust washers Washers scored burnt or reduced in thickness should be renewed F Range Change Planet Gears Spindles and Needle Roller Bearings 1 If it is found necessary to dismantle the planet gears retain each gear spindle rollers spacers and washers in their respective set for Assembly in the same relative positions 2 If uneven wear is found in the planet gears check lubr...

Page 15: ...for the installation of bearings Heating the bearing inner tracks where instructed will aid installation 7 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 operated torque wrench or a stall torque motor Failure to carry out these instructions can cause damage to the locking medium of t...

Page 16: ...ed by the truck manufacturer Maintain Proper Oil Level Make sure oil is level with the filler opening Being able to reach oil with your finger does not mean oil is at proper level Never mix different brand of oils Operating Temperature It is important that the transmission operating temperature does not exceed 120 C 250 F for an extended period of time Operating temperatures above 120 C 250 F caus...

Page 17: ...E Gear Oil SAE50 Eaton PS 164 The use of lubricants not meeting these requirements will affect warranty coverage Buy from a reputable dealer Transmission Operating Angles Transmission operating angle up to 20 deg 18 road slope at transmission installation angle 9 8 deg Refer OEM recommendatations for oil change maintenance intervals ...

Page 18: ...itable solvent and dry thoroughly Renew the washer and the O ring if necessary When refitting tighten to the torque 40 to 47 Nm 2 Dry the strainer thoroughly 3 Clean the drain plug 4 Inspect the washer and replace if necessary Before checking the oil level or refilling ensure that 1 Vehicle is on level ground 2 Lubricant temperature is between 20 C and 50 C 3 Lubricant is at the level of the fille...

Page 19: ...operating temperatures over 120 C 1 Operating consistently at road speeds under 32 km hour 2 High engine RPM 3 High ambient temperature 4 Restricted air flow around transmission 5 Exhaust too close to transmission 6 High power PTO operation for extended periods Towing Before towing the vehicle place the transmission in neutral and lift the rear wheels off theground or remove the axle shafts or dis...

Page 20: ...20 Power flow ...

Page 21: ... line length measured from valve to transmission to be below 0 3m The transmission air supply is required to be routed from the air tank which supplies air to service brakes with gauge indicator in the cab Transmission airlines should not be routed or attached at the bottom air tank fittings to avoid any chances of introducing moisture into the airline Care should be used when routing the air supp...

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Page 23: ...23 Exploded Views ...

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Page 29: ...29 Loctite locations ...

Page 30: ...30 Section 2 Main Transmission Overhaul ...

Page 31: ...31 Transmission case Dis assembly ...

Page 32: ... wood blocks on the clutch housing until it is inverted It should then be stood on the rear flange of the intermediate case on the blocks taking great care not to damage the case flange to complete the removal of the mainshaft 1 Mount transmission on stand with the help of a hoist Mark the Air tube end connections Disconnect the Air tube connections from the Pressure Regulator Direction Control Va...

Page 33: ...the threads in the housing and on the plug Wash or replace the strainer Inspect and replace the washer if necessary 4 Remove the range and neutral switched Collect detent balls from each of the two bores Use a magnet or tap the case gently to release the balls if necessary 5 Remove speedo sensor ...

Page 34: ...ase 8 Attach a sling to output flange With a hoist lift rear case gently as vertical as possible to separate rear case from intermediate case Note Use soft mallet to separate the Rear Case from the Intermediate Case if necessary WARNING Do not use pry bars or screw drivers as the case contact surfaces may get scratched ...

Page 35: ...10 Remove the sun gear if possible by hand otherwise with a suitable puller legs gripping between the oil muff and oil pump under the collar of oil muff Take care not to damage the two Sealing Rings on the Oil muff 11 Take out oil muff without damage to the two sealing 12 Remove capscrews securing the oil pump assembly to transmission ...

Page 36: ...he lugs or a lever through the Drain plug bore lift the Oil pump from the locating dowels and take out pump assembly 14 Collect range change interlock pin located in the bore between the selector rods using a magnet if necessary ...

Page 37: ...f layshaft cover 8 and take out cover layshaft c Loosen bolts 3 4 11 nuts 6 of casing cover 5 and take out casing cover d Follow the reverse sequence of dis assembly to complete assembly e During installation apply recommended sealant on face of front cover 2 casing cover 5 bearing cover layshaft 8 f Apply loctite of reused bolts screws during fitment ...

Page 38: ...e out bearing cup cone 12 gear layshaft 2 from layshaft 1 e Now take out layshaft and rear cup cone 12 f Check the condition of case bush for any wear damage remove and replace with new one if required g Follow the reverse sequence of dis assembly to complete assembly h Install gears 5 2 with suitable press on mainshaft layshaft respectively i Install front rear bearings on the layshaft with the h...

Page 39: ... carrier assembly downwards Remove the bolts 15 from the range cylinder 9 b Take out rod spring range 14 and take out compression springs 12 13 alongwith its retainers after circlips removal 10 c Remove piston range cylinder 5 bush 3 check the condition of O ring 2 4 6 7 8 of piston bush d Take out bush 3 ...

Page 40: ...ot be knocked or allowed to move relative to the output shaft while the nut is being removed or after the nut has been removed the range change synchronizer sleeve may be displaced and the rollers plungers and likely springs may fall out f Slide the rear case out from the output shaft and the Range shaft g Remove the range fork from the sliding sleeve Separate the range change selector rod by drif...

Page 41: ...te the annulus from the sliding sleeve insert a rivet or steel pin of 2 0 2 3 mm diameter and 10 mm length in 3 holes in the annulus Tighten a large hose clip around the rivets or pins to compress the inside snap ring in the sliding sleeve Slide the sliding sleeve out from the annulus k Remove the snap ring securing the synchronizer hub bearing to the output shaft Remove the rollers plungers and s...

Page 42: ... the shaft onto a stout wood block to shock the hub synchronizer ring high and fixed hub range off the shaft m Invert the assembly Remove the snap ring securing synchronizer flange high to the planet carrier n Remove the synchronizer flange high ...

Page 43: ...0 50 Maximum Ref 2 16 o Remove the socket headed countersunk screws and retainers holding the synchronizer flange low to the rear case p Lift out the reaction plate and the synchronizer flange q Lift out the reaction plate and the synchronizer flange ...

Page 44: ...snap ring from the synchronizer flange t Remove four capscrews retaining the oil seal cover and output shaft bearing housing remove oil seal cover Note its orientation u Remove bearing housing tapping it sideways v Drive bearing out if necessary of housing using a drift ...

Page 45: ...45 w If necessary remove bearing retaining snap ring from range change synchronizer hub and remove the ball bearing x Remove rear PTO opening cover plate from rear case ...

Page 46: ...maged and needs to be replaced Usually the wear or damage or a product related failure are seen on all of the five planet gears that need to be replaced However you can replace it individually if need be Make sure you use new pin screws In either case check the condition of the sun gear ...

Page 47: ...b screw has to be drilled preferably a flat drill out before the screw can be removed b Using a soft faced mallet and a drift drive the bearing spindle out of the carrier in the direction shown Note that the spindle has a step The spindle can be driven out only one way c Slide the gear bearing rollers spacers and thrust washers out of the carrier Repeat these operations for the other four gears ...

Page 48: ... gear carrier Assembly a Place one thrust washer on a flat plate if using old washer grooved side up Apply petroleum jelly to it b Place the gear on the thrust washer Apply petroleum jelly to the bore of the gear ...

Page 49: ... above the rollers e Insert the 18 rollers above the spacer and then insert the washer Place the thrust washer old washer worn side down f Support the planet carrier on the work bench such that the output shaft is down and slide the assembled gear into position in the carrier ...

Page 50: ...soft faced mallet Note There is a lubrication hole directly opposite the locating hole Align both the holes correctly lubrication hole towards the center and locating hole away from the center i Ensure the threads are clean and dry Install a new locking grub screw using thread locking sealant Loctite 270 Tighten to 5 8 N m and peen the head with a punch or drift Repeat the operations for remaining...

Page 51: ...on the outer periphery of the bush carrier Lubricate it sparingly with silicone grease c Install the bush until the O ring has just entered the case Wipe off any excess grease and apply sealer Loctite 641 around the exposed part of the bush carrier Drive it into casing using special tool d Install a new O ring into the range change selector rod rear bush carrier Lubricate with silicone grease ...

Page 52: ...e cylinder as per below steps I Install a new O ring 11 in plug 12 lubricate O ring with silicone grease II Now place rod spring range 7 on to piston III Fit the circlip 6 on rod 7 IV Fit the retainer 5 on rod spring range 7 spring 4 3 and then retainer 2 and finally fit the circlip 1 V Install the mounting bolts of cylinder range 8 tighten to specified torque VI Fit the elbow 10 ...

Page 53: ...d to align the holes two slots in the rod to right b Align retaining pin holes so that with threaded end of selector shaft to the left the interlock detents face you Install a new grooved pin c Install snap ring into the range change synchronizer hub and place the bearing into hub against snap ring d Install second snap ring to retain bearing in hub ...

Page 54: ...pands into the annulus locking the two parts together If necessary use a hose clip to compress the snap ring uniformly all around g Stand output shaft assembly on a firm support or a block about 100 mm thick Place the synchronizer flange over the locating splines Install retaining snap ring h Place the synchronizer ring over the synchronizer flange Press the cone firmly down With feeler gauges mea...

Page 55: ...k one flat internal tooth on shifting sleeve as shown Sliding sleeve up align the annulus coinciding the mark with one central slot and slide the assembly over the planet gears l Lift up annulus and support it by about 15 mm thick piece Ensure the plungers and the springs are fully inside the holes in all the six slots and no plunger projects out of spring Snap one roller with grease applied to it...

Page 56: ...hree central slots Snap in by hand one roller each into each of three central slots Place synchronizer ring low on the synchronizer hub locating it in the slots of the synchronizer hub Hold the synchro ring and shifter sleeve with both the hands Holding the sliding sleeve with both hands keeping the synchro ring pressed down with thumbs of both hands lift the annulus up with the fingers a little T...

Page 57: ...lange low q Place synchronizer flange low with the snap ring in the rear case bore r Place reaction plate rounded edges of internal splines and teeth towards flange over synchronizer flange s Install the three retaining plates and countersunk head screws Tighten screws to 27 30 N m ...

Page 58: ...s tilting while installing the rear case over it u Ensure that the O ring in selector shaft bush is in position lubricate it with silicone grease Invert the partly assembled rear case and place it over the output shaft aligning the selector shaft through the bush v Place speedo rotor teeth up over output shaft w Install output shaft bearing in bearing housing using a soft faced mallet and a suitab...

Page 59: ...to the face either of the baring housing or rear case Place the bearing housing assembly over the shaft and tap the bearing inner race all around till the bearing housing touches the rear case z Apply sealant Loctite 5900 to the face of the bearing housing and carrier with oil seal fitted in it ...

Page 60: ...t temporarily to be removed later the old nyloc nut nylon insert sheared to tighten the coupling flange tight enough so range hub rollers do not slip out Note The output shaft must not be knocked or driven inwards while the nut is loosened or removed the range change synchronizer sleeve may be displaced and the rollers plungers and springs fall out of the hub cc Apply Loctite 5900 sealant and fit ...

Page 61: ... on the table Apply loctite 7649 where magnet to be installed Note This is a primer to clean the surface Apply Loctite 7649 Resin 326 Glue Install the magnet press magnet for 15 seconds Fit the elbow adaptor 2 ff Ensure that the mating faces of the pump and case halves are clean DO NOT use sealant Fit the oil pump ensuring that the flats on the oil pump rotor engage the flats on the countershaft e...

Page 62: ...Compressing sealing rings push oil muff into pump hh Install sun gear onto the mainshaft if it was removed by hand otherwise heat the sun gear 130 150 deg C and then install on the mainshaft ii Place retaining washer against the sun gear and fit a new patchlock retaining cap screw jj Using special tool to lock the sun gear tighten the capscrew to 225 255 N m ...

Page 63: ... o rings nn Fit drain filler plug oo Support rear case assembly with a suitable sling and hoist as illustrated keeping the shaft as vertical as possible pp Lower the rear case over the intermediate case ensuring that the range change selector rod aligns with the bush in the intermediate case Rotate the output flange slightly to aid alignment over the sun gear if necessary qq Install mainshaft lays...