Eaton EEV-7202 Service Manual
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Eaton EEV-7202 Service Manual

Eaton EEV-7202 Service Manual

2-speed transmission
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Service Manual: 2-Speed Transmission
(EEV-7202)
Feb-14
1

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Summary of Contents for Eaton EEV-7202

  • Page 1 Service Manual: 2-Speed Transmission (EEV-7202) Feb-14...

  • Page 2: Table Of Contents

    3. How to Use This Manual………………………. …………………………………...………………..…...5 4. Serial Tag Information and Model Nomenclature…………………………………...………………...…..6 5. General Description - Features …………………………………………………………………….….…..8 6. The Epicyclic Reduction Gear...……………………………………………...……………………….…...9 7. Specifications Eaton 2-Speed Transmission ……………….…………………………………………..10 8. Features Description……………………………………………………………………………………...11 9. Setting Values …….……………………………………………………………………………………...12 10. Disassembly precautions and inspection of expendable parts……...…………………………………….13 11.

  • Page 3: Section 1 General

    Section 1 - General...

  • Page 4: Safety - Alert Symbol And Terms

    Note: The word NOTE indicates additional detail 21. Eaton Corporation reserves the right to discontinue or modify its that will aid in the diagnosis or repair of a models and/or procedures and to change specifications at any component/system for more efficient and time without notice.

  • Page 5: Purpose And Scope Of Manual

    Purpose and Scope of Manual This manual is designed to provide detailed information necessary to service and repair the Eaton transmission EEV-7202. How 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.

  • Page 6: Serial Tag Information And Model Nomenclature

    Serial Tag Information and Model Nomenclature Transmission model designation and other transmission identification information is stamped 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.
  • Page 7 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 necessary with basic model number for correct technical support. CUSTOMER’S NUMBER...

  • Page 8: General Description - Features

    Oil cooler ports option Suitable for rear support The Eaton 2-speed transmissions have one low & one high speed selection and are part of a medium duty range of synchromesh transmissions. An epicyclic reduction gear with air operated synchromesh engagement is located rear section of the transmission and the output flange.

  • Page 9: The Epicyclic Reduction Gear

    The Epicyclic Reduction Gear Principle If the annulus is held fixed and the sun gear is rotated, the planet gears spin about their shafts and in turn force the planet carrier to rotate in the same direction as sun gear, but at a slower speed. The output shaft integral with the planet carrier also rotates with it.

  • Page 10: Specifications Eaton 2-Speed Transmission

    Specifications Eaton 2-Speed Transmission Speeds L – Low, H – High, N – 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°...

  • Page 11: Features Description

    Features Description...

  • Page 12: Setting Values

    Settings Values Synchronizer Ring - Flange, Clearances, mm Range Minimum 0.50 Maximum (for ref) 2.16 Oil Pump Oil Muff Sealing Rings Clearances, mm Minimum Oil Pump Clearances, mm Outer Rotor to Pump Body 0.50 (maximum) Inner to Outer Rotor 0.50 (maximum)

  • Page 13: Disassembly Precautions And Inspection Of Expendable Parts

    Disassembly precautions and inspection of expendable parts It is assumed in the detailed disassembly instructions that the lubricant has been drained and the necessary linkage and air lines have been removed from the chassis. Follow each procedure closely in each section, making use of both the text and the pictures. Cleanliness - Provide a clean place to work.
  • Page 14 B. Gears 1. Check gear teeth for pitting of the tooth faces. Gears with pitted teeth should be renewed. 2. Check the internal bearing surfaces for wear or the effects of overheating. 3. Check axial clearances of gears. Where excessive clearance is found, check gear, ring and hub for excessive wear.

  • Page 15: Assembly Precautions

    Assembly precautions Make sure that interiors of all housings are clean. It is important that dirt be kept out of transmission during assembly. Dirt is abrasive and can damage polished surfaces of bearings and washers. Pay attention to certain precautions, as listed below, during assembly. 1.

  • Page 16: Lubrication Recommendations

    Lubrication Information Proper lubrication procedures are the key to a good all-around maintenance program. Eaton Transmissions are designed so that the internal parts operate in an oil circulating bath created by the motion of the gears and shafts. All parts will be properly lubricated if these procedures are closely followed: 1.

  • Page 17: Maintenance Interval Chart

    Required Lubricant Type Grade (SAE) 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)

  • Page 18: Lubrication Checking Procedure

    Lubrication checking procedure Oil Level Before checking the oil level or refilling, ensure vehicle is on level ground. Make sure that the oil is level with the filler opening. Draining Oil Drain transmission while oil is warm. To drain oil remove the drain plug at the bottom of the case, or Remove strainer from the intermediate case (see below).

  • Page 19: Operating Temperature

    Operating Temperature It is important that the transmission operating temperature does not exceed 120° C for an extended period of time. Operating temperatures above 120° C cause breakdown of the oil and shorten the transmission life. The following conditions can cause operating temperatures over 120° C: 1.

  • Page 20: Power Flow

    Power flow...

  • Page 21: Air System

    Air System • Air system Transmission is supplied without valves, regulators and filters. • Air system requirements It is required to use high quality commercially available air dryer in the air supply line before the transmission Air pressure requirements 7.5-8.3 bar for best performance (minimum pressure 4.6 bar) Minimum 8mm diameter air supply line to filter regulator is required, 6mm diameter air line after filter regulator Flow range through valve shall be from 300 dm3/min to 500 dm3/min at 7.5bar...

  • Page 23: Exploded Views

    Exploded Views...

  • Page 29: Loctite Locations

    Loctite locations...

  • Page 30: Section 2 Main Transmission Overhaul

    Section 2 - Main Transmission Overhaul...

  • Page 31: Transmission Case Dis-Assembly

    Transmission case Dis-assembly...
  • Page 32 Drain oil from transmission while oil is still warm. Check for leakage, seepage around the drain plug. Remove filler plug. Clean the strainer, internal and external threads thoroughly refit drain plug very carefully not damaging the internal threads in the housing. Refit filler plug. It is recommended that the transmission is mounted on the stand illustrated and overhauled.
  • Page 33 3. Remove drain plug. Drain gear oil from the transmission while the oil is still warm. Clean 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.
  • Page 34 6. Rotate transmission on stand to bring rear end up. 7. Remove capscrews and nuts securing rear case to intermediate case. 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.
  • Page 35 Using sun gear retaining tool ST 6209 24 (E 118) to lock the sun gear, unscrew and remove sun gear retaining bolt and special washer. 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.
  • Page 36 Using pry bar under the 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: Front Cover Dis-Dis-Assembly

    1. Front Cover Dis-assembly Removal of front cover assembly as follows: a) Loosen screws (1) of front cover (2) and take out front cover. b) Loosen screws (9) of 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.

  • Page 38: Intermediate Case Dis-Assembly

    2. Intermediate case Dis-assembly a) Remove bearing (3) from mainshaft (4) with the help of suitable puller. b) Pull out gear mainshaft (5) from mainshaft , and then take out mainshaft. c) Take out rear bearing (6) from housing. d) Take out bearing cup & cone (12), gear layshaft (2) from layshaft (1). e) Now take out layshaft and rear cup &...

  • Page 39: Rear Case Dis-Assembly

    3. Rear case Dis-assembly a) Support the rear case assembly on a suitable clean block, keeping the planet 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).
  • Page 40 Remove the output flange retaining nut (18) alongwith spacer (33) and tap drive flange out (using a suitable puller if available) – the flange outer diameter is a tight fit in the ball bearing. Note the flange boss fits in the bearing inner race.
  • Page 41 i) Remove the synchronizer ring low. j) Make identification marks on the sliding sleeve in line with the plungers, springs and rollers. Place the planetary assembly on wooden block and remove the annulus with sliding sleeve. To separate 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.
  • Page 42 l) Invert the assembly and drop the end of 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.
  • Page 43 Synchronizer Ring- Flange, Clearance (mm) Minimum 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 r) Lift the spacer ring and take it out. s) If necessary remove the 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.
  • Page 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: Planet Gear Carrier Dis-Assembly

    4. Planet gear carrier Dis-assembly It is unusual that only one planet gear gets damaged 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.
  • Page 47 a) Remove the bearing spindle retaining screws (Allen key 3 mm) from the planet gear carrier. The screws are locked by deforming the screw top. So a very little portion at the top of the head of grub screw has to be drilled (preferably a flat drill) out before the screw can be removed.

  • Page 48: Planet Gear Carrier Assembly

    5. Planet 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 c) There are 36 rollers. Place 18 rollers into position. d) Place the spacer 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 g) Slide in the gear assembly until the bore of the planet carrier and gear assembly align. h) Ensure the locating hole in the spindle aligns with the hole in the carrier. Drive the spindle into carrier using a soft faced mallet. Note: There is a lubrication hole directly opposite the locating hole.

  • Page 51: Rear Case Piston & Range Cylinder Assembly

    6. Rear Case Piston & Range Cylinder Assembly a) Range change selector rod bush - rear case. Drift out the rear bush complete with carrier from the rear case. b) Install a new O-ring into the groove on the outer periphery of the bush carrier.
  • Page 52 e) Assemble O-ring (1) on bush, O-ring (3, 5 & 6) in piston (4); lubricate O-ring with silicone grease. f) Place O-ring on range cylinder; lubricate O-ring with silicone grease. g) Assemble range cylinder as per below steps: Install a new O-ring (11) in plug (12), lubricate O-ring with silicone grease. Now place rod spring range (7) on to piston.

  • Page 53: Rear Case Assembly

    7. Rear Case Assembly a) Insert selector rod through range change selector fork (flat face of fork and threads of shaft on the same side). Rotate the rod 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.
  • Page 54 e) Stand the annulus assembly, sliding sleeve up, on a bench. Fit the snap ring in the external groove on synchronizer sleeve. Insert the sliding sleeve, pressing the snap ring in the sleeve groove all around, in the annulus aligning it so that snap ring ends DO NOT come on any hole on the periphery of the annulus.
  • Page 55 i) Place synchronizer hub and bearing assembly onto the shaft aligning the slots in the hub with the shoulders on the synchronizer ring. Use a soft mallet and drift or mandrel to ensure the bearing is fully home against the stop. j) Install retaining snap ring.
  • Page 56 m) Place synchronizer ring, low, on the synchronizer hub locating it in the slots of the synchronizer hub. The annulus rests on the six rollers. Place the synchro ring on sliding sleeve. Hit on the synchro ring with both hands on either side of the shaft and remove the support piece.
  • Page 57 p) Install the large circlip into the outer peripheral groove on synchronizer flange, 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.
  • Page 58 t) Place Planet Carrier and Annulus Assembly, rear end up, on table. Locate selector fork and shaft assembly into synchronizer sleeve, threaded end of shaft up. Support shaft under its bottom end to prevent its 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.
  • Page 59 x) Install a new oil seal into the carrier using special tool. y) Apply sealant Loctite 5900 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.
  • Page 60 aa) Apply thread sealant Loctite 243 to the cap screws, four, and tighten them to 35 – 39 N m. bb) Smear grease on the inner periphery of the oil seal and install the output drive flange. Note: Coupling flange fits inside the bearing inner race).Fit temporarily (to be removed later) the old nyloc nut (nylon insert sheared) to tighten the coupling flange tight enough so range hub rollers...
  • Page 61 dd) Fit the speedo sensor assembly; tighten to 24 – 30 N m. ee) During transmission overhauling, inspect the magnet (1) for any wear / dislocation. If any wear / dislocation observed, replace magnet with new one. To fit new magnet, follow the procedure as below: Place the case on the table Apply loctite 7649 where magnet to be installed.
  • Page 62 gg) If necessary install new sealing rings on oil muff if the rings are excessively worn or scored. Lubricate oil muff and locate it on the rear of mainshaft. Compressing sealing rings push oil muff into pump. hh) Install sun gear onto the mainshaft if it was removed by hand;...
  • Page 63 kk) Apply sealant to intermediate case rear flange in a continuous bead around the flange and the retaining cap screw holes. ll) Install detent plunger, spring and ball using a magnet if necessary. mm) Fit the range & reverse switch alongwith balls & o rings. Fit drain &...

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