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拆卸变速器的步骤及注意事项拆卸变速器是车辆维护保养中的一个重要步骤，其操作繁琐且需要一定的专业知识和技能。
本文将从简述拆卸变速器的步骤及注意事项出发，为您详细介绍这一过程。
一、准备工作1. 为了安全起见，首先确保车辆停稳在平整的地面上，并且将驻车制动器牢固地固定住。
2. 另外，要记得提前切断电池的正极，以免触电事故发生。
3. 准备好相应的工具，如扳手、起重机等。
二、拆卸步骤1. 拆下车身下的护板，以便于接下来的工作顺利展开。
2. 打开变速器油排放螺丝，将变速器油排放至容器中，避免污染环境。
3. 用扳手拆下变速器液压油管、传感器、电子线束等相关零部件。
4. 使用适当的工具，拆下变速器与发动机之间的螺栓。
5. 使用专业的起重机，小心地将变速器从发动机上卸下。
三、注意事项1. 操作过程中要保持工作环境干净整洁，避免异物进入变速器内部造成损坏。
2. 拆卸变速器时，需时刻保持注意力集中，防止因疏忽大意而造成意外伤害。
3. 拆卸后的变速器需妥善保管，避免受潮或遭受外部损坏。
总结回顾拆卸变速器是一项复杂且需要细心操作的工作，需要严格按照步骤进行，避免疏漏。
在操作过程中，注意事项更是至关重要，确保操作的安全性和有效性。
个人观点和理解作为一项维修保养工作，拆卸变速器需要严格遵循相关步骤和注意事项，以免造成不可挽回的损坏。
这也需要操作人员具备一定的专业知识和技能，因此建议在没有足够经验和技术的情况下，尽量寻求专业人士的帮助。
通过本文的介绍，相信您对拆卸变速器的步骤及注意事项有了更深入的了解。
在日常维护中，务必谨慎对待这一环节，以保障车辆的正常运行和安全。
拆卸变速器是一项需要专业技能和经验的工作，其复杂性和繁琐程度需要操作人员具备一定的专业知识和技能。
在进行拆卸变速器时，有一些特殊情况需要注意，接下来我将详细介绍这些情况以及应对方法。
当拆卸变速器时，操作人员需要特别注意变速器内部的液压系统，因为液压系统是变速器正常运行的关键。
简述变速器拆装的步骤
变速器拆装的步骤通常包括以下几个步骤：
1. 准备工作：首先要确保车辆处于安全的工作状态，如将车辆停放在平坦的地面上，并拉起手刹。
然后，打开车辆的引擎盖，并用千斤顶将车辆抬起，以便能够更方便地接触到变速器。
2. 排除液压压力：在开始拆装变速器之前，需要排除液压压力，以免发生意外。
这通常可以通过拆下变速器油箱上的液压软管或者拆下变速器油底壳的油塞来实现。
3. 拆卸传动轴及连接件：在拆卸变速器之前，需要先拆卸传动轴和与之连接的部件。
这包括拆下传动轴的万向节和支撑架，拆掉传动轴和变速器的连接螺栓，以及拆下其他与变速器连接的零件。
4. 拆卸变速器支架：变速器通常是由支架支撑在车辆底盘上的，因此在拆卸变速器之前，需要先拆卸变速器支架。
这通常需要拆掉支架上的螺栓和螺母，然后将支架与变速器分离。
5. 拆卸变速器本体：最后，可以开始拆卸变速器本体。
这通常需要拆下变速器的油底壳、离合器套筒、换挡杆及其相关连接杆，以及变速器的其他零件。
拆卸过程中需要小心操作，以避免损坏变速器或其他零件。
完成以上步骤后，就可以将拆下的变速器进行维修、更换零件或安装新的变速器。
拆卸变速器后，也需要进行仔细清洁，以
防止污染变速器内部。
最后，根据逆序的顺序重新安装变速器和与之相关的零件，并确保每个零件正确定位、固定和连接好。
变速箱拆装工艺流程一 概述变速箱安装在液力变矩器的后面，来自变矩器的动力通过变速箱的输入轴传递到变速箱，再有驱动轴传递到前后驱动轴。
二 变速箱常见故障故障现象 检查结果 故障分析 故障排除 在某一档位行车无力或者无法行驶变速箱油底壳油发黑并有异味1.变速箱长期处于超载工作2.变速箱没有按运行时间进行换油3.频繁的突然变速操纵对离合片进行更换变速箱壳体上有渗油迹象变速箱前后盖有裂纹 深沟轴承磨损，变速箱在运行时，轴体发生圆跳动，频繁冲击壳体换新的深沟轴承三 需修装载机验收经过技术员对故障机器进行故障检查并确诊验收。
四 装载机大修前期处理将机器停在坚硬平整的地面上，将工作装置降至地面，并且堵塞住轮子，防止车辆移动，之左边：主动摩擦片右边;从动摩擦片均已经受到严重划伤和磨损后拆除司机室下面的外围挡板，再用高压水枪认真清洗机器表面和内部的泥土和油污，尤其是变速箱外围件。
六变速箱外围件拆除1.拆除并移走司机室。
2.解除变速箱上面的相关联的管路和电线。
3.取下发动机与变速箱的联结螺栓，两人配合用吊具吊出变速箱。
注意：a)在吊取变速箱时一定要确保变速箱平衡并且晃动小。
b)拆除的管道口要用布头堵住。
c)用遮布盖住发动机飞轮。
七变速箱安置将变速箱平稳安置在修理车间的特定位置，确保空旷平整清洁。
八变速箱总成分解1.拆解变速箱外围件。
2.解体变速箱的前后壳体。
3.两人配合取出变速箱三根主轴，之后拆除变矩器和停车制动离合器。
4.两人配合拆解各档位离合器和变矩器和壳体上各轴承。
注意：a)在拆解时一定要把零件进行分类分开摆放防止错乱。
b)在拆解停车制动中的保持器是一定要与壳体之间做好记号。
九零件清洗和除油将拆解的各个零件用超声波清洗机清洗（没有条件可用清洁柴油清洗），之后用压缩空气吹干净。
十技术员对零件鉴定并分类，同时记录需更换的零件号和数量1.技术员对清洁后的所有零件进行鉴定并分类为报废零件，可用零件，需修零件。
2.对需修零件进行修理，对报废零件进行记录，申报新的零件。
变速器的拆装与调整一、实践内容1)变速器传动机构的拆装。
2)变速器操纵机构的拆装与调整。
二、实践的目的与要求通用实际操作，熟悉三轴式变速器与二轴式变速器的分解与装合，掌握其操纵机构的拆装与调整。
三、教具和工具常用工具一套、铜棒一根、变速器拆装车一辆、二轴式变速器和三轴式变速器各一台、配套的挂图一套。
四、操作技能训练1．三轴式变速器的拆装与调整（以EQ1091为例进行分析）(1)自车上拆下变速器总成1)首先拆下与传动轴相连的万向节（注意：拆卸前应在传动轴凸缘叉和变速器二轴凸缘上作上装配标记）。
2)拆下倒车警报开关导线、速度表传动软轴。
3)拆下离合器分离拉杆锁紧件，使离合器踏板机构与离合器叉拉臂分离，拆下手制动器软轴接头等操纵机构连接件，拆下驾驶室内变速器盖板。
4)拆下固定在变速器壳体上的离合器助力分泵。
5)用变速器拆装车托住变速器总成，拆下飞轮壳与离合器壳之间的固定螺栓，拆下变速器与发动机后悬架及车架的固定螺栓。
6）拆下变速器总成。
（注意：应先将变速器第一轴沿轴向平稳退出后才可放下变速器总成）(2）三轴式变速器的分解（见图1)图1 变速器分解图1-第一轴后轴承内圈卡环 2-滚柱轴承及卡环 3-第一轴 4-隔环 5、20、32、40-滚针轴承 6-滚针轴承卡环 7-第一轴齿轮接合齿圈 8-第五、六挡同步器锁环 9、15、18、22-卡环 10-花键毂 12-定位块 13-推块 14-第五、六挡结合套 16-第二轴五档齿轮 17-第五档齿轮滚针轴承 19-四档齿轮衬套 21-第二轴四档齿轮 23-第三、四挡齿轮接合齿圈24-第三、四挡同步器锁环 25-花键毂 26-第三、四档结合套 27-第二轴三挡齿轮 28、33-隔套 29防转销 30-第二轴 31-第二轴二档齿轮 34-第二档同步器总成 35-第一档接合齿圈 36-第二轴一挡齿轮 37-一挡齿轮衬套 38-倒挡齿轮接合齿圈 39-倒挡齿轮接合套41-倒挡齿轮衬套 42-第二轴倒挡齿轮 43-倒挡齿轮止推垫 44-后盖油封总成 45-挡尘罩总成 46-第二轴凸缘 47、62-O形环 48-锁紧螺母 49-第一轴轴承盖螺栓 50-第一轴轴承盖 51-密封垫 52-第一轴油封总成 53-外壳 54、67-衬垫 55-取力孔盖板 56-取力孔盖板螺栓 57-速度表齿轮标牌 58-变速器标牌 59-加油螺塞 60-放油螺塞 61-垫圈 63-偏心套 64-速度表传动齿轮 65-偏心固定螺栓 66-蜗杆 68-后盖 69-后盖螺栓1)拆下放油螺塞，放尽齿轮油。
Eaton 9-Speed Synchronized Transmissions Double “H” Shift Control ConfigurationTRDR0070February 2008FS(O) 6109FS(O) 6209FS(O) 6309FS(O) 8209FS(O) 8309FS(O) 10209FS(O) 10309Warnings and CautionsRead the entire driver instruction before operating this transmission.Set the park brakes before starting the vehicle, always be seated in the driver's seat, move the shift lever to neutral, and depress the master clutch.If engine cranks in any gear other than neutral or without the master clutch depressed, service your vehicle neutral safety start circuit immediately (where a safety start circuit is fitted).Before working on a vehicle, parking the vehicle, or leaving the cab with the engine running, place the transmission in neutral, set the parking brakes, and block the wheels.Do not release the parking brake or attempt to select a gear until the air pres-sure is at the correct level.TOWING: To avoid damage to the transmission during towing, place the trans-mission in neutral and lift the drive wheels off the ground or disconnect the driveline.iWarnings & Cautions (i)Introduction (1)Tag Information (1)Operation (2)Nomenclature (2)Shift Pattern (2)General Information (3)High to Low Range Shifting (3)Driving Tips (4)Initial Start-Up (5)Upshift (5)Downshift (6)Service & Maintenance (7)Proper Lubrication (7)Mixing Oil Types (7)Proper Transmission Lubrication Levels (8)Lubricant Change Intervals (9)Operating Temperatures (10)Lubricant Change (11)Maintenance Checks (12)Tag InformationTransmission model designation and other transmission identification information are 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.IMPORTANT: DO NOT REMOVE OR DESTROY THE TRANSMISSION IDENTIFICATION TAG.Transmission TagRecord the Transmission Model and Serial Number below. Have these reference numbers handy when ordering replacement parts or requesting service information:Transmission Model:Transmission Serial Number:Every effort has been made to ensure the accuracy of all information in this manual. However, Eaton Truck Components Operations makes no expressed or implied warranty or representation based on the enclosed information. Any errors or omissions may be reported to Eaton Corporation, Truck Components, Global Marketing Services, P.O.Box 4013, Kalamazoo, Michigan, 49003.1NomenclatureShift PatternCNote: The shift lever is cross gate biased and will rest naturally in 3rd / 4th gate position when in LOW and in 5th / 6th gate position when in HIGH.The cross gate bias could vary or may be omitted depending on thevehicle manufacturer. Ensure you are familiar with this before driving the vehicle2General Information9-Speed Double “H”Models in this series provide nine forward speeds and one reverse speed, consisting of a five-speed front section and a two-speed auxiliary range section.Crawler gear (C) in the front section is used only as a starting gear. The other four ratios are used once in LOW range and once again in HIGH range.After shifting out of Crawler gear, shift the remaining gears in LOW range and HIGH range as you would shift any synchronized transmission.Shift range from LOW to HIGH and HIGH to LOW by moving the shift lever fully to the right or fully to the left as described in the Operation section. The transmission will automatically make the synchronized range shift as the shift lever is moved fully left or right.High to Low Range ShiftingNever attempt to shift down at too high a vehicle speed as this will result in major damage to the driveline.Note: Some vehicles are fitted with a range shift over-speed protection device in conjunction with the vehicle manufacturer. Never assume a rangeover-speed device is fitted.As a guide never shift from HIGH range to LOW range above 30 kph - not even if the vehicle is in neutral and the clutch pedal is depressed.Note: This speed will vary based on the overall driveline configuration.3Shift Pattern DiagramsA shift pattern diagram / etched shift knob should be in your vehicle (depending on vehicle manufacture).Driving Tips•Always use the clutch when making up shifts or down shifts.Premature synchronizer failure can result from not using the clutch.•Always select an initial starting gear that provides sufficient reduction for load and terrain.•Never slam or jerk the shift lever to complete gear engagement.•Never coast with the shift lever in the neutral position.•Never downshift at too high of a road speed.•Never shift to crawler gear (C) while the vehicle is moving.•Never select reverse gear while the vehicle is moving.4Initial Start-UpBefore starting the vehicle, always be seated in the drivers seat, move the shift lever to neutral, and depress the master clutch fully.Before moving a vehicle, make sure you understand your shift pattern configuration.1.Make sure the shift lever is in neutral, the range section is in LOW,and the parking brakes are set.2.Turn on the key switch. Start the engine.3.Build up the air pressure to cut off.4.Apply the service brakes.5.Depress the clutch pedal to the floor.6.Move the shift lever to the desired initial gear.7.Release the parking brakes.8.Slowly release the clutch pedal and apply accelerator.In the following instructions it is assumed that the driver is familiar with operating a commercial vehicle and can coordinate the shift lever movement and clutch pedal to make a smooth gear engagement while upshifting and downshifting.Upshift1.Fully depress the clutch pedal. Move the shift lever to the nextdesired speed.2.Release the clutch pedal.3.Accelerate the vehicle.4.Continue upshifting to 4th speed.5Range Shift Low to High (4th to 5th)1.When in the last LOW range gear position (4th) and ready for thenext upshift, with the engine / vehicle speed at a point that will allowthe vehicle to accelerate.2.Release the accelerator.3.Fully depress the clutch pedal. Move the shift lever to neutral.4.Move the shift lever fully RIGHT for a short period - doing this willtrigger the range valve to automatically shift the transmission toHIGH range.5.Allow the shift lever to return to its natural cross gate position.6.With the clutch still depressed shift to 5th speed.7.Release the clutch and apply the accelerator.8.Continue upshifting to 8th speed.Downshift1.Fully depress the clutch pedal, move the shift lever to the nextdesired speed.2.Release the clutch pedal.3.Continue downshifting to 5th speed.Range Shift High to Low (5th to 4th)1.When in the last HIGH range gear position (5th) release theaccelerator.2.Fully depress the clutch pedal. Move the shift lever to neutral.3.Move the shift lever fully LEFT for a short period - doing this willtrigger the range valve to automatically shift the transmission toLOW range.4.Allow the shift lever to return to its natural cross gate position.5.With the clutch still depressed shift to 4th speed.6.Release the clutch.7.Slow the vehicle and continue downshifting.Note: Never shift to crawler gear (C) while the vehicle is moving.6Proper LubricationProper lubrication procedures are key to a good all-around maintenance program. If the lubricant level is ignored, all the maintenance procedures in the world are not going to keep the transmission running or assure long transmission life.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 lubricated if these procedures are closely followed:•Maintain oil level and inspect regularly.•Follow maintenance plan.•Use correct grade and type of oil. Prolonged oil change will cause internal damage.•Do not overfill as this causes overheating and effects fuel economy.•Buy from a reputable dealer.Mixing Oil TypesNever mix engine oils and gear oils in the same transmission.Note: Additives and friction modifiers must not be introduced. Engine oils and gear oils may not be compatible; mixing can cause breakdown of thelubricant and affect component performance. When switching between types of lubricants, all areas of each affected component must bethoroughly flushed.7Proper Transmission Lubrication Levels•Make sure the transmission lubricant is level with the bottom of the fill opening.Always check the oil on level ground•8Lubricant Change Intervals•Lubricant change intervals will be included in the vehicle operating handbook and will be defined based on the type of oil used and theoperating conditions.•As a base rule the following should be followed:Mineral Oils* On Highway UseInitial oil change -At the operator’s discretion.Every 20,000 km -Inspect oil level and check for leaks.-Change oil (see Note below) Every 100,000 km (orannually)Note: Whichever comes first.* Off Highway UseInitial oil change -At the operator’s discretion.Every 40 hours -Inspect oil level and check for leaks.Every 500 hours -Change oil (see Note 1 below)Every 1000 hours -Change oil (see Note 2 below)Note 1: Oil change - where severe dirt conditions exist.Note 2: Oil change - where normal conditions exist.910Operating TemperaturesTransmissions must not be allowed to operate at temperatures above 120o C (250o F). Operating above this temperature causes loaded gear toothtemperatures to exceed 177o C (350o F), which will ultimately destroy the heat treatment of the gears. If the elevated temperature is associated with an unusual operating condition that will recur seek advice from your vehicle manufacturer.Synthetic / Semi-Synthetic Oils* On Highway UseEvery 20,000 km-Inspect oil level and check for leaks.Every 300,000 km to500,000 km- OR -Every 3 years - -Change oil (see Note below)Change oil.Note: Mileage will depend on type of oil used.* Off Highway UseEvery 40 hours-Inspect oil level and check for leaks.Every 500 hours-Change oil (see Note below)Every 1000 hours -Change oil (Normal operation)Note: Change oil where severe dirt conditions exist.Lubricant ChangeDraining OilHot oil may be present during this activity.•Drain the transmission when the oil is warm.•Remove the two drain plugs from the transmission.•Clean the oil strainer before replacing it.•Replace copper washer / o-ring as required.Re-filling•Fill transmission to the level of the filler opening.•Do not inter mix different types of brands of oil.•Do not use additives i.e. friction modifiers.•Do not overfill the transmission, as this will cause overheating and may cause oil leaks through the input and output shaft oil seals. 11Maintenance ChecksConduct regular maintenance checks where possible regarding:-Clutch mechanism -General operation-Lubricant-Correct level-Filler and drain plug -Correct tightness / damage towashers-Cap screws and gaskets -Loose / oil leaks-LRC / Shift tower -Secure / free play / wear12Copyright Eaton Corporation, 2012.Eaton hereby grant their customers,vendors, or distributors permission to freely copy, reproduce and/or distribute this document in printed format. It may be copied only in its entirety without any changes or modifications. THIS INFORMATION IS NOT INTENDED FOR SALE OR RESALE, AND THIS NOTICE MUST REMAIN ON ALL COPIES.Note: Features and specifications listed in this document are subject to change without notice and represent the maximum capabilities of the software and products 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 accuracy and assumes no responsibility for any errors or omissions. Features and functionality may vary depending on selected options.For spec’ing or service assistance, call 1-800-826-HELP (4357) or visit /roadranger.In Mexico, call 001-800-826-4357.Eaton Corporation Vehicle Group P .O. Box 4013Kalamazoo, MI 49003 USA 800-826-HELP (4357)/roadrangerPrinted in USA Roadranger: Eaton and trusted partners providing the best products and services in the industry, ensuring more time on the road.。
变速器拆装规范实验规范变速器拆装规范（做2份）一、实训内容（1）变速器拆卸第一步：拆卸五档齿轮罩盖，将五档齿轮拨叉，拉出五档齿轮及同步器衬套。
第二步：将倒档轴固定螺栓，拆下两个法兰轴，拆下换挡轴，将变速器壳体紧固螺栓按对角线交叉法旋松并卸下，把变速器壳体小心向上撬起，取下变速器壳体。
第三步：取出变速器第一轴。
第四步：取下变速器四、五档换挡同步器。
第五步：取下第二轴。
第六步：分解第二轴。
（1）观察变速器内齿轮啮合情况。
仔细观察变速器（输入轴、输出轴、倒档轴）、（拨叉）、（同步器）的结构特点，熟悉各零部件的名称和相互连接关系及作用。
（3）装配转配顺序与拆卸顺序相反2、拆装实训要求（1）拆卸时，应注意安全（2）正确使用工具，严格遵照拆装顺序（3）装配时各轴应在空挡位置（4）装配时输入轴、输出轴、主减速齿轮轴及主减速器时，注意轴承预紧力（5）在装入变速器壳时，注意接触面密封情况（6）装配好变速器操纵机构后，操纵应轻便灵活，锁止机构能起作用发动机拆装工艺（做3份）一、发动机拆卸：（1）拆下气缸盖13固定螺丝，注重螺丝应从两端向中心交叉旋松，而且分3次才卸下螺丝。
（2）抬下气缸盖，取下气缸垫，注重气缸垫的安装朝向。
（3）翻转发动机，拆卸油底壳固定螺钉（注意螺钉也应从两端向中间旋松）。
（4）拆下油底壳和油底壳密封垫。
（5）旋松机油粗滤清器固定螺钉，拆卸机油滤清器、机油泵链轮和机油泵。
（6）拆卸发动机活塞连杆组，转动曲轴，使发动机1、4缸活塞处于下止点。
（7）分别拆卸1、4缸的连杆的紧固螺母，取下连杆轴承盖，注意连杆配对记号，并按顺序放好。
（8）用橡胶锤或锤子木柄分别推出1、4缸的活塞连杆组件，用手在气缸出口接住并取出活塞连杆组件，注意活塞安装方向。
（9）将连杆轴承盖，连杆螺栓，螺母按原位置装回，不同缸的连杆不能互相调换。
用同样方法拆卸2、3缸的活塞连杆组。
（10）拆卸发动机曲轴飞轮组，旋松飞轮紧固螺钉，拆卸飞轮，飞轮比较重，拆卸时注意安全。
