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Mod TLB1 2WD / 4WD 液力变速箱维修手册

REPAIR MANUAL 维修手册


TRANSMISSION 变速箱
Mod. TLB1 2WD / 4WD

1st Edition date: 07/2002


Revision date: 00/00 P/N: CA357231
Mod TLB1 2WD / 4WD 液力变速箱维修手册
Index 目录
GENERAL INFORMATION . . . . . . . . . . . . 1
Manual use. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
通用信息 1
Agreements and definitions . . . . . . . . . . . . . . . . . . . 4 用户手册 2
General description . . . . . . . . . . . . . . . . . . . . . . . . . 6 约定与定义 4
General recommendations 通用描述 6
for disassembly and assembly operations . . . . . . . . 对分解与组装操作的建议 7
7
SAFETY INSTRUCTIONS. . . . . . . . . . . . . 9
安全说明 9
General safety recommendations . . . . . . . . . . . . . 10 通用安全建议 10
Safety symbols. . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 安全符号 11
General precautions. . . . . . . . . . . . . . . . . . . . . . . . 12 注意事项 12
GENERAL SPECIFICATIONS. . . . . . . . .
14
通用说明书 14
Foreseen uses . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Forseen uses 15
Product identification . . . . . . . . . . . . . . . . . . . . . . . 16 产品标识 16
Technical features . . . . . . . . . . . . . . . . . . . . . . . . . 17 技术特征 17
Main points nomenclature . . . . . . . . . . . . . . . . . . . 22 命名要点 22
Filling and checks. . . . . . . . . . . . . . . . . . . . . . . . . . 25 填充与检查 25
Service schedule . . . . . . . . . . . . . . . . . . . . . . . . . . 29 服务表 29
Lubrication: 润滑:
grades and application range. . . . . . . . . . . . . . . . . 30 等级与应用范围 30
Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . 31 紧固力矩 31
Hydraulic components . . . . . . . . . . . . . . . . . . . . . . 33 液压件 33
Oil pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 油泵 38
Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 分配阀箱(mainfold) 39
Kinematic scheme . . . . . . . . . . . . . . . . . . . . . . . . . 41 运动学图表 41
DISASSEMBLY AND ASSEMBLY
OPERATIONS . . . . . . . . . . . . . . . . . . . . . 42
拆卸与组装操作 42
Plugs and filters . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 plugs and filters 43
Converter and oil pump . . . . . . . . . . . . . . . . . . . . . 50 变矩器和油泵 50
Pipes and sensors . . . . . . . . . . . . . . . . . . . . . . . . . 56 管路与传感器 56
Hydraulic control valve. . . . . . . . . . . . . . . . . . . . . . 59 液压控制阀 59
Solenoid valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 电磁阀 69
Transmission housing . . . . . . . . . . . . . . . . . . . . . . 73 变速箱室 73
3Shaft A - D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 3 轴 A-D 95
Shaft B - C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 轴 B-C 114
Shaft E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139 轴E 139
Speed controls . . . . . . . . . . . . . . . . . . . . . . . . . . . 148 速度控制 148
TROUBLESHOOTING. . . . . . . . . . . . . . 155
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 156
故障诊断 155
Troubleshooting 故障诊断 156
of transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . 161 变速箱故障诊断 161
SPECIAL TOOLS . . . . . . . . . . . . . . . . . 164 专用工具 164
Special tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165 专用工具 165
Mod TLB1 2WD / 4WD 液力变速箱维修手册

A GENERAL INFORMATION

通用信息
Mod TLB1 2WD / 4WD 液力变速箱维修手册

A.1 Manual use A.1 手册的使用


End users 最终用户
• Installer  装配人员
• User  使用人员
• Maintenance operator  维护人员
Maintenance 维护
CONSULT THIS MANUAL THOROUGHLY, as 请仔细阅读本手册。为使机器各个部件具有良
proper functioning and good efficiency of 好的性能和效率,应坚持长期进行正确的例行
mechanical organs depends mostly on constant 维护工作,以使设备完好和达到预期寿命。
and correct routine maintenance ensuring 在任何损坏和异常情况下,专业人员的及时处
product integrity and expected life duration. 置都能避免进一步的损伤,并可延长工作寿命。
In case of any damages or anomalies, quick 修理
intervention of specialized personnel can avoid 在拆卸和安装说明部分对整个机器的大修做了
future impairment and lengthen the working life. 略述。使用有说明的图片,按顺序对专门的处
Repair 置进行了讲解。这样,对每一步操作都有完整
The disassembly/assembly procedures have 安全的指导。
been outlined for a total product overhauling. 操作说明是假设部件已从车辆上拆卸下来。
They have also been described in sequence 在需要对整机进行拆装的大修和维护工作中应
through photographs with relevant explanation for 参考由主机制造商提供的维修手册。
specific interventions, thus obtaining a complete 而且,对产品仔细的检查可以准确的估计维修
and safe guide for each and every phase of an 工作,可能只拆下几个零件,或在部件上就可
operation. 以进行维修工作。
Operation description presumes that the unit has
already been removed from the vehicle.
The manual supplied by the vehicle manufacturer
should be consulted in case of a overhauling or
maintenance intervention requiring the removal of
the machine.
Moreover, the attentive product inspection leads
to a correct repair work estimation that could
merely require dismounting only few components,
and thus operating partially on the group.
Mod TLB1 2WD / 4WD 液力变速箱维修手册

A.2 Information property A.2 版权


This manual should be considered as CARRARO
S.p.A. confidential information. All rights 本手册的内容是 CARRARO Spa 公司的机密。保
reserved. 留版权。
No part of this manual may be reproduced, in any 未经 CARRARO Spa 公司的允许,不得以任何形
form or by any means, without prior written 式复制本手册的任何内容。
permission of CARRARO S.p.A. 手册随产品发给用户。用户只能使本手册用于
Only the customer, whom the manual, together 使用和维修产品,不能用于其他目的。
with the product, has been issued to, is allowed to CARRARO Spa 声明,本手册的主题与本手册所
use this document, and only in order to use, 指设备的技术和安全数据一致。对于因为不正
maintain and repair the unit. 确使用本手册和设备或将其用于本手册规定以
CARRARO S.p.A. declares that the subject of this 外的用途而造成对人、物或动物的伤害,制造
manual consists with the technical and safety 商将不承担责任。
specifications of the machine that the manual is
referred to.
The manufacturer shall not be held liable for
direct or indirect damages to persons, things or
animals due to an improper use of this document
or of the machine or to a different use of them,
which does not comply with what is provided for
in this manual.
Mod TLB1 2WD / 4WD 液力变速箱维修手册

A.3 Agreements and definitions A.3 约定和定义


Agreements 约定
Illustrations like pictures, drawings and 由于空间和编辑的限制,本手册所用图解,包
components of this manual are NOT in scale, 括图片、图纸以及其他手册的内容与实际并非
because of limited space and editing limits, 比例关系,因此通过这些内容所获得的尺寸和
therefore they are NOT reliable to obtain values 重量是不可靠的。
about size or weight. 图解是用于指出设备及其组成部分的操作方
Illustrations are supposed to point out the correct 法,因此并不能确切展示其实际构成。
methods to working on the machine and its 定义
components, therefore they could not display 左侧:是指车辆行进时,设备的左侧。
exactly the same elements. 右侧:是指车辆行进时,设备的右侧。
Definitions 印刷约定
Left side: it is the left side of the unit considering 注释:注释是从外面指出正文中所提及的部分,
the vehicle running conditions. 其中包含重要信息。
Right side: it is the right side of the unit 警告:警告指出某些规程若被部分或全部违背,
considering the vehicle running conditions. 可能导致机器或其连接设备的损坏。
Typographic agreements 危险:危险指出某些规程若被部分或全部违背,
Note: The notes, pointed out externally to the text 可能对操作人员造成伤害。
they refer, include important information. 度量单位
Warning: Warning indications point out the 本手册采用国际单位制,可以通过下面的转换
procedures, whose partial or complete 表将其转换为英制。
non-observance can damage the machine or the
connected equipment.
Danger: Danger indications point out the
procedures, whose partial or complete
non-observance can injure the operator.
Measurements
This manual indicates all measurements in
International System (SI).
Use the following conversion table to convert
Imperial Measure.
单位转换表
Mod TLB1 2WD / 4WD 液力变速箱维修手册
Mod TLB1 2WD / 4WD 液力变速箱维修手册

A.4 General description A.4 通用描述


The machine should be checked and/or repaired 应该由了解其工作特性并且非常熟悉安全操作
only by qualified technicians, acquainted with its 规范的有资格的技术人员进行检查和修理。
peculiar features and well aware of all safety 建议在进行任何操作之前对设备进行精确的清
instructions. 理,除掉润滑脂油污及其堆积物。
Before performing any operation it is advisable to 所有拆解的机械部件必须用适当的制剂进行清
carry out unit cleaning accurately by removing oil/ 洗以避免可能造成的损害。
grease encrustations and accumulation. 应该更换出现破坏、磨损、裂纹以及失灵的部
All disassembled mechanical parts must be 件,因为它们会对设备的正常工作造成影响。
cleaned accurately with suitable products to avoid 应该仔细检查旋转部件(轴承,齿轮,轴)以
possible damage. 及五金件(O 型圈,油封),因为它们易受到主
Parts should be replaced if damaged, worn out, 要压力作用、磨损以及老化。
cracked, seized, etc. as they could affect proper 我们强烈建议每次拆卸和修理时更换紧固件。
working. 恰当使用备件,螺母以及螺栓以避免出现其他
Rotating parts (bearings, gears, shafts) and that 问题。而且,对于米制螺母和螺栓应使用米制
of hardware/fasteners (O-Ring, oil seals) should 工具,而对其他的则使用英制工具。
be examined carefully, as they are subject to 一些操作对一些部件是破坏性的。请非常仔细
major stress, wearing and ageing. 的阅读此说明,避免对其他零件造成不必要的
We highly advise to replace tightening parts 损伤。
during every teardown or repair.
Use appropriate spare parts, nuts and bolts to
avoid any other problems. Moreover, use metric
tools for metric nuts and bolts and Imperial tools
for the others.
Some repairs are destructive for some axle
components. Carefully reading and thorough
understanding of these instructions will avoid
damage to other components unnecessarily.
Mod TLB1 2WD / 4WD 液力变速箱维修手册

A.5 Recommendations for repair A.5 对维修操作的建议


在进行任何拆卸和安装前,仔细阅读以下建议
operations 轴的密封
Before starting any disassembly and assembly 在轴的密封装配中应遵循下面的建议:
operations, read carefully the following  对轴进行仔细清洗,确保轴与轴封接触的
recommendations. 部分未被破坏、切割或者圆度被破坏。
Shafts seals  装配时保证密封圈的唇部要朝向有润滑油
Respect the following recommendations during 一侧。
shaft seal assembly:  润滑密封唇(用油),用润滑脂填充 3/4 的
- Clean shaft very carefully and ensure that the 密封腔。
part in contact with the shaft seal is not damaged,  使用合适的装拆工具,不要直接用锤敲击
cut or out of roundness. 密封圈。
- Assemble the seals so that the lip is fitted  安装轴的时候不要损伤密封圈。
towards the oil side. O 型圈
- Lubricate seal lips (use oil) and fill 3/4 of seal 将他们装入恰当位置之前要进行充分的润滑,
cavity with grease. 装轴的时候要避免 O 型圈被挤压。
- Use appropriate drivers. Do not use a hammer 调整垫片
directly on the seals. 使用恰当的调整垫片,并分别对每一个调整垫
- Do not damage the seals while assembling the 片进行测量。
shaft. 对垫片完成整体测量或打标记并不总是可靠
O-rings 的,要检查。
Lubricate adequately before inserting them at the 轴承
right place and avoid O-ring rolling while inserting 建议将轴承装到各自的轴上之前加热到 80℃~
the shaft. 90℃,而在将其装入相应的孔之前进行冷却(干
Adjusting shims 冰)。用适合的拆卸工具拆卸轴承。重新装配轴
Use appropriate adjusting shims and measure 承之前要进行清洗、检查和润滑。
each one separately. 开口销
Complete group measurement or stampings on 装配弹性销之前,确保开口朝向压力方向。
the shims are not always reliable: check 螺旋弹性销没有方向要求。
Bearings 密封
Its advisable to heat up bearings to 80°C - 90°C 使用说明书推荐的密封,确保被密封的部件清
before assembling them onto their respective 洁,干燥,并彻底清除润滑油。
shafts or to cool them (dry ice) before inserting
them into corresponding bore.
Always use suitable extractors to remove the
bearings.
Before reassembling the bearings, clean, check
and lubricate them.
Split pins
Before assembling elastic pins, make sure that
the notch is oriented towards the stressing force.
Spiral elastic pins do not need orientation.
Mod TLB1 2WD / 4WD 液力变速箱维修手册
Sealing 清洁
Use sealing as advised by specifications. 要用柴油或煤油对所有活动件(齿轮、轴承等)
Ensure that parts to be sealed are clean, dry and 准确地清洗。
completely grease free. 要避免汽油和多水的碱性溶液。不要用蒸汽和
Cleaning 热水清洗,因为很难出去表面湿度。
Wash all moving parts (gears, bearings, etc.) 用棉布或风管将所有部件擦干以避免残余磨料
accurately with diesel fuel or kerosene. 引起划痕。
Avoid gasoline and watery alkaline solutions. Do 所有的表面都要用润滑剂覆盖以保护它们不被
not wash with steam or hot water, as it will be 氧化。
very difficultto eliminate surface humidity.
Dry all parts with a rag or air jet to avoid 检查
scratching from abrasive residuals. 精确检查所有轴承、可能会卡在它们的位置上
All surfaces should be covered with lubricant so 的外圈以及枢轴。
as to protect it from future oxidation. 更换那些已经磨损和损坏的件。
Checks 检查所有沟槽,确定它们不被磨损和破坏。
Examine accurately all bearings, external rings 用原装备件去更换那些损坏件。
which may be still stuck in their position and pivot 重新装配之前,更换旋转轴的油封。
pins on which rolls rotate.
Replace those which are worn out or damaged. 法兰和工具的端部
Check all grooves: assure that they are not worn 在锤击和法兰端部的过程中要小心,以避免对
out or damaged. 工具和部件的功能和完整性造成伤害。
Replace spoiled parts with original spare parts.
Replace seals on rotating shafts, before 重新装配方法
reassembly. 为重新装配所有组件,必须使用恰当的安装工
Ends of flanges and tools 具。
Be careful when hammering tool or flange ends, 为定位组件、拆卸或重新安装环形齿轮以及支
in order to avoid jeopardizing functionality and 撑齿轮箱,需要一套提升设备。
integrity of either the tools or the components on 为使拆卸和安装操作简化,可以使用一张部件
which you are operating. 装配图。
Reassembly methods
In order to reassemble the group, an appropriate
fixture must be used.
In order to position the group, to disassemble and
reassemble the ring gear and to support the gear
housing, a lifting system is needed.
To make disassembling and assembling
operations easier, use a group assembly
drawing.
Mod TLB1 2WD / 4WD 液力变速箱维修手册

B SAFETY INSTRUCTIONS
安全说明
Mod TLB1 2WD / 4WD 液力变速箱维修手册

B.1 General safety B.1 通用安全建议


重要提示
recommendations 在进行任何操作之前请仔细阅读本章。
IMPORTANT:
Before proceeding with any operations please read
this chapter very carefully.

安全注意事项:
正确的使用和修理组件及其部件对于安全性和
可靠性非常重要。本章所给出的所有建议和操
Safety precautions: 作规程都是经过试验的,因此是有效的操作方
Correct use and repair of Carraro products and of 法。请遵循每一道规程。文本与图解结合使用。
their components is very important for safety and 图解展示了专用工具的使用方法,并使操作可
reliability. 清晰正确的进行。
Recommendations and all described procedures 在进行特殊操作时必须使用专用工具。
given in this manual have been experimented and 不可能推荐每一种操作方法或者知道所有方
hence are effective operational methods. Please 法,也不可能去预测每一道操作的风险。因此,
follow every procedure. Use the text as well as the 以非推荐的规程或工具进行操作对操作人员、
illustrations. 机器以及车辆都是危险的。
Certain procedures show use of special tools, 危险
designed so that the operations can be carried out 进行每道安装和拆卸操作时都要戴好防护眼
in a clear and correct manner. 镜。
Special tools must be used when a particular
operation is being carried out.
It is impossible to advise every working method or
know all possible methodologies for carrying it out
or to predict risky consequences of each operation.
Hence, performing procedures or using instruments
which have not been advised could be dangerous
for the operator/mechanic as well as the vehicle.
Danger
Safety goggles must be worn while carrying out
every assembling or disassembling operations.
Mod TLB1 2WD / 4WD 液力变速箱维修手册

B.2 Safety symbols B.2 安全符号


Recognize safety information 辨认安全信息

This is the safety alarm symbol; whenever you find


it in the manual or see it on the machine, you are 这是安全警告符号,任何时候你在手册或机器
being warned about potential danger of accidents or 上发现这个符号,你都在被警告有潜在的事故
harm to personnel. Follow the do’s and don’t’s to 危险或有潜在的伤人危险。一定遵守安全警告
operate in total safety. 中规定的应做什么和不应做什么。
Understanding written warnings 理解文字警告

危险

警告

Written warning (DANGER, WARNING or 小心


CAUTION) is used along with an alarm symbol on
the machine. 文字警告(危险,警告或小心)与安全符号同
DANGER or WARNING signs are used near danger 时使用。
zones, while CAUTION sign indicates general 危险和警告标志在危险区域附近使用,而小心
precaution. 标志用于一般预防提示。
Follow safety instructions ! 遵循安全说明!
Read all suggestions given in this instruction 仔细阅读本手册给出的所有建议。
manual very carefully.

未经许可的改变可能危及性能、工作安全性和
Unauthorized changes could endanger the 工作范围。
functioning, work safety and work span. 如果您不能理解本手册,请联系最近的销售代
If you do not understand this instruction manual, 理商。
contact the nearest sales representative.
Mod TLB1 2WD / 4WD 液力变速箱维修手册

B.3 General precautions B.3 通用注意事项


Observe safety instructions, accident prevention 在工作中的每一步都要遵守安全说明,事故预
rules and all general safety regulations in each and 防措施以及所有通用安全规则。
every step at work. 在进行保养和维修工作之前要确保所有工具、
Before going ahead with maintenance or repair 支撑平台、支架、杠杆、拔取器以及扳手处于
work ensure that all the tools, the supporting bench, 良好状态,以便使得工作容易进行。
stands,levers, extractors and spanners are in good 这样对于各部分即部件的风险将会降低,操作
condition so that the work can be carried out easily. 人员的工作环境也会更安全。
Risks to various parts and components will also be 对于由于任意改变产品结构而导致的事故和损
reduced in this way and working condition for the 害,CARRARO Spa.将拒绝承担任何责任。
operator will also be safer. 如果产品被用于非预见性用途,CARRARO Spa.
CARRARO S.p.A declines any responsibility in case 将拒绝承担任何责任。
of an accident or damage resulting due to changes 这种情况下的所有后果都由用户承担。
made arbitrarily on product. 安全维护规则
The product is used for any other purpose different 1. 在清洁干燥的环境下操作;
from the one foreseen, than CARRARO S.p.A 2. 在运行过程中,不要进行润滑、触摸和调整
declines any responsibility. 组件;
In this case all consequences will be at the 3. 手、脚和衣服要远离移动部件;
customer’s expense. 4. 随时准备应付火灾。保证灭火器及主要辅助
Safety maintenance rules 工具伸手可及;
1 Operate in a clean and dry environment. 5. 将医生、救护车、医院以及火警部门的电话
2 Do not lubricate, handle or adjust the group 在电话机旁个准备一份;
underway.
3 Keep your hands, feet and clothing away from
moving parts.
4 Always be prepared for fires. Keep the
extinguisher and the first aid kit within reach.
5 Keep the phone number of a doctor, an
ambulance, a hospital and a fire department within
reach near the telephone set.
Mod TLB1 2WD / 4WD 液力变速箱维修手册

6 Wear suitable clothing and protection such as pointed out, in detail, in the assembly and disassembly
overalls, safety gloves and ear safety devices. procedures. During maintenance, follow carefully all
7 Use suitable ear protection, like ear plugs, to keep the safety procedures indicated in the manual.
out noise and prevent injury to the ears. 6.穿戴好合适的服装及防护装置,例如工作服、
A prolonged exposure to noise can damage your 安全手套及护耳装置等;
hearing. 7.使用合适的护耳装置,例如耳塞,以防止噪
音伤及耳朵,
将耳朵长期置于噪声之中将伤及听力;

8 The operator must be very careful with the


equipment.
Do not use headphones to listen music while you 8.操作人员使用设备要非常谨慎,在整车上工
are working on the product or on the group. 作或在部件上工作时不要用耳机听音乐。
Risks elimination 风险消除
• Risk of squashing and shearing due to the 运动件碾压和剪切的危险。
presence of moving parts. 警告
Warning 一切维护操作都要在机器静止的状态下进行。
Carry out all maintenance operations when the 吸入毒气发生危险,在焊接过程中油漆受热会
machine is stationary. 产生有毒气体。
• Risk due to inhalation of poison gases that can be 警告
produced by heating the varnishes during any 在有除烟、除尘设备的环境中使用。
welding. 在焊接、再加热或再次对部件工作之前,要驱
Warning 散烟气至少 15 分钟。
Use work stations equipped with dust and fume 用过的溶剂和机器中的油料可能引起火灾。
discharging systems. 警告
Let the fumes disperse for at least 15 minutes, 使任何热源远离工作区域。当溶剂和油漆去除
before welding or reheating, or working on the 剂用过之后,应用肥皂和水清洗,然后才能进
group again. 行焊接。
• Risk of fire due to the solvents used and to the oil 将装有溶剂、油漆去除剂或任何易燃物的器皿
in the machine. 从工作区域移除。
Warning 机器上物体的坠落或油料的喷射都可能造成危
Keep away any heat sources from the working area. 险。
When solvents or paint removers are used, they 警告
should be removed with soap and water, before 安装和拆卸过程中的其余风险及其相关消除规
welding. 则都已详细指明。在维护过程中要认真遵循手
Remove any containers of solvent, paint remover or 册中给出的所有安全规则。
any other inflammable products from the working
area.
• Risk due to fall, drop or violent ejection of objects
or oil.
Warning
These residual risks and the suitable relative
procedures to eliminate them completely are
Mod TLB1 2WD / 4WD 液力变速箱维修手册

C GENERAL SPECIFICATIONS

总体说明
Mod TLB1 2WD / 4WD 液力变速箱维修手册

C.1 Foreseen uses C.1 可预见性使用


This transmission has been designed and 本变速器是为工业机器设计和制造的。
manufactured to be mounted on industrial machines. 变速箱是用于将动力从发动机按指定传动比
The transmission box is a component that transmits 传递到车轮的装置。
the power from the engine to the wheels with an 变速箱也称为“TLB”,是根据用户的要求制
assigned transmission ratio. The transmission box 造的。
named also “TLB” is manufactured according to the 不要将变速箱安装到专门为变速箱设计和制
customer’s technical specifications. 造的地方以外的任何地方。
Never mount this transmission box on machines 如果本变速箱被用于非可预见性用途而引起
different from the ones for which it has been 的破坏和事故,CARRARO SpA 拒绝承担任
designed and manufactured If the transmission is 何责任。所有后果均由用户承担。
used for any other purpose than the one foreseen, 但是,即使用于可预见性用途,也要严格遵
CARRARO SpA declines any responsibility 守 CARRARO SpA 提供的操作手续和维护维
regarding damages or accidents caused by it. All 修规则。
consequences will be at the expense of the
client. However, when used as foreseen,
operational formalities as well as regular
maintenance repair specifications given by
CARRARO SpA are to be observed strictly.
Mod TLB1 2WD / 4WD 液力变速箱维修手册

C.2 Product identification C.2 产品识别

Transmission serial plate


Mod TLB1 2WD / 4WD 液力变速箱维修手册

C.3 Technical features C.3 技术规格

变速箱零件号
变速箱型号

净重

档位

前进档速比
1档

2档
3档

4档
倒退档速比
1档

2档
3档

4档

最大发动机功率
最大输入转速
变矩器型号

失速比

变矩器回路油量

用油规格
吸油过滤

过滤能力及过滤器型号

发动机飞轮规格
前后输出法兰型号

动力输出接盘
Mod TLB1 2WD / 4WD 液力变速箱维修手册
Sealing compounds and adhesives 密封要求
Mod TLB1 2WD / 4WD 液力变速箱维修手册
Overall dimensions 总体尺寸
(Millimeters)
Mod TLB1 2WD / 4WD 液力变速箱维修手册
Overall dimensions 总体尺寸
(Millimeters)
Mod TLB1 2WD / 4WD 液力变速箱维修手册

C.4 Main points nomenclature

*only for 4WD version


Mod TLB1 2WD / 4WD 液力变速箱维修手册
Mod TLB1 2WD / 4WD 液力变速箱维修手册
Main points nomenclature
Mod TLB1 2WD / 4WD 液力变速箱维修手册
reference value.
C.5 Filling and checks
The oil quantity for the correct operation of the
C.5 填充与检查
transmission is obtained by combining one volume 变速器正确的操作油量要结合体积检查和水
check and and level check. 平检查获得。
Correct determination of oil on the vehicle (in 在车上(工厂)正确的测定油量
the factory) 按下面的说明进行
Carry out the following instructions:  向变速箱注入一定体积 W 的油液,约
• Fill the transmission with a measured volume W of 19.5 升。
oil, about 19.5 litres.  停车制动。
• Apply the parking brake.  保持 shuttle shaft 控制在中间范围。
• Keep the shuttle shaft control in NEUTRAL range.  起动发动机,使其以 800-1000rpm 低速运
• Start the engine by keeping the slow running of 转持续一分钟。
800÷1000 rpm for about one minute.  关闭发动机。
• Stop the engine.  拧下泄油塞,将变速箱的油液排出。并
• Drain the oil from transmission by unscrewing the 使其滴数分钟。
oil drain plug. Let drip for some minutes .  测量泄出油的体积 Z 升。
• Measure the oil discharged quantity Z litres.  计算首次安装耗费的油液体积 X,
• Calculate the X quantity of oil to fill the first X=W-Z。
installation where X = W - Z litres.  拧上泄油塞。
• Screw again oil drain plug.  将建议的 16 升油液加入变速箱。
• Fill the transmission with the oil volume suggested  起动发动机,保持 800-1000rpm 低速运
of 16 litres. 转,直至油温超过 25℃。
• Start the engine by keeping the slow running of  从变速箱加油口轴上(轴 A)查得变速
800÷1000 rpm until an oil temperature higher than 箱油面为 195mm。
25°C is obtained.  必要的话,将油液加至前面的参考值。
• Check that the transmission oil level is 195 mm 第一次安装加油
from the transmission inlet axis (axis A). 按下面的说明进行:
• If necessary, top up with oil to keep to the previous  向变速箱加入 16+X 升油,X 为前面的计
reference value. 算值。
First installation filling  停车制动。
Carry out the following instructions:  保持 shuttle shaft 控制在中间范围。
• Fill the transmission with a volume of oil of about  起动发动机,保持 800-1000rpm 低速运
16+X litri, where X has been previously calculated. 转,直至油温超过 25℃。
• Apply the parking brake.  从变速箱加油口轴上(轴 A)查得变速
• Keep the shuttle shaft control in NEUTRAL range. 箱油面为 195mm。
• Start the engine by keeping the slow running of  必要的话,将油液加至前面的参考值。
800÷1000 rpm until an oil temperature higher than
25°C is obtained.
• Check that the transmission oil level is 195 mm
from the transmission inlet axis (axis A).
• If necessary, top up with oil to keep to the previous
Mod TLB1 2WD / 4WD 液力变速箱维修手册
Scheduled maintenance filling 预定维护填充
Carry out the following instructions: 按下面的说明进行:
• Fill the transmission with a volume of oil of about  向变速箱加入约 16 升油。
16 litres.  停车制动。
• Apply the parking brake.  保持 shuttle shaft 控制在中间范围。
• Keep the shuttle shaft control in NEUTRAL range.  起动发动机,保持 800-1000rpm 低速运
• Start the engine by keeping the slow running of 转,直至油温超过 25℃。
800÷1000 rpm until an oil temperature higher than  从变速箱加油口轴上(轴 A)查得变速
25°C is obtained. 箱油面为 195mm。
• Check that the transmission oil level is 195 mm  必要的话,将油液加至前面的参考值。
from the transmission inlet axis (axis A).
• If necessary, top up with oil to keep to the previous
reference value.
Mod TLB1 2WD / 4WD 液力变速箱维修手册
Mod TLB1 2WD / 4WD 液力变速箱维修手册

油箱通气塞

通过非供应软管的加油泄油塞
油面检测塞

Routine checks: 常规检查:


If leakage or any other factor determining fall in the 如果发现泄漏及由其它原因引起的油面下
oil level is found, then it is advisable to check 降,建议立即予以检查,以免对机器部件造
immediately, in order to avoid damages to the 成损害。松开并拧掉泄油塞(2)。
mechanical parts.
Loosen and remove the drain plug for oil draining
(2).
Mod TLB1 2WD / 4WD 液力变速箱维修手册

C.6 Service schedule C.6 保养计划

更换油液

更换滤油器

油面检查填充

连接与紧固力矩(法兰、
螺纹件)检查

液压件(变矩器、油泵、
管路、管接头)检查

电气电子器件(连接、线
路、控制器)检查

remarks 批注:
l this operation can be performed only by personnel 1 只能由制造商认可的人员进行操作。
authorized by the manufacturer n 只能由经过训练的人员进行操作。
(1)
n operation performed only by trained personnel 按先到的时间。
(1) which of both conditions comes first
Mod TLB1 2WD / 4WD 液力变速箱维修手册

C.7 Lubrication: grades and C.7 润滑:等级和应用范围

application range

Preferred oil viscosity 参考油液粘度:


Select highest oil viscosity compatible with 根据主要的环境温度和油液应用表,选用最
prevailing ambient temperatures and oil application 高的油液粘度。
chart. Temperature ranges (2) and (3) may be used 如果使用油箱预热器,温度范围(2)和(3)可能
to lower ambient temperatures when sump 用于较低的环境温度。
preheaters are used. Temperature range (4) should 温度范围(4)只能用于已说明的温度。
be used only in ambient temperature range shown.
Mod TLB1 2WD / 4WD 液力变速箱维修手册

C.8 Tightening torques C.8 拧紧力矩


Mod TLB1 2WD / 4WD 液力变速箱维修手册
Tightening torques 拧紧力矩
Mod TLB1 2WD / 4WD 液力变速箱维修手册

C.9 Hydraulic components C.9 液压部件


Mod TLB1 2WD / 4WD 液力变速箱维修手册
Hydraulic scheme 液压原理图
Mod TLB1 2WD / 4WD 液力变速箱维修手册

液压系统
吸油滤油器
变速箱油泵

Spin-on 滤油器
压力调整阀
滤油器溢流阀

四轮驱动脱开电磁阀
四驱连接与脱开易操作系统
变矩器溢流阀
变矩器

油液冷却器
冷却器后轴润滑(温度端口)
流量分配器
FWD/REV 缓冲阀

调制溢流阀
FWD/REV 选择阀
FWD 离合器
REV 离合器

FWD/REV 换档润滑
换档润滑

4 轮驱动压力检测端口
变矩器压力检测端口

冷却器后轴润滑(压力端口)
主压力检测端口
前进压力检测端口
后退压力检测端口

通气口
Mod TLB1 2WD / 4WD 液力变速箱维修手册
Torque converter 液力变矩器
Mod TLB1 2WD / 4WD 液力变速箱维修手册
T.Shafts torque converter connections 变矩器轴端结构
Mod TLB1 2WD / 4WD 液力变速箱维修手册

C.10 Oil pump C.10 补油泵


Mod TLB1 2WD / 4WD 液力变速箱维修手册

C.11 Manifold C.11 换档阀


Mod TLB1 2WD / 4WD 液力变速箱维修手册
Mod TLB1 2WD / 4WD 液力变速箱维修手册

C.12 Kinematic scheme C.12 传动轴系


Mod TLB1 2WD / 4WD 液力变速箱维修手册

D DISASSEMBLY AND ASSEMBLY


OPERATIONS
拆卸和装配操作
Mod TLB1 2WD / 4WD 液力变速箱维修手册

D.1 Plugs and filters D.1 塞杆和过滤器

D.1.1 Disassembly D.1.1 拆卸


Some of the following pictures could not show 下面的一些图片不能准确的显示您的变速
exactly your transmission, but the procedure is the 箱,但过程是一样的。
same.

Remove the drain (1) plug and drain the oil from the
transmission.
取下排油塞(1)使油从变速箱中流出
Mod TLB1 2WD / 4WD 液力变速箱维修手册

Remove the two cap screws (2) which fasten the


cover for the oil
screen.
Remove the cover (3).
取下紧固油筛门的两个螺钉(2)
拿掉油筛门(3)

Filter handling and wash according to the rules in


force. In case of
replacement, use only authorized disposal
procedures and, in case of
doubt, refer to the authorized bodies.
Remove the oil screen (4) and the O-ring (5).
根据有效的规则对过滤器清洗和操作。如需
替换,只能用专门的处理程序,如有疑问,
请查阅专业作品。
取下油筛(4)和 O 型环(5)。

Filter handling and disposal according to the rules in


force. Use only
authorized disposal procedures and, in case of
doubt, refer to the
authorized bodies.
取下油过滤器(6)。
根据有效的规则对过滤器操作和处理。只能
用专门的处理程序,如有疑问,请查阅专业
作品。

Remove the connector for the oil filter (7).


取下油过滤器的连结器(7)。
Mod TLB1 2WD / 4WD 液力变速箱维修手册

Remove the spool (8).


取下线轴(8)。

Remove the spring (9).


取下弹簧(9)

Use a puller to remove the four-wheel drive priority


valve (10).
Note: The four-wheel drive priority valve is adjusted
at the factory. DONOT try to disassemble or adjust
the four-wheel drive priority valve. Ifany of the parts
are damaged, use a new four-wheel drive
priorityvalve.
用拆卸器取下四轮驱动的定压阀(10)。
注意:四轮驱动的定压阀是在工厂校核过的。
不要试图拆开或调整四轮驱

动的定压阀,如果该零件被损坏,请更换新
的四轮驱动的定压阀。
Mod TLB1 2WD / 4WD 液力变速箱维修手册

DO NOT remove the plug unless the plug is leaking.


The plug is sealed with Loctite® 542 and is difficult to
remove. If removal
is necessary, clean all oil from the threads and apply
Loctite® 542
before installation.
不要取下堵头,除非堵头泄漏。
堵头是用 loctite542 密封的,很难被取下。如
非要取下,要在安装之前清洗螺丝上的所有
油渍,并用 loctite542 密封。

It is not necessary to remove the test port plugs (11),


the breather (12),
or the temperature sender (13) unless these parts
are leaking or
damaged.
没有必要取下检验舱门的堵头(11)、通气
阀(12)或温度传感器,除非这些零件泄漏
或损坏。
Mod TLB1 2WD / 4WD 液力变速箱维修手册

D.1.2 Assembly
Some of the following pictures could not show
D.1.2 装配
exactlyyour transmission, but the procedure is the 下面的一些图片不能准确的显示您的变速
same. 箱,但过程是一样的。

Assemble the test port plugs (11), the breather (12),


or the temperature
sender (13).
Torque wrench (Sec. C.8).
安装检验舱门堵头(11)、通气阀(12)或
温度传感器(13)。
转矩扳手(Sec.C.8)

Assemble valve (10).


安装阀(10)。

Assemble spring (9)


安装弹簧(9)
Mod TLB1 2WD / 4WD 液力变速箱维修手册

Assemble spool (8).


安装线轴(8)。

Assemble connector (7).


Torque wrench (Sec. C.8).
安装连结器(7)。
转矩扳手(Sec.C.8)

Assemble filter (6) after replacement.


Note: put a thin coat of oil or grease on the filter
gasket, turn clockwise until the gasket makes
contact with the base, continue to turn the filter 2/3
turn.
安装替换的过滤器(6)。
注意:在过滤器的垫圈上涂上一薄层油或油
脂,顺时针旋转直到垫圈和基础接触,继续
旋转过滤器 2/3 圈。

Assemble filter (4) and O-ring (5) after having


washed or replaced it.
安装清洗或置换过的过滤器(4)和 O 型环
(5)
Mod TLB1 2WD / 4WD 液力变速箱维修手册

Assemble cover (3) and screws (2).


Torque wrench (Sec. C.8).
安装盖(3)和螺钉(2)。
转矩扳手(Sec.C.8)

Assemble plug (1).


Torque wrench setting (Sec. C.8).
安装堵头(1)、
转矩扳手(Sec.C.8)
Mod TLB1 2WD / 4WD 液力变速箱维修手册

D.2 Converter and oil pump D.2 转炉和油泵

D.2.1 Disassembly
Some of the following pictures could not show
D.2.1 分解
exactly your transmission, but the procedure is the 下面的一些图片不能准确的显示您的变速
same. 箱,但过程是一样的。

Drain oil from transmission hydraulic circuit.


Remove torque converter (1) from vehicle.
从变速箱液压油路中排出油。
从推进装置中取下液力变矩器(1)
Mod TLB1 2WD / 4WD 液力变速箱维修手册

Remove screws (2).


Warning: mark the pump position with respect to
the bellhousing
before untightening the screws.
取下螺钉(2)
警告:松开螺钉前标记泵相对于钟腔的位
置。

Remove the pump by means of two levers.


用两个杆取下泵。

Remove the oil pump (3).


Warning: oil pump seal ring can be damaged during
this operation.
取下油泵(3)。
警告:在此操作中,可能会损坏油泵密封环。

If replacement is necessary, remove O-ring (4).


Warning: do not open/disassemble the pump or its
operation may be compromised.
Special tools from the manufacturer are required for
reassembly.
如需替换,取下 O 型环(4)。
警告:不要打开/分解泵,否则可能会有损
坏。
重新组装需要用厂商提供的专用工具。
Mod TLB1 2WD / 4WD 液力变速箱维修手册

If replacement is necessary, remove seal ring (5).


如需替换,取下密封环(5)。
Mod TLB1 2WD / 4WD 液力变速箱维修手册

D.2.2装配
D.2.2 Assembly
Some of the following pictures could not show 下面的一些图片不能准确的显示您的变速
exactly your transmission, but the procedure is the 箱,但过程是一样的。
same.

Assemble seal ring (5) on oil pump (3).


Use tool CA715409.
安装油泵(3)上的密封环(5)。
用工具 CA715409。

Fit O-ring (4).


安装 O 型环(4)。

Warning: before oil pump assembly (if new), check


that oil passage
holes between pump and half-case or the visual
marks coincide.
警告:安装油泵前(如果是新的),检查泵
和半容器或可见的符合标记之间的油路孔。
Mod TLB1 2WD / 4WD 液力变速箱维修手册

Grease the ring to keep it centred/coaxial with


respect to the shaft slot
centre line and to make the introduction onto the
pump easier.
在环上涂上油脂使它据于中心/和轴的中线
对齐,使得泵容易装配上。

Apply a thin film of grease on the coupling seat with


the front half-case.
Assemble the oil pump (3).
在和前半盖的连结处涂上一薄层油脂。
安装油泵(3)。

Fit screws (2). Torque wrench setting (Sec. C.8).


Warning: Carefully check that marks on the oil
pump and on the
bellhousing coincide.
拧上螺钉(2)。转矩扳手(Sec.C.8)。
警告:小心检查油泵和钟形腔结合处的标
记。
Mod TLB1 2WD / 4WD 液力变速箱维修手册

In order to avoid damage to the pump seal ring, it is


recommended to fit the converter on the TLB
transmission by hand (the two teeth of the pump
driving converter can cut the seal ring lip).
Match the transmission and the converter to the
vehicle engine flywheel with the screws of the
converter driving disc of engine SAE3
bellhousing.
Fit converter (1). Turn the torque converter until
engaging the relative splined shafts.
为了避免损坏泵的密封环,推荐手动把转炉
安装到 TLB 变速箱上(泵驱转炉的两个牙
可能会破坏密封环的边缘)。
用发动机 SAE3 钟形腔的转炉主动片上的螺
钉把变速箱和转炉配合到机器发动机的调
速轮上。
安装转炉(1)。旋转液力变矩器直到啮合上
有花键的轴。
Mod TLB1 2WD / 4WD 液力变速箱维修手册

D.3 Pipes and sensors D.3 导管和传感器

D.3.1 Disassembly
Some of the following pictures could not show
D.3.1 分解
exactly your transmission, but the procedure is the 下面的一些图片不能准确的显示您的变速
same. 箱,但过程是一样的。

Drain oil from transmission hydraulic circuit. and


remove screws (1)
and (2). Remove pipe (3). Collect gaskets (4).
从变速箱液压油路中排出油。取下螺钉(1)
和(2)。取下导管(3)。收集垫圈(4)。
Mod TLB1 2WD / 4WD 液力变速箱维修手册

Untighten and remove 4th speed sensor (5).


Remove washer (6) and pin (7).
松开并取下第四速度传感器(5)。
取下垫圈(6)和销(7)。
Mod TLB1 2WD / 4WD 液力变速箱维修手册
D.3.2 Assembly
Some of the following pictures could not show
D.3.2 装配
exactly your transmission, but the procedure is the 下面的一些图片不能准确的显示您的变速
same. 箱,但过程是一样的。

Assemble pipe (3), screws (1) and (2).


Warning: replace gaskets (4) .
Torque wrench setting (Sec. C.8).
安装导管(3),螺钉(1)和(2)。
警告:替换垫圈(4)。
转矩扳手(Sec.C.8)。

Assemble pin (7), washer (6) and 4th speed sensor


(2).
Torque wrench setting (Sec. C.8).
安装销(7),垫圈(6)和第四速度传感器
(2)。
转矩扳手(Sec.C.8)。
Mod TLB1 2WD / 4WD 液力变速箱维修手册

D.4 Hydraulic control valve D.4 液压控制阀

D.4.1 Disassembly
Some of the following pictures could not show
D.4.1 分解
exactly your transmission, but the procedure is the 下面的一些图片不能准确的显示您的变速
same 箱,但过程是一样的。

Drain oil from transmission hydraulic circuit,


disconnect all electrical
connections.
Remove screws (1).
从变速箱液压油路中排出油。断开所以线
路。
取下螺钉(1)。
Mod TLB1 2WD / 4WD 液力变速箱维修手册

Lift control valve assy (2).


举起控制阀

Remove gasket (3).


取下垫圈(3)。

Remove screws (4).


取下螺钉(4)。

Remove the plate (5).


取下金属板(5)。
Mod TLB1 2WD / 4WD 液力变速箱维修手册

Remove the gasket (6).


取下衬垫(6)。

Untighten the solenoid valve retaining nut (7).


松开电磁阀锁紧螺母(7)。

Remove washer (8).


取下垫圈(8)。

Remove O-Ring (9) and solenoid valve (10).


取下 O 型环(9)和电磁阀(10)。
Mod TLB1 2WD / 4WD 液力变速箱维修手册

Remove the O-Ring (11).


取下 O 形环(11)。

Remove O-Ring (12) and solenoid valve (13).


取下 O 形环(12)和电磁阀(13)。

Remove the O-Ring (14).


取下 O 形环(14)。

Untighten cartridge (15).


松开滤筒(15)。
Mod TLB1 2WD / 4WD 液力变速箱维修手册

Remove the O-Ring (16).


取下 O 形环(16)。

Remove the four screws (17) which fasten the


modulation cover to the
control valve body.
松 开 紧固 调 制盖 和控制 阀 体的 四 个螺 钉
(17)。

This photo shows the relationship among the parts


of the control valve. In case of replacement, replace
the whole unit.
Remove the outer modulation piston (18) from the
modulation cover (19).
Remove the upper and lower gaskets (20) and the
modulation plate (21).
Remove the check ball (22) and spring (23).
Remove the outer modulation piston spring (28), the
inner (24) and outer spring (25), and the inner
modulation piston pin (26) and piston (28).
本图显示了控制阀部件之间的关系。如需替
换,要整体替换。
从调制盖(19)取下外部调制活塞(18)。
取下上部和下部衬垫(20)及调制板(21)。
取下测试球(22)及弹簧(23)。
取下外部调制活塞弹簧(28),内部(24)
和外部(25)弹簧,以及内部调制活塞销(26)
和活塞(28)。
Mod TLB1 2WD / 4WD 液力变速箱维修手册
D.4.2 Assembly
Some of the following pictures could not show
D.4.2 装配
exactly your transmission, but the procedure is the 下面的一些图片不能准确的显示您的变速
same 箱,但过程是一样的。

Assemble the O-Ring (16).


安装 O 形环。

Tighten cartridge (15).


Torque wrench setting (Sec. C.8).
紧固滤筒(15)。
转矩扳手(Sec.C.8)

Assemble the O-Ring (14).


安装 O 形环(14)
Mod TLB1 2WD / 4WD 液力变速箱维修手册

Assemble solenoid valve (13) and O-ring (12).


安装电磁阀(13)和 O 形环(12)。

Assemble the O-Ring (11).


安装 O 形环(11)

Assemble solenoid valve (10) and O-ring (9).


安装电磁阀(10)和 O 形环(9)。

Assemble washer (8).


安装垫圈(8)。
Mod TLB1 2WD / 4WD 液力变速箱维修手册

Untighten the solenoid valve retaining nut (7).


Torque wrench setting (Sec. C.8).
松开电磁阀锁紧螺母(7)。
转矩扳手(Sec.C.8)
Lubricate the inner modulation piston (27) with clean
transmission oil
Install the inner piston (27) so that the end with the
deeper bore is towards the outside of the valve body.
Install the spring (23) into the small bore. Install one
gasket (20) on the valve body. Install the check ball
(22) on top of the spring (23) in the small bore.
Install the modulation plate (21) so the coined
(radius) side contacts the ball. Install the
remaining gasket (20) onto the modulation plate
(21). Install the inner modulation piston pin (26), the
inner (24) and outer (25) spring and the outer
modulation piston spring (28) into the bore.
Lubricate the outer modulation piston (18) with
clean transmission oil and install the piston (18) into
the modulation cover (19) with the closed end
towards
the modulation cover.
用洁净的润滑油润滑内部调制活塞(27)安装内
部活塞使有深孔的一端朝向阀体的外部。把弹簧
(23)装进小孔中。在阀体上安装一个衬垫(20)。
在装进小孔中的弹簧(23)的顶部安装检测板
(22)。安装调制金属板(21)使铸造(半径)的
一端和球接触。在调制金属板(21)上安装剩下
的衬垫(20)。在孔内安装内部调制活塞销(26),
内部(24)和外部(25)弹簧和外部调制活塞弹
簧(28)。用洁净的润滑油润滑外部调制活塞(18)
并把活塞(18)安装进调制盖内,使封闭的一端
朝向调制盖。

Install the four screws (17) into the cover.


Tighten the four screws to the prescribed torque
(see Sec. C.8).
安装盖上的四个螺钉(17)。
紧固四个螺钉至指定的转矩。
Mod TLB1 2WD / 4WD 液力变速箱维修手册

Assemble new gasket (6) on transmission.


在变速箱上安装新的衬垫(6)。

Assemble the plate (5).


安装板(5)。

Assemble screws (4).


Torque wrench (see Sec. C.8)
安装螺钉(4)。
转矩扳手

Assemble new gasket (3).


安装新的衬垫(3)
Mod TLB1 2WD / 4WD 液力变速箱维修手册

Assemble control valve assy (2).


安装控制阀(2)

Assemble screws (1).


Torque wrench (see Sec. C.8)
安装螺钉(1)。
转矩扳手
Mod TLB1 2WD / 4WD 液力变速箱维修手册

D.5 Solenoid valve D.5 电磁阀

D.5.1 Disassembly
Some of the following pictures could not show
D.5.1 分解
exactly your transmission, but the procedure is the 下面的一些图片不能准确的显示您的变速
same 箱,但过程是一样的。

Drain oil from transmission hydraulic circuit,


disconnect all electrical
connections.
Remove screws (1) and remove valve retainer (2).
从变速箱液压油路中排出油。断开所有线
路。
取下螺钉(1)和阀固定器(2)。
Mod TLB1 2WD / 4WD 液力变速箱维修手册

Remove nut (4) and O-ring (5) if in the nut.


Remove solenoid (6) and cartridge (8).
Remove O-rings (7) from the cartridge if it is to be
replaced.
Configuration "A" is an alternative to configuration
"B".
取下螺母(4)和 O 形环(如果在螺母内)。
取下螺线圈(6)和滤筒(8)。
如果要被替换,从滤筒中取出 O 形环。
结构“A”是结构“B”的替换形式。

Remove the gasket (3).


取下衬垫(3)。

Remove valve (9).


DO NOT try to disassemble the valve (9).
There are no serviceable parts. If there is a problem,
use a new check valve.
取下阀(9)。
不要试图拆开阀(9)。
它们是非耐用零件。如果有问题,用一个新
的检测阀。
Mod TLB1 2WD / 4WD 液力变速箱维修手册
D.5.2 Assembly
Some of the following pictures could not show
D.5.2 装配
exactly your transmission, but the procedure is the 下面的一些图片不能准确的显示您的变速
same 箱,但过程是一样的。

Assemble valve (9) to the solenoid valve block.


把阀(9)安装到电磁阀块上。

Assemble O-rings (7) into the cartridge (8).


Assemble cartridge (8) and solenoid (6) in the
solenoid valve block.
Assemble nut (4) with O-ring (5) if any.
Configuration "A" is an alternative to configuration
"B".
Torque wrench setting (Sec. C.8).
安装 O 形环(7)到滤筒(8)上。
安装滤筒(8)和螺线管(6)到电磁阀块上。
安装螺母(4)和 O 形环(5),如果有的话。
结构“A”是结构“B”的替换形式。
转矩扳手。
Mod TLB1 2WD / 4WD 液力变速箱维修手册

Assemble new gasket (3).


安装新的衬垫(3)。

Assemble valve retainer (2) and screws (1).


Torque wrench setting (Sec. C.8).
安装阀固定器(2)和螺钉(1)。
转矩扳手。
Mod TLB1 2WD / 4WD 液力变速箱维修手册

D.6 Transmission housing D.6 变速箱

D.6.1 Disassembly
Some of the following pictures could not show
D.6.1 分解
exactly your transmission, but the procedure is the 下面的一些图片不能准确的显示您的变速
same 箱,但过程是一样的。

Remove bearing snap ring (1).


取下轴承卡环(1)。
Mod TLB1 2WD / 4WD 液力变速箱维修手册

Untighten and remove flange retaining screw (2).


Use a screwdriver and two screws to avoid flange
rotation.
松开并取下法兰盘固定螺丝(2)。
用一个螺丝起子和两个螺丝防止法兰盘旋
转。

Remove washer (3).


取下垫圈(3)。

Remove flange (5) and O-ring (4).


取下法兰盘(5)和 O 形环(4)。

Remove the three cap screws (6).


取下三个螺栓(6)。
Mod TLB1 2WD / 4WD 液力变速箱维修手册

Remove the cover (7).


取下盖子(7)

Remove the O-ring (8) from the cover (7).


从盖子(7)上取下 O 形环(8)

Remove the seal (9) from the cover (7).


从盖子(7)上取下密封圈(9)

Untighten and remove flange retaining screw (10).


Use a screwdriver and two screws to avoid flange
rotation.
松开并取下法兰盘固定螺丝(10)。
用一个螺丝起子和两个螺丝防止法兰盘旋
转。
Mod TLB1 2WD / 4WD 液力变速箱维修手册

Remove washer (11).


取下垫圈(11)

Remove flange (12) and O-ring (13).


取下法兰盘(12)和 O 形环(13)

Remove the three cap screws (14).


取下三个螺栓(14)

Remove the shift tower assembly (15) and the O-ring


(16).
取下装配变速塔(15)和 O 形环(16)。
Mod TLB1 2WD / 4WD 液力变速箱维修手册

Remove the eight cap screws (17) which fasten the


rear cover to the
rear housing.
取下紧固后罩和箱体八个螺栓(17)

Use a prybar to loosen the rear cover from the


housing.
Remove the rear cover (18).
用一个撬杆从箱体上松开后罩。
取下后罩(18)

Remove the seal (19) from the rear cover.


从后罩上取下密封环(19)

Use a punch to remove the pins (20) which fasten the


shift collars to
the shift rods.
用一个打孔机取下紧固变速轴环和变速杆的
销(20)
Mod TLB1 2WD / 4WD 液力变速箱维修手册

Remove the shift collars (21).


取下变速轴环(21)

Remove the two screws (22) which hold the plate


between the two
shift rods.
取下支撑两个变速杆之间板的两个螺钉(22)

Remove the plate (23).


取下板(23)

Remove the two detent balls (24) from the groove


between the two
shift rods.
从两个变速杆之间的凹槽中取下两个制动球
(24)
Mod TLB1 2WD / 4WD 液力变速箱维修手册

Untighten and remove screws (25) and washers (26).


松开并取下螺钉(25)和垫圈(26)

Remove springs (27).


取下弹簧(27)

Remove balls (28).


取下球(28)
Mod TLB1 2WD / 4WD 液力变速箱维修手册
Pull the secondary shaft to the rear so that there is
clearance between the snap ring and the rear
housing. Remove the snap ring (29).
Note: if the bearing is not very tight on the secondary
shaft, parts could fall from secondary shaft when you
remove the secondary shaft from the rear housing.
To prevent this, you can install a hose clamp
on the output end of the secondary shaft. This will
keep the bearing in position during removal of the
secondary shaft.
取出齿轮从动轴,从而在卡环和齿轮箱之间
有间隔。
取下卡环(29)。
注意:如果轴承没有紧固在从动轴上,当你
从齿轮箱中取出从动轴时,零件可能会从从
动轴上滑落。为了避免这种情况,你可以在
从动轴的外端安装一个软管夹。这样就可以
在取出从动轴时保证轴承的位置不变。

Push the primaryshaft to the rear so that there is


clearance between
the snap ring and the rear housing. Remove the snap
ring (40).
取出齿轮主动轴,从而在卡环和齿轮箱之间
有间隔。
取下卡环(40)。

Remove transmission shaft PTO (30) by pushing


lightly on the opposite
side.
轻推相反的一端,取出传动轴 PTO(30)
Mod TLB1 2WD / 4WD 液力变速箱维修手册

Widen and remove oil seal (31).


放宽并取下油密封环(31)。

Remove snap ring (32).


取下卡环(32)

Extract bearing (33) with tool CA715004.


用工具 CA715004 拔出轴承(33)

Remove screws (34).


取下螺钉(34)
Mod TLB1 2WD / 4WD 液力变速箱维修手册

Remove screws (35).


取下螺钉(35)

Use lever to remove the cover (36).


Lift the front half box by means of two hooks.
用杆取下盖子(36)。
用两个吊钩吊起上半箱体。

Remove the 4WD collar (37).


取下 4WD 轴环(37)

Widen and remove seal rings (38).


放宽并取下密封环(38)
Mod TLB1 2WD / 4WD 液力变速箱维修手册

The outer rings of the bearings for the primary shaft


(42) and for the secondary shaft (43) can stay with
either the shafts or the front housing.
Remove the two bearings.
主动轴(42)和从动轴(43)的轴承外环可
以放在轴或前箱体二者任何一个上。
取下这两个轴承。

Remove bearing (41).


取下轴承(41)

Replace O-rings (39) if necessary.


如果需要,替换 O 形环(39)
Mod TLB1 2WD / 4WD 液力变速箱维修手册
D.6.2 Assembly
Some of the following pictures could not show
D.6.2 装配
exactly your transmission, but the procedure is the 下面的一些图片不能准确的显示您的变速
same 箱,但过程是一样的。

Push the primary shaft toward the rear of the rear


housing so that there is clearance between the snap
ring groove and the rear housing. Install the snap
ring (40).
在齿轮箱中,朝着齿轮装上主动轴。使得卡
环凹槽和齿轮箱之间有间隔。
装上卡环(40)

Push the secondary shaft toward the rear of the rear


housing so that there is clearance between the snap
ring groove and the rear housing.
Install the snap ring (29).
在齿轮箱中,朝着齿轮装上从动轴。使得卡
环凹槽和齿轮箱之间有间隔。
装上卡环(29)

Assemble the O-Rings (39).


安装 O 形环(39)
Mod TLB1 2WD / 4WD 液力变速箱维修手册

Apply a thin film of Loctite® 510 on the edge of the


rear half-housing.
在齿轮的半箱边缘涂上一薄层 Loctite 510

Use clean transmission oil to lubricate the bearing


for the primary shaft(42) and the bearing for the
secondary shaft (43).
Install the bearings.
用洁净的润滑油润滑主动轴(42)和从动轴
(43)上的轴承
安装轴承。

Install the front (36) housing on the rear housing.


Make sure that the bearings on the shafts go
straight into the bores in the front housing.
Push the front housing all the way down on the rear
housing.
安装齿轮箱的前箱体(36)。确保轴上的轴
承能直接装入前箱体上的孔中。
在齿轮箱上一直压前箱体。

Assemble screws (34).


Torque wrench setting (Sec. C.8).
安装螺钉(34)。
转矩扳手。
Mod TLB1 2WD / 4WD 液力变速箱维修手册

Assemble screws (35).


Torque wrench setting (Sec. C.8).
安装螺钉(35)。
转矩扳手。

Assemble oil seal (38).


安装油密封环(38)

Use clean transmission oil to lubricate the collar for


the 4WD shaft.
Install the collar (37) on the 4WD shaft.
用洁净的润滑油润滑 4WD 轴上的轴环。
把轴环(37)装到 4WD 轴上。

Use clean transmission oil to lubricate the bearing


for the 4WD shaft.
Install the bearing (41) on the 4WD shaft.
用洁净的润滑油润滑 4WD 轴上的轴承。
安装轴承(41)到 4WD 轴上。
Mod TLB1 2WD / 4WD 液力变速箱维修手册
(9) in the cover(7). Push just until the seal stops
moving. DO NOT use excessive force.
Fill the cavity under the lip of the seal with high
temperature wheel bearing grease.
用专用工具 CA715354 在盖子上安装一个新
的密封环(9)。
压密封环直到它停止转动。不要用过多的
力。
用高温轮轴轴承油脂填充密封环边缘的空
隙。

Assemble the O-Ring (8).


安装 O 形环(8)

Install the cover (7) in the front housing.


在前箱体上安装盖子(7)

Install the three cap screws (6) which fasten the


cover to the front housing.
Torque wrench setting (see Sec. C.8).
安装紧固盖子和前箱体的三个螺栓(6)。
转矩扳手。

Use the CA715354 special tool to install a new seal


Mod TLB1 2WD / 4WD 液力变速箱维修手册

Install a new O-ring (4) in the four-wheel drive flange.


Use clean transmission oil to lubricate the O-ring.
在四轮驱动的法兰盘上安装一个新的 O 形
环(4)。
用洁净的润滑油润滑 O 形环。

Install the four-wheel drive flange (5) on the


four-wheel drive shaft.
在四轮驱动的轴上安装四轮驱动的法兰盘
(5)

Install the washer (3).


安装垫圈(3)

Assemble screw (2).


Use screwdriver to avoid flange rotation.
Torque wrench setting (Sec. C.8).
安装螺钉(2)
用螺丝起子防止法兰盘转动。
转矩扳手。
Mod TLB1 2WD / 4WD 液力变速箱维修手册

Assemble snap ring (1).


安装卡环(1)

Assemble balls (28).


Note: in steps 21 through 23 the photos show the
installation of lower detent parts 1st and 2nd speed
pipe. It is necessary for you to install both the upper
detent parts 3rd and 4th speed pipe and the lower
ones 1st and 2nd speed pipe according to the
instructions in the procedure.
Make sure that you start with both shift rods in the
NEUTRAL position.
安装球(28)。
注意:步骤 21 至 23 中的图显示了安装下面
制动器部件第一和第二速度导管。你必须按
照程序的指导安装上面制动器部件第三和
第四速度导管和下面制动器部件第一和第
二速度导管。
确保你能在齿轮的空档位置转动两个变速
杆。

Assemble springs (27).


安装弹簧(27)

Assemble screw (25) and washer (26).


Torque wrench setting (Sec. C.8).
安装螺钉(25)和垫圈(26)。
转矩扳手。
Mod TLB1 2WD / 4WD 液力变速箱维修手册
Assemble screws (25) and washer (26).
Torque wrench setting (Sec. C.8).
Repeat steps 21 through 23 to install the upper
detent ball, spring and
plug.
安装螺钉(25)和垫圈(26)
转矩扳手
重复步骤 21 至 23 ,安装上部的制动球,
弹簧和堵头。

Assemble bearing (33) on transmission shaft PTO


(30).
安装传动轴 PTO(30)上的轴承(33)

Assemble snap ring (32).


安装卡环(32)

Install oil seal (34).


安装油密封环(34)
Mod TLB1 2WD / 4WD 液力变速箱维修手册

Insert transmission shaft PTO (30) to the stroke.


把传动轴 PTO(30)插入 stroke 中

Install the two detent balls (24).


安装两个制动球(24)

Install the plate (23).


安装板(23)

Apply Loctite® 542 to the threads of the two Allen


head screws. Install the two Allen head screws (22 )
to fasten the plate in position.
Torque wrench setting (Sec. C.8).
在两个内六角头螺钉的螺纹上涂上
Loctite542。安装这两个内六角头螺钉使板
紧固。
转矩扳手
Mod TLB1 2WD / 4WD 液力变速箱维修手册

Install shift collars (21) on the shift rods.


安装变速轴环(21)到变速杆上。

Install the pins (20) to fasten the shift collars to the


shift rods.
安装销(20),使变速轴环和变速杆紧固。

Use the CA715501 special tool to install a new seal


(19) in the rear cover. Push the seal just until the
seal makes contact with the lip in the bore.
用专用工具 CA715501 在后罩上安装一个新
的密封环(19)
压密封环直到密封环和孔的边缘接触。
Mod TLB1 2WD / 4WD 液力变速箱维修手册
the pin (44) is correctly installed both in the rear
housing and through the hole in the rear cover.
Install the eight cap screws (17) to fasten the rear
cover to
the rear housing.
If necessary, tap the rear cover with a soft faced
hammer to close the gap between the rear housing
and the rear cover before you tighten the cap
screws.
Torque wrench setting (Sec. C.8).
把后罩安装到正确的位置。确保在齿轮箱和
后罩上的孔中,销是正确的安装的。安装八
个螺栓,使后罩和后箱体紧固。
如果需要,在拧紧螺栓之前,用一个软质平
面锤轻敲后罩,使得后罩和后箱体紧密接
触。
转矩扳手。

Install a new O-ring (16) on the shift tower assembly


(15).
Use clean oil to lubricate the O-ring and assembly it
on the rear housing.
在变速塔装配(15)上安装一个新的 O 形
环(16)
用洁净的油润滑 O 形环,并把它安装到后
箱体上。

Install the three Allen head screws (14) to fasten the


shift tower assembly to the rear cover.
Torque wrench setting (Sec. C.8).
安装三个内六角头螺钉(14),使变速塔紧
固在后罩上。
转矩扳手。

Put the rear cover (18) in position. Make sure that


Mod TLB1 2WD / 4WD 液力变速箱维修手册

Install a new O-ring (13) in the output flange (12).


Use clean oil to lubricate the O-ring.
在输出法兰盘(12)安装一个新的 O 形环
(13)。
用洁净的油润滑 O 形环。

Install the washer (11).


安装垫圈(11)

Use a prybar between the two cap screws to hold


the output flange while you tighten the cap screw
(10) in the secondary shaft.
Torque wrench setting (Sec. C.8).
当你紧固从动轴上的螺栓(10)使,在两个
螺栓之间用一个撬杆控制这输出法兰盘。
转矩扳手
Mod TLB1 2WD / 4WD 液力变速箱维修手册

D.7 3Shaft A - D D.7 3 轴 A---D

D.7.1 Disassembly
Some of the following pictures could not show
D.7.1 分解
exactly your transmission, but the procedure is the 下面的一些图片不能准确的显示您的变速
same 箱,但过程是一样的。

Grasp with pliers shaft assembly A. Remove with


shaft assembly D
and lift.
用钳子夹住 A 轴。
取下 D 轴并提起。
Mod TLB1 2WD / 4WD 液力变速箱维修手册

If to be replaced, remove oil seal (1).


如需替换,取下油密封环(1)

Remove snap ring (2).


取下卡环(2)

Install a bearing separator under the gear as shown


(do not install the bearing separator between the
gear and the bearing).
Use a puller on the bearing separator and insert a
shaft protector between the puller and the end of the
input shaft.
By means of puller which operates between bearing
separator and shaft protector pull only until the
bearing is free.
Pulling anyfarther can damage the parts.
在如图的齿轮下安装一个轴承座(不要在齿
轮和轴承之间安装轴承座)
在轴承座上用一个拆卸器并在拆卸器和输
入轴的末端插入一个轴保护器。
用轴承座和轴保护器之间的拆卸器拉轴承
直到轴承自由。
拉时可能会损坏零件。
Mod TLB1 2WD / 4WD 液力变速箱维修手册

Remove bearing (3).


取下轴承(3)

Remove spacer (4) and washer (5).


取下分离器(4)和垫圈(5)

Remove pin (16).


取下分离器(4)和垫圈(5)

Remove gear (6).


取下齿轮(6)
Mod TLB1 2WD / 4WD 液力变速箱维修手册

Remove bearings (7).


取下轴承(7)

Remove washer (8).


取下垫圈(8)

Remove spring pin (9).


取下弹簧销(9)

Remove snap ring (10).


取下卡环(10)
Mod TLB1 2WD / 4WD 液力变速箱维修手册

Use prybars to lift and to remove the backing plate


(11) evenly.
用撬杆均匀地提起并取下后板(11)

Lower spring retaining cover (13).


Use tool CA715358.
降低弹簧保持盖(13)
用工具 CA715358

Lower spring retaining cover (13) and remove snap


ring (14).
Use tool CA715358.
降低弹簧保持盖(13)并取下卡环(14)
用工具 CA715358

Loosen the nuts and the threaded rods to release


the tension from the
spring. Remove the top piece of the CA715358
special tool.
松开螺母和螺杆,释放弹簧的张力。
取下专用工具 CA715358 的上部。
Mod TLB1 2WD / 4WD 液力变速箱维修手册

Remove the clutch pack (17) and (18).


取下离合器包(17)和(18)

Lift the backing plate and the steel discs and the
friction discs out of the housing as a complete unit.
Set the complete unit on top of the body.
Place a mark below the groove on the friction bell.
Place a mark on each steel and friction disc and the
thrust plate.
These marks will be used for reference during the
reassembly procedure.
提起后板和铁片以及箱体外面的摩擦片作
为一个整体。
把这个整体房子箱体的顶部。
在摩擦钟凹槽的下面做个标记。
在每个铁片和摩擦片及插板上做标记
在拆卸过程中,这些标记将要被作为参考。

Place a mark on top of the backing plate and each


steel and friction disc as they are removed.
These marks will be used for reference during the
reassembly procedure.
在移动时,在后板的顶部及每个铁片和摩擦
片上做标记。
在拆卸时,这些标记将被作为参考。
Mod TLB1 2WD / 4WD 液力变速箱维修手册

Remove spring retaining cover (13) and spring (15).


取下弹簧保持盖(13)及弹簧(15)

Remove clutch piston (19) by blowing in


compressed air through the
delivery hole.
通过导出管吹入压缩空气取下离合器活塞
(19)。

Widen and remove oil seal (20) if necessary.


如果需要,加宽并取下油密封环(20)。

Widen and remove oil seal (21) if necessary.


如果需要,加宽并取下油密封环(21)
Mod TLB1 2WD / 4WD 液力变速箱维修手册

Turn the shaft.


If to be replaced, remove oil seals (22) if necessary.
转动轴。
如果要替换,如需要,取下油密封环(22)

Remove snap ring (23).


取下卡环(23)

Remove bearing (24) by means of an extractor.


通过提取器取下轴承(24)

Remove bearing (24) and washer (25).


取下轴承(24)和垫圈(25)
Mod TLB1 2WD / 4WD 液力变速箱维修手册

Remove gear (26).


Remove pin (37).
取下齿轮(26)。
取下销(37)。

Remove roller retainers (12), spacer (27) and


washer (28).
For the disassembly of the other parts, repeat the
operations from step 11 to step 24.
取下滚筒固定器(12),分离器(27)和垫
圈(28)。
为了分解其它的零件,重复从步骤 11 至 24
的操作。

31 如果需要,检查密封环凹槽(大和小)是否
Check the sealing ring grooves (large and small) for 磨损和损坏。
wear and damage if necessary. 必须用新零件。
Use new parts as required. 检查输出轴是否磨损和损坏。
Check on the output shaft for wear and damage. 检查输出轴上的油路,确信它处于开放状态
Check oil passages in the output shaft to be sure 并且没有外国材料。
that the passages are open and free of foreign 必须用新零件。
material. Use new parts as required. 检查球轴承和滚针轴承的平面面积、蚀损斑
Check the ball bearings and the needle bearings for 和其它的损坏。
flat areas, pitting, and other damage.Use new parts 必须用新零件。
as required.
If the clutch discs are to be used again, keep the
clutch packs in the same previous assembly order
separate and record which clutch pack goes with
each clutch.
Use new parts as required.
如果要再次使用离合器片,保持离合器包在
先前的相同的装配位置,保证离合器包和每
个离合器的分离和记录。
必须用新零件。
Mod TLB1 2WD / 4WD 液力变速箱维修手册

Use a straight edge to check each steel disc (17) and each friction disc(18) to be sure each part is flat. If they
are not flat (17, 18), a new part must be installed during assembly.
If the friction discs (18) are smooth or almost smooth, use new parts during assembly. If the friction material is
damaged or appears burned, use new parts during assembly. Also, check the splines for wear. Inspect the
steel discs (17) for pitting, scoring, or other damage. If there is any damage, use new parts during assembly. If
you will be using new friction discs, soak the friction discs in clean transmission oil for at least an hour before
assembly. If you are using the old friction discs, make sure that the contact surfaces are coated with
transmission oil before assembly, check the wear conditions (see chart belove). If it is 50% compared to the
nominal alue it is suggested its replacement.
用一个直尺检测每个铁片(17)和摩擦片(18),确保每个零件都是平的。如果它们(17,18)
不平,在装配时必须用一个新的零件。如果摩擦片(18)光滑或几乎光滑,在装配时必须用
一个新的零件。如果摩擦材料损坏或者出现灼伤,在装配时用新零件。并且,检查花键是否
磨损。检查铁片是否有蚀损斑,擦痕或其它损坏。有任何损坏,在装配时都要用新零件。如
果使用旧摩擦片,确保在装配前用润滑油润滑摩擦片的摩擦面。检查磨损情况(见下图)如
果和图中的名义值相比有50%的磨损,建议更换。
35 Inspect the bore and the shaft in the input shaft housing for damage that will cause leakage when the
clutch is assembled. Check the slots in the side of the input shaft housing for
damage from the tangs on the steel discs. Use new parts as required during assembly.
检查输入轴腔中的孔和轴,如果损坏,在装配离合器时,将会导致泄漏。
检查输入轴腔面上的狭槽在铁片的一面是否损坏。
在装配时,必须用新零件。
6 Number of clutch plate (each side) 离合器片的数目(每面)

7 Number clutch steel plate (each 离合器铁片的数目(每面)


side)

2.5  0.05mm Nominal clutch plate thickness 名义离合器片厚度

2.5  0.05mm Nominal brake clutch steel plate 名义制动离合器片厚度


thickness

0.2mm Maximum clutch plate wearing 最大离合器片磨损(每面)


(each side)
Mod TLB1 2WD / 4WD 液力变速箱维修手册

Remove shaft D axle bearing (41) by means of an


extractor.
通过一个提取器取下轴 D 的轮轴轴承(41)。

Remove shaft D axle bearing (42) by means of an


extractor.
通过一个提取器取下轴 D 的轮轴轴承(41)。
Mod TLB1 2WD / 4WD 液力变速箱维修手册
D.7.2 Assembly
Some of the following pictures could not show
D.7.2 安装
exactly our transmission, but the procedure is the 下面的一些图片不能准确的显示您的变速
same 箱,但过程是一样的。

Insert oil seal (21).


插入油密封环(21)

Insert oil seal (20) on clutch piston (19).


在离合器活塞(19)上插入油密封环(20)

Apply a thin film of grease on the outer edge and in


the inner part of
clutch piston (19) and insert.
在离合器活塞(19)外部边缘和内部涂上一
薄层油脂并插入。
Mod TLB1 2WD / 4WD 液力变速箱维修手册

Assemble spring (15) and spring retaining cover


(13).
安装弹簧(15)和弹簧保持盖(13)。

Lower the spring retaining cover (13). Insert snap


ring (14).
Use tool CA715358.
降低弹簧保持盖(13)。嵌入止动环(14)。
使用工具 CA715358。

Remove tool CA715358 and assemble pin (9).


取下工具 CA715358 并装上销子。

Insert washer (8).


嵌入垫圈(8)。
Mod TLB1 2WD / 4WD 液力变速箱维修手册

Insert bearings (7).


放入轴承(7)。

To assemble the clutch pack start with the gear (6)


on the bench. Install the backing plate (11) so that
the reference mark on top of the plate made during
disassembly is facing towards the gear.
从台上的齿轮(6)开始的目的是为了装配离
合器组件。安装背板(11)是为了使背板顶
上的参考符号在拆卸时面朝着齿轮。

Assemble disc pack (18), counterdiscs (17) and


backing plate (11) on gear (6). Repeat step 9 and
step 10 until all the clutch discs are installed. The
assembled clutch pack must contain seven steel
discs and six friction discs.
把磁盘组件(18)、背向磁盘(17)和背板
(11)装在齿轮上。重复步骤 9 和步骤 10
直到所有的离合器片安装完毕。装配完的离
合器组件必须包括 7 个钢盘和 6 个摩擦片。

Locate the pack assembly by means of two


screwdrivers.
用两个螺丝刀来定位装配好的组件。
Mod TLB1 2WD / 4WD 液力变速箱维修手册

Assemble snap ring (10).


安装止动环(10)。

Assemble spring pin (16).


安装弹簧销(16)。

Assemble washer (5), spacer (4) and bearing (5).


装配垫圈(5)、保持架(4)和轴承(5)。

Heat the bearing to 80÷100 °C (176° to 212 °F).


Assemble bearing (3).
Use tool CA715004.
加热轴承到80—100°C(176°—212°F)。
装配轴承(3)。
使用工具 CA715004。
Mod TLB1 2WD / 4WD 液力变速箱维修手册

Install the snap ring (2).


安装止动环(2)。

Insert oil seal (1).


放入油封(1)。

Measure the clutch disc clearance for each clutch


assembly. The backing plate must be all the way up
against the snap ring. Use a feeler gauge to
measure the distance between the backing plate
and the first metal disc. The distance must be 2.3 to
4.3 mm . If the distance is not within specification,
the clutch is probably assembled wrong.
为每个离合器部件测量离合片间距。背板必
须全部紧贴止动环。用塞规测量背板和第一
个金属盘间的距离。间距保证在 2.3mm 到
4.3mm。如果距离没有在此规格内,那离合
器可能是装配错误。
Mod TLB1 2WD / 4WD 液力变速箱维修手册

Note: overturn the shaft and execute the operations


from the sequence 1 to the sequence 13 sec D.7.2.
Use clean transmission oil to lubricate the washer
(25).Install the washer so that the notch in the inner
edge fits over the pin. Make sure that the side with
the oil grooves is down.
注释:翻转轴并完成 D.7.2 节中的序列 1 到
序列 13 的操作。使用清洁的润滑油来润滑垫
圈(25)。安装垫圈是为了让内边上的槽口
与销子吻合。确保带油槽的面朝下。

Heat the bearing to 80÷100 °C (176° to 212 °F)


Use tool CA715004 to drive the bearing (24) onto
the input shaft until the bearing makes contact with
the thrust washer.
加热轴承到 80—100°C(176°-212°F)。
使用工具 CA715004 来把轴承(24)装到输
入轴上直到轴承和轴力垫圈接触。

Assemble snap ring (23).


装配止动环.

Insert and close oil seals (22).


放入并拧紧油封。
Mod TLB1 2WD / 4WD 液力变速箱维修手册

1. Lubrication oil passage 2.前进离合器通道


2. Forward clutch passage 3.换向离合器通道
3. Reverse clutch passage 4.前进齿轮
4. Forward gear 5.前进离合器部件
5. Forward clutch pack 6.换向离合器部件
6. Reverse clutch pack 7.换向齿轮
7. Reverse gear 8.输入轴
8. Input shaft 见上面注释。
See the illustration above. 把大约 6 巴的压缩气体应用到前进离合
Apply compressed air of approximately 6 bar to the 器通道。听到前进活塞移动并锁止前进离合
forward clutch passage. Listen to hear the forward 器部件。
piston moving to lock the forward clutch pack. Try to 尽力移动前进齿轮。前进齿轮不能在输
move the forward gear. The forward gear must not 入轴上转动。尽力移动换向齿轮。换向齿轮
turn on the input shaft. Try to move the reverse gear. 必须能在输入轴自由转动。如果离合器不能
The reverse gear must turn freely on the input shaft. 正确运行,就拆开它们去找问题。
If the clutches do not work correctly, disassemble
the clutches to find the problem. 见上面的注释。
See the illustration above. 把大约 6 巴的压缩气体应用到换向离合
Apply compressed air of approximately 6 bar to the 器通道。听到换向活塞移动并锁止换向离合
reverse clutch passage. Listen to hear the reverse 器部件。尽力移动换向齿轮。换向齿轮不能
piston moving to lock the reverse clutch pack. Try to 在输入轴上转动。尽力移动前进齿轮。
move the reverse gear. The reverse gear must not 前进齿轮必须能在输入轴自由转动。如果离
turn on the input shaft. Try to move the forward gear. 合器不能正确运行,就拆开它们去找问题。
The forward gear must turn freely on the input shaft.
If the clutches do not work correctly,disassemble the
clutches to find the problem.

1.润滑油通道
Mod TLB1 2WD / 4WD 液力变速箱维修手册

Assemble D shaft bearing (41).


Use tool CA715149.
装配 D 轴承(41)。
使用工具 CA715149。

Assemble D shaft bearing (42).


Use tool CA715149.
装配 D 轴承(42)。
使用工具 CA715149。

Lubrificate with oil the shaft seat A.


用油润滑轴座 A。

Fit shaft assembly D and shaft assembly A.


The operation is correct only if the two shafts are
fitted at the same time.
安装轴部件 D 和轴部件 A。只有两轴同时安
装时操作才是正确的。
Mod TLB1 2WD / 4WD 液力变速箱维修手册

same.
D.8.1 Disassembly D.8.1 拆卸
Some of the following pictures could not show 下列一些图片不能准确的说明变速器,但过
exactly your transmission, but the procedure is the 程是相同的。

Rotate the rear housing so that the open side is up.


Connect acceptable lifting equipment to the top gear
on the secondary shaft.
旋转后面的机架使开口朝上。连接合适的升
降装置到副轴上部齿轮上。
Mod TLB1 2WD / 4WD 液力变速箱维修手册
shaft back and forth to keep the primary shaft
moving freely. It can be necessary to tap the ends of
the shift rods (from below the rear housing) so that
the shift rod and fork assemblies continue to move
freely. When the primary shaft is free of the rear
housing and the secondary shaft, remove the
primary shaft.
在你用手拿起主轴时,用提升装置开始提起
副轴。同时,前后移动主轴使主轴自由移动。
轻敲变速杆端部(从后面机架的下端)目的
是变速杆和叉部件继续自由移动,这是必要
的。当主轴与后机架和副轴分离时,移开主
轴。

Connect acceptable lifting equipment to the top gear


on the secondary shaft. Lift the secondary shaft over
the rear housing. Engage the shift forks with the
synchronizers as shown. Begin to lower the
assembly into the rear housing.
用合适的提升装置连接副轴上部齿轮。把副
轴提到后机架之上。让变速叉和所给的同步
器啮合。然后开始把组件放入后机架中。

Remove bearing (1) by means of an extractor.


用拆卸工具拆掉轴承(1)。

Use the lifting equipment to begin lifting the


secondary shaft while you use your hands to lift the
primary shaft. At the same time, move the primary
Mod TLB1 2WD / 4WD 液力变速箱维修手册

Remove washer (2) and gear third speed (3).


拆下垫圈(2)和三速齿轮(3)。

Remove snap ring (47).


拆下止动环(47)

Remove third/fourth speed synchronizer assembly


(4).
拆下三速/四速同步器部件。

Remove the clutch ring (5) from each side of the


synchronizer assembly.
Note: the synchronizer assembly component parts
are serviced as a complete unit. The synchronizer
assembly may be disassembled for inspection and
cleaning. If any of the parts are damaged, the entire
synchronizer assembly must be replaced. Use new
parts as required.
从同步器部件两边拆下离合环(5)。
注:同步器各零件是作为一个完整单元工作
的。为了检查和清洗,同步器可以拆开。如
果其中的任何零件损坏,则必须置换整个同
步器。按要求使用新零件。
Mod TLB1 2WD / 4WD 液力变速箱维修手册
between the bottom of the teeth on the synchronizer
ring and the edge of the sleeve on the outside of the
synchronizer assembly. This clearance should be
approximately 1.0 mm with used parts in good
condition. If the clearance is 0.5 mm or less, use a
new synchronizer assembly. Repeat the
measurement for the opposite side of the
synchronizer assembly before disassembly. Repeat
the measurement for the opposite side of the
synchronizer assembly before disassembly.
用塞规测量同步环上的齿根和同步器外面衬
套边的间距。
间距在良好状态下应在1.0mm左右。
如果间距是0.5mm或更小,换一个新同步器。
在卸前重复测量同步器相对的边。在卸前重
复测量同步器相对的边。

Remove the friction ring (6) from each side of the


synchronizer assembly.
从同步器的各面上拆下摩擦环(6)。

Remove the sleeve (7) from the synchronizer hub.


When the sleeve is removed from the synchronizer
hub the spring plates, hub pins and hub springs will
be released from the synchronizer hub.
Warning: do not lose any of these parts.
从同步器轴上取下套管(7)。
在套管从同步器轴的弹性板上取下时,轴销
和轴簧将从同步器轴上释放出。
警告:切勿丢失任何零件。

Use a feeler gauge to measure the clearance


Mod TLB1 2WD / 4WD 液力变速箱维修手册
This photo shows the relationship of the spring
plates (8), the balls (9),the hub springs (10), and the
synchronizer hub (11).
The synchronizer hub contains 3 spring plates (8), 3
balls (9), and 3hub springs (10).
这幅照片说明了弹性板(8)、球(9)、轴
簧(10)和同步器轴(11)的关系。
同步器轴包括 3 个弹性板(8)、3 个球(9)
和 3 个轴簧(10)。

Remove the snap ring (41).


拆下止动环(41)。

Remove fourth speed gear (12).


拆下四速齿轮(12)。

Remove snap ring (13).


拆下止动环(13)。
Mod TLB1 2WD / 4WD 液力变速箱维修手册

Remove the 4WD gear (14).


拆下 4WD 齿轮(14)。

Turn the shaft.


Remove snap ring (16).
旋动轴。
卸下止动环(16)。

Remove the bearing outer part with your hands and


remove bearing inner ring (15) with a suitable
extractor.
手动卸下轴承外圈并用合适的拆卸工具卸下
轴承内环(15)。

Remove thrust washer (17).


取下止推垫圈(17)。
Mod TLB1 2WD / 4WD 液力变速箱维修手册

Remove spring pin (19).


取出弹簧销(19)。

Remove second speed gear (18) and shim (21).


卸下二速齿轮(18)和垫片(21)。

Remove the synchronizer ring (22).


卸下同步器环(22)。

Remove the snap ring (20).


取出止动环(20)。
Mod TLB1 2WD / 4WD 液力变速箱维修手册

Remove the first/second speed synchronizer


assembly (23).
卸下初速/二速同步器(23)。

Remove the steel ring (24) and the bronze ring (25)
together. Install the synchronizer ring on top of the
synchronizer assembly. Use a feeler gauge to
measure the clearance between the bottom of the
teeth on the synchronizer ring and the edge of the
sleeve on the outside of the synchronizer assembly.
一起拆下钢环(24)和铜环(25)。在同步
器上安装同步器环。用塞规测量同步环上的
齿根和同步器外面衬套边的间距。

This clearance should be approximately 1.0 mm


with used parts in good condition. If the clearance is
0.5 mm or less, use a new synchronizer assembly.
Repeat the measurement for the opposite side of
the synchronizer assembly before disassembly.
旧零件中此间距在良好状态下应在1.0mm左
右。如果间距为0.5mm或更小,换一个新同
步器。在卸前重复测量同步器相对的边。在
卸前重复测量同步器相对的边。

Remove the tapered friction ring (26).


卸下锥形摩擦环(26)。
Mod TLB1 2WD / 4WD 液力变速箱维修手册

Turn the synchronizer assembly (23) over and


remove the synchronizer ring (27) from the other
side.
旋转同步器(23)并从另一边取下同步器环
(27)。

Remove the steel ring (28) and the bronze ring (29)
together.
一起取下钢环(28)和铜环(29)。

Remove the tapered friction ring (30).


卸下锥形摩擦环(30)。

Support the sleeve on blocks.


Push down on the hub while you use a punch to
push the detent assemblies out of the sleeve and
hub.
Remove the sleeve (31) from the hub.
把套靠在铁砧上。
当你用冲子把锁销推出套管和毂的时候推下
毂子。
从衬套上取下套管(31)。
Mod TLB1 2WD / 4WD 液力变速箱维修手册

This photo shows the relationship of the balls (32),


the spring plates(33), the springs (34), and the hub
(35).
这幅照片说明了球(32)、弹性板(33)、
弹簧(34)和同步器轴(11)的关系。

Remove spacer (36).


取下垫片(36)。

Remove the snap ring (42).


卸下止动环(42)。

Remove first speed gear (37).


卸下初速齿轮(37)。
Mod TLB1 2WD / 4WD 液力变速箱维修手册

Remove snap ring (38).


卸下止动环(38)。

Remove bearing inner ring (39) with an extractor.


用拆卸工具拆下轴承内环(39)。

Turn the shaft.


Remove snap ring (43).
旋转轴。
取下止动环(43)。
Mod TLB1 2WD / 4WD 液力变速箱维修手册

Remove bearing (40).


卸下轴承(40)。

Remove thrust washer (44).


卸下止推垫圈(44)。

Remove small gear (45).


卸下小齿轮(45)。

Turn the primary shaft over so that the large gear is


down. Tap the gear with a soft hammer to remove
the gear (46) from the primary shaft.
旋转主轴以拆下大齿轮。用软锤轻敲齿轮以
从主轴上卸下齿轮(46)。

D.8.2 Assembly
Some of the following pictures could not show
Mod TLB1 2WD / 4WD 液力变速箱维修手册
exactly your transmission, but the procedure is the 下列一些图片不能准确的说明变速器,但过
same. 程是相同的。
D8.2 装配
first-second gear end is up. You can use a vise with
soft jaws to hold the secondary shaft inposition.
Install the snap ring (38) as shown.
把副轴放在台上以使一、二级齿轮末端立起。
可以用一个软爪老虎钳夹紧副轴。
按图示安装止动环(38)。

Install first speed gear (37).


安装初速齿轮(37)。

Assemble snap ring (42).


装上止动环(42)。

Put the secondary shaft on the bench so that the


Mod TLB1 2WD / 4WD 液力变速箱维修手册

Assemble washer (36).


装上垫圈(36)。

This photo shows the correct positions of the hub


(35), the sleeve (31),the springs (34), the blocks
(33), and the balls (32) prior to final assembly. The
springs are installed in the hub, and the blocks are
on the springs. The blocks are not yet pushed down
into the sleeve and are holding the hub up out of the
sleeve. The balls are loose in the recesses of the
blocks.
这幅图片显示了毂(35)、套圈(31)、弹
簧(34)、块(33)和球(32)在最后装配
前的正确位置。弹簧装在毂内,块在弹簧上。
块不是被推进套管内而是支撑毂脱离套管。
球在块的凹窝内是松动的。
Use a punch or screwdriver to push the balls (32)
into the blocks and to push the blocks down so that
the balls are on the flat faces of the teeth, but not
into the detent grooves. When all the balls are in
position, push the hub and the blocks down until the
balls move into the detent groove.
用钢针或螺丝刀把球(32)推进块内并把块
推下以使球在齿的平面上,而不是定位槽内。
当所有球装到位时,把毂和块推下直到球进
入定位槽。

Install the tapered friction ring (30) on the


synchronizer assembly.
在同步器上安装锥形摩擦环(30)。
Mod TLB1 2WD / 4WD 液力变速箱维修手册

Use clean transmission oil to lubricate the bronze


ring (29) and the steel ring (28).
Install the bronze ring (29) and the steel ring (28) as
shown.
用清洁的润滑油润滑铜环(29)和钢环(28)。
按图示安装铜环(29)和钢环(28)。

Install the synchronizer ring (27) as shown. The flat


sides of the teeth must be up.
按图示安装同步器环(27)。齿平的一面保
证朝上。

Turn the synchronizer assembly over and install the


tapered friction ring (26) on the other side.
转动同步器并在另一端安装锥形摩擦环
(26)。
Mod TLB1 2WD / 4WD 液力变速箱维修手册
hold the sleeve in this position. Push the sleeve
back down to the neutral position, turn the
synchronizer assembly over, and repeat the
procedure with the bottom synchronizer ring.
If the sleeve does not engage the teeth smoothly or
does not stay in position when moved to any of the
three posi t ions, the synchronizer assembly has
damaged parts or was not assembled correctly.
Disassemble the synchronizer assembly to find the
problem.
用清洁的润滑油润滑铜环(25)和钢环(24)。
Use clean transmission oil to lubricate the bronze 按图示安装铜环(25)和钢环(24)。在同
ring (25) and the steel ring (24). Install the bronze 步器上安装上同步器环。确保上同步器环上
ring (25) and the steel ring (24) as shown. Install the 的齿与套管内的齿成一条直线。提高套管直
top synchronizer ring on the synchronizer assembly. 到套管与上同步器环接合。
Make 要完成操作,你必须用足够的力来克服棘爪
sure that the teeth on the top synchronizer ring are 弹簧和球的强度。当同步器环和套管完全接
aligned with the teeth on the inside of the sleeve. 合时,棘爪在此位置支撑套管。
Push the sleeve up until the sleeve engages the 把套管推回到中间位置,转动同步器,并重
teeth on the top 复下同步器环的操作。
synchronizer ring. To do this, you must use enough 当移动到三个中的任何一个位置,假如套管
force to overcome the strength of the detent springs 没有光滑接合或不在位置,则是同步器中的
and balls. When the synchronizer ring and the 零件损坏或者安装有误。
sleeve are completely engaged, the detent must 拆卸同步器找出问题。

Install the first/second speed synchronizer assembly


(23) without the top synchronizer ring.
安 装 初 速 /二 速 不带上 同 步 器环 的 同步 器
(23)。
Mod TLB1 2WD / 4WD 液力变速箱维修手册

Assemble snap ring (20).


安装止动环(20)。

Install the top synchronizer ring (22) so that the flat


sides of the teeth are up.
安装上同步器环(22)使齿平的一面朝上。

Install the spacer (21) and second speed gear (18).


The teeth in the inside diameter of the spacer must
engage the teeth on the bottom of second speed
gear before second speed gear is installed.
安装垫圈(21)和二速齿轮(18)。
在二速齿轮安装前,垫圈内径齿必须和二速
齿轮底部齿啮合。

Assemble pin (19).


装销(19)。
Mod TLB1 2WD / 4WD 液力变速箱维修手册

Assemble washer (17).


装垫圈(17)。

Heat the inner race of the bearing to 80÷100°C


(176°÷212°F).
Assemble the inner race of the bearing (15).
Use tool CA715149.
加热轴承内圈到 80—100℃(176°—212℉)。
装配轴承内圈(15)。
有工具 CA715149。

Assemble snap ring (16).


装止动环(16)。

Turn the shaft.


Install the 4WD gear (14).
旋动轴。
安装 4WD 齿轮(14)。
Mod TLB1 2WD / 4WD 液力变速箱维修手册

Assemble snap ring (13).


安装止动环(13)。

Assemble fourth speed gear (12).


安装四速齿轮(12)。

Assemble snap ring (41).


安装止动环(41)。

This photo shows the correct positions of the hub


(11), the sleeve (7), the springs (10), the blocks (8),
and the balls (9) prior to final assembly.
The springs are installed in the hub, and the blocks
are on the springs.The blocks are not yet pushed
down into the sleeve and are holding the hub up out
of the sleeve. The balls are loose in the recesses of
the blocks.
这幅图片展示了毂(11)、套管(7)、弹簧(10)、
块(8)和球(9)在最后装配前的正确位置。
弹簧安装在毂内,块装在弹簧上。块不是被
推进套管内而是支撑毂脱离套管。球在块的
凹窝内是松动的。
Mod TLB1 2WD / 4WD 液力变速箱维修手册

Install the 3 sets of hub springs (8), hub pins (9),


and spring plates (10) into the synchronizer hub
(11).
Use a punch or screwdriver to push the spring
plates as the synchronizer hub is installed into the
sleeve (7).
Be sure that the spring plates are aligned with the
grooves in the sleeve.
安装3套毂弹簧(8)、轴销(9)和弹性板(10)
到同步器毂(11)中。
当同步器毂装进套管(7)时用钢针或螺丝刀
推动弹性板。
保证弹性板和套管内槽对齐。

Install the friction ring (6) on each side the


synchronizer assembly.
在同步器各面安装摩擦环(6)。
Mod TLB1 2WD / 4WD 液力变速箱维修手册
Use clean transmission oil to lubricate and install the
clutch ring (5) on each side of the synchronizer
assembly. Install the top synchronizer ring on the
synchronizer assembly. Make sure that the teeth on
the top synchronizer ring are aligned with the teeth
on the inside of the sleeve. Push the sleeve up until
the sleeve engages the teeth on the top
synchronizer ring. To do this, you must use enough
force to overcome the strength of the detent springs
and balls. When the synchronizer ring and the
sleeve are completely engaged, the detent must
hold the sleeve in this position. Push the sleeve
back down to the neutral position, turn the
synchronizer assembly over, and repeat the
procedure with the bottom synchronizer ring. If the
sleeve does not engage the teeth smoothly or does
not stay in position when moved to any of the three
positions, the synchronizer assembly has damaged
parts or was not assembled correctly. Disassemble
the synchronizer assembly to find the problem.
用清洁的润滑油润滑并在同步器各面安装离
合环(5)。在同步器上安装上同步器环。
确保上同步器环上的齿与套管内的齿成一条
直线。提高套管直到套管与上同步器环接合。
要完成操作,你必须用足够的力来克服棘爪
弹簧和球的强度。当同步器环和套管完全接
合时,棘爪在此位置支撑套管。
把套管推回到中间位置,转动同步器,并重
复下同步器环的操作。假如套管没有光滑接
合或不在位置,则是同步器中的零件损坏或
者安装有误。拆卸同步器找出问题。

Install the third/fourth speed synchronizer assembly


(4) onto the shaft.
把三速/四速同步器安装到轴上。
Mod TLB1 2WD / 4WD 液力变速箱维修手册

Assemble snap ring (47).


安装止动环(47)。

Use clean transmission oil to lubricate the thrust


washer (2).
Install third gear (3) and the thrust washer onto the
shaft.
用清洁的润滑油润滑止推垫圈(2)。
把三齿轮(3)和止推垫圈安装到轴上。

Heat the bearing to 80÷100°C (176°÷212°F).


Assemble bearing (1).
Use tool CA715004.
加热轴承到 80—100℃(176°—212°F)。
安装轴承(1)。
用工具 CA715004。
Mod TLB1 2WD / 4WD 液力变速箱维修手册

Heat the inner race of the bearing to 80°÷100°C


(176°÷212°F.) Assemble the inner race of the
bearing (39).
Use tool CA715149.
加热轴承内圈到 80—100℃(176°—212°
F)。安装轴承内圈(39)。
用工具 CA715149。

Turn the primary shaft over. Use a soft hammer to


tap the large gear(46) into position.
翻转主轴。用软锤轻敲大齿轮(46)到位。

Install small gear (45).


安装小齿轮(45)。
Mod TLB1 2WD / 4WD 液力变速箱维修手册

Use clean transmission oil to lubricate the thrust


washer. Install the thrust washer (44) so that the
side with the oil grooves is down.
用清洁润滑油润滑止推垫圈。安装止推垫圈
(44)使带油槽面朝下。

Heat the bearing to 80÷100°C (176°÷212°F).


Assemble bearing (40).
Use tool CA715004.
加热轴承到 80—100℃(176°—212°F)。
装配轴承(40)。
用工具 CA715004。

Install the snap ring (43).


安装止动环(43)。

Connect acceptable lifting equipment to the top gear


on the secondary shaft. Lift the secondary shaft over
the rear housing. Engage the shift forks with the
synchronizers as shown. Begin to lower the
assembly into the rear housing.
用合适的提升装置连接副轴上部齿轮。把副
轴提到后机架之上。让变速叉和所给的同步
器啮合。然后开始把组件放入后机架中。
Mod TLB1 2WD / 4WD 液力变速箱维修手册
As you lower the assembly into the rear housing,
also begin to install the primary shaft so that the
gears on the primary shaft go into mesh with the
gears on the secondary shaft. Continue to lower the
parts,
making sure that each part goes into the correct
bore in the rear housing. (Remember that the shift
rod and fork assembly for third and fourth gear goes
into the bore nearer the top of the rear housing).
When all the parts are in position, disconnect the
lifting equipment.
当你把部件降低进后机架时,开始安装主轴
以使主轴上的齿轮和副轴上的齿轮啮合。继
续降低,要确保每个零件进入对应的后机架
孔中。
(谨记三四齿轮的变速杆叉进到离后机
架顶部较近的孔内。)所有零件到位时,脱开
提升装置。

Reposition shaft assemblies B and C into the half


box complete with forks.
Warning: position the group with care paying
attention to the location of fork pins in their seats.
完全用叉子把 B 轴部件和 C 轴部件重新配置
到半箱中。
警告:小心组件位置,注意叉形销放进他们
的位置。
Mod TLB1 2WD / 4WD 液力变速箱维修手册

D.9 Shaft E D.9 E 轴

same.
D.9.1 Disassembly D.9.1 拆卸
Some of the following pictures could not show 下面一些图片不能准确说明变速器,但过程
exactly your transmission, but the procedure is the 是一样的。

Lift shaft E.
提起轴 E。
Mod TLB1 2WD / 4WD 液力变速箱维修手册

Remove the four-wheel drive clutch gear (8).


取下四轮驱动离合齿轮(8)。

Remove bearing (7).


取下轴承(7)。

Use an acceptable tool CA715410 to press the


springs retainer down until you have access to the
snap ring (see arrow). Remove the snap ring (1)
from the groove.
Release the tension and remove the tool.
用合适的工具 CA715410 压低弹簧挡板直到
能够到止动环(看到箭头)。从槽上取下止动
环(1)。
松开张紧器拿开工具。

Remove washer (2).


取下垫圈(2)。
Mod TLB1 2WD / 4WD 液力变速箱维修手册

Remove springs (3).


取下弹簧(3)。

Remove sleeve (4).


取下套管(4)。

Remove the two O-rings (5) and (6) from the shaft.
从轴上取下 O 形环(5)和(6)。

Remove snap ring (9).


取下止动环(9)。
Mod TLB1 2WD / 4WD 液力变速箱维修手册

Remove cylinder (11).


取下圆筒(11)。

Remove O-rings (10) from cylinder (11).


从圆筒(11)上取下 O 形环(10)。

Remove valve (13) and spring (12) from cylinder


(11).
从圆筒中取出阀(13)和弹簧(12)。

Remove the four-wheel drive clutch tube (14) from


the front housing only if the front housing must be
replaced or if the tube is leaking or damaged.
仅在前机架必须替换或软管泄露或损坏的情
况下,才能从前机架取下四轮驱动离合器软
管(14)。
Mod TLB1 2WD / 4WD 液力变速箱维修手册
D.9.2 Assembly D.9.2 装配
Some of the following pictures could not show
exactly 下面一些图片不能准确说明变速器,但过程
your transmission, but the procedure is the same. 是一样的。

Install O-rings (10) on cylinder (11).


在圆筒(11)上装上 O 形环(10)。

Install spring (12) and valve (13) in cylinder (11).


把弹簧(12)和阀(13)装进圆筒(11)。

Install cylinder (11) in the shaft.


把圆筒(11)装进轴内。
Mod TLB1 2WD / 4WD 液力变速箱维修手册

Assemble snap ring (9).


装上止动环(9)。

Assemble the O-Rings (5) and (6).


装上 O 形环(5)和(6)。

Assemble sleeve (4).


装上套管(4)。

Assemble springs (3).


装上弹簧(3)。
Mod TLB1 2WD / 4WD 液力变速箱维修手册

Install springs support washer (2).


装上弹簧挡靠的垫圈(2)。

Position snap ring (1).


定位止动环(1)。

Use an acceptable tool CA715410 to press the


springs retainer down until you have access to the
snap ring. Install the snap ring (1) in the groove.
Release the tension and remove the tool. Make sure
that the snap ring is seated in the recess in the
spring retainer.
用合适的工具 CA715410 压低弹簧挡板直到
能够到止动环。把止动环(1)装进槽内。
松开张紧器拿开工具。确保止动环在弹簧挡
板凹窝的位置。
Mod TLB1 2WD / 4WD 液力变速箱维修手册

1) 4WD oil passage problem.


2) 4WD gear
3) Shaft 1)4WD 油道
4) Springs 2)4WD 齿轮
5) Sleeve 3)轴
6) Valve 4)弹簧
Apply air compressed at about 6 bar to 4WD clutch 5)套管
oil passage (1) by plugging the opposite hole with a 6)阀
finger. The sleeve should be moving when 用手指堵住相对的孔,把大约 6 巴的压缩气
compressing the springs. The 4WD gear should 体充到 4WD 离合器油道(1)。套管在压缩弹
move freely on 4WD shaft. Valve (6) , if operating 簧时应移动。4WD 齿轮应在 4WD 轴上能自
correctly reaches the end of stroke making a noise. 由移动。阀(6)如正确操作到达报时点有声
If the operation is incorrect, dismantle to find the 音。如操作有误,拆除找出问题。

Install bearing (7).


安装轴承(7)。
Mod TLB1 2WD / 4WD 液力变速箱维修手册

Install gear (8).


安装齿轮(8)。

Install shaft E.
安装轴 E。

If the four-wheel drive clutch tube (12) was removed


from the front housing, install the four-wheel drive
clutch tube.
Torque wrench setting (Sec.C.8).
如果四轮驱动离合器软管(12)已从前机架
中取出,装上四轮驱动离合器软管。
扭矩扳手底座(C.8 节)。
Mod TLB1 2WD / 4WD 液力变速箱维修手册

D.10. 速度控制装置 D.10 Speed controls

D.10.1 Disassembly D.10.1 拆卸


Some of the following pictures could not show 下面一些图片可能不能准确的说明变速器,
exactly your transmission, but the procedure is the 但过程是相同的。
same.

Untighten and remove screws (1).


Warning: for the disassembly of the two half boxes
it is necessary to remove the shift tower assy.
松开拿掉螺丝钉(1)。
警告:为了拆卸两个半箱体,必须移开变速塔
座。
Mod TLB1 2WD / 4WD 液力变速箱维修手册

Remove shift tower assy (2) and O-ring (3).


取下变速塔座(2)和 O 形环(3)。

Use side cutters as shown to release the catch on


the band which fastens the boot. Remove the band
(4).
用图示的剪边机松开用来固定壳体的箍上的
抓爪。取下箍(4)。

Remove the boot (5).


取下壳体(5)。

Remove the two pins (7).


取下两个销钉(7)。
Mod TLB1 2WD / 4WD 液力变速箱维修手册

Remove the two pins (7).


从变速杆上取下止动环(8)。

Remove the bushing (9) from the shift lever.


从变速杆上取下轴衬(9)。

Remove the spring (10).


取下弹簧(10)。

Remove the shift lever (6).


取下变速杆(6)。
Mod TLB1 2WD / 4WD 液力变速箱维修手册

If disassembly is required, remove the pins (11)


and separate the shift forks from the shift rods.
Make sure that you remember how the parts are
assembled and which parts go together. Except for
the pins, none
of the parts are interchangeable. Inspect all parts for
burrs and excessive wear. Assembly is the reverse
of disassembly.
如果拆卸需要,取下销钉(11)并把变速叉
与变速杆分离。你一定要记住零件的装配和
哪些在一起。除了销钉,零件不可互换。
检查所有零件的毛头和过度磨损。

D.10.2 Assembly D.10.2 装配


some of the following pictures could not show 下面一些图片可能不能准确说明变速器,但
exactly your transmission, but the procedure is the 过程是一样的。
same.

Apply grease to the ball of the shift lever.


Install the shift lever (6).
在变速杆的球上涂润滑油。
安装变速杆(6)。

The correct alignment of the shift lever and the


cover flange is shown above.
The slot (6) in the shift lever must be toward the flat
side of the cover flange.
The slots on each side of the shift lever must be
aligned with the holes (7) in each side of the cover
flange.
转换杆和表面凸缘所成的正确直线上面有显
示。
转换杆里的槽(6)必须对着表面凸缘的平面。
转换杆每面的槽必须和表面凸缘每个面上的
孔(7)成一线。
Mod TLB1 2WD / 4WD 液力变速箱维修手册

Install the spring (10).


安装弹簧(10)。

Install the bushing (9).


安装轴衬(9)。

Put the snap ring (8) on the shift lever.


在变速杆上放上止动环(8)。

Install the pins (7) through the holes in the cover


flange so that the pins engage the slots in the shift
lever.
在凸缘孔中装入销钉(7)以使销钉与变速杆
内的细孔接合。
Mod TLB1 2WD / 4WD 液力变速箱维修手册

Install the boot (5) so that the end of the boot fits
over the ends of the pins.
Be careful so that the pins do not fall out during this
step.
安装壳体(5)使壳体末端接合销钉末端。
注意在此步中销钉不要脱落了。

Install the band (4) on the boot as shown.


Use the side cutters to engage the catch on the
band.
按图示在壳体上安装箍(4)。
用修边机接上箍上的抓爪。

Install a new O-ring (3) into flange cover seat. Use


clean oil to lubricate the O-ring.
Put the shift tower assy into position on the rear
cover.
在凸缘座内安装一个新的 o 形环(3)。用润
滑油润滑 O 形环。
把变速塔座放进后罩上面的位置。

Assemble screws (1).


Torque wrench (see Sec. C.8).
安装螺丝钉(1)。
扭矩扳手(见 C.8 节)。
Mod TLB1 2WD / 4WD 液力变速箱维修手册

Fit the other two pins (11) to lock gear control fork
3rd and 4th speed(13) and gear control fork 1st and
2nd speed (14).
安装另外两个销钉(11)来锁三速和四速齿
轮控制叉(13)与初速和二速齿轮控制叉
(14)。
Mod TLB1 2WD / 4WD 液力变速箱维修手册

E TROUBLESHOOTING
发现并修理故障
Mod TLB1 2WD / 4WD 液力变速箱维修手册

E.1 Troubleshooting E.1 发现并修理故障


Valid for TLB1-TLB2 type transmissions TLB1—TLB2 型装在车辆上的带有变速器
with transmission mounted on vehicle. 的有效变速箱。
Introduction 说明
This list of possible failures and remedies provides 关于可能的失败和修补的这个目录提供的仅
no more than an indication of what the problem 仅是一个会出现什么问题和如何安装的指
might be and how to fix it. 示。
It should be remembered that problems are not 有一点应该记住,那就是问题不是仅仅由一
caused by just one part, but by that part’s interaction 个零件引起的,而是由带有其他元件相互作
with other elements; accordingly, additional action 用的零件引起的。相应地,其他操作和上面
over and above the steps described is frequently 提到的步骤经常需要。
required.
This list may not cover all possible problems and 这个目录可能包括不完所有的出现的问题和
remedies. 修补方法。
Specialist personnel must identify the problem and 专业人员必须确定问题和引起原因,然后进
its cause and then proceed with the necessary 行必要的维修。
repairs. 警告:所有检查和测试须在油温在 80℃±2。
Warning: All checks and tests must be performed
with the oil at working temperature: 80 °C ±2.

E.1.1 Checks and Tests E.1.1 检查和测试


Transmission oil check 润滑油检查
Always check the correct oil level (see section C.5) 经常检查合适的油高(见 C.5 节)和正确油
and correct oil specifications (see section C.3) 的规格(见 C.3 节)
Pressure check
Several transmission breakdowns can be identified 压力检查
by running pressure checks (see section C.9 某些变速器故障可以用压力检查(见 C.9 节
hydraulic diagram). Irregular measurements might 压力示图)确定。不规律的测量可能暗示出
indicate that there is a problem, which specialist 有问题,这一点须专业人员确定。
personnel must
identify. 安装测试
Stall test 为了为发现并修理故障创造理想条件,变换
In order to create ideal conditions for 器安装操作须首先完成。此测试的目的是确
troubleshooting,the converter stall procedure must 定变换器和压力离合器单元的操作是否正
be performed first. The purpose of this test is to 确。
determine whether the torque converter and
hydraulic clutch units are operating correctly. 这项操作也把油温升高到 80℃±2 的工作温
This operation will also bring the oil up to its working 度,允许在发动机、变换器或变速器里的出
temperature of 80°C ±2, allowing any problems in 现任何问题。
the engine, converter or
Mod TLB1 2WD / 4WD 液力变速箱维修手册
transmission to be identified. 如下进行:
Proceed as follows: ·检查油的高度(见 C.5 节)。
• Check the oil level (see section C.5). ·用刹车锁住车轮。
• Activate the parking brake to block the wheels.
• Start the engine and keep it ticking over at idle · 发 动 发 动 机 保 持 以 空 转 速 度 ( 800 —
speed(800 - 1000 [rpm]). 1000[rpm])慢速运转。
• Put the gear lever into 4th. ·把齿轮控制杆放到四速位置。
• Put the reverser in the FORWARD position. ·把换向器放到前进档位置。
• Rev the engine for short periods to a maximum of
1500 - 1700 [rpm], to bring the oil up to working ·迅速将发动机转速提高到 1500—1700[rpm]
temperature. 的最大值,油温升到工作温度。
Important: the converter stall test must not exceed 重点:变换器安装测试每次不能超过 30 秒的
a maximum duration of 30 seconds each time. After 最大时间 。30 秒后,把换向器放到中位 15
this 30 second period, put the reverser in NEUTRAL 秒,然后重复这个过程。
for 15 seconds, then repeat the procedure.
Warning: Failure to keep to these test periods may
result in the oil overheating and attendant damage 警告:如果没能保持这个时间,可能导致油
to the clutches, filter, converter and seals. 过热并对离合器、过滤器、变换器和密封有
• Gradually reduce the engine revs to minimum. 损坏。
• Put the reverser in NEUTRAL. ·慢慢降低发动机转速到最小值。

·把换向器放到中位。

E.1.2 Guide to Problems E.1.2 问题指南


Mechanical problems 机械性问题
• Check that all of the transmission’s internal and ·检查变速器内外所有机械零件安装正确(见
external mechanical parts are correctly fitted (see 拆卸和装配章节)。
disassembly and assembly chapters).
• Check the efficiency of the parking brake.
• Check that the cooling system is in good operating ·检查刹车效率。
condition. ·检查冷却系统在良好运转状态。
• Check the efficiency of the engine. Make sure that
the engine’s idling speed is set correctly and that it ·检查发动机效率。确保发动机空转速度的
complies with the maximum speed specifications 正确设定并服从不满载情况下的最大速度的
under loadless conditions. 规格。
Hydraulic problems
• Check the transmission oil level (see section C.5).
• Use the specified oils (see section C.3). 液压问题
• Check that the hydraulic system is correctly ·检查润滑油高(见 C.5 节)。

·用指定油(见 C.3 节)。


·检查液压系统正确供给。
Mod TLB1 2WD / 4WD 液力变速箱维修手册
filled.
• Check the efficiency of the hydraulic system. ·检查液压系统效率。检查油的泄露。
Check for oil leaks.
• Check the efficiency of the transmission’s ·检查变速器液压元件的效率(变换器、油
hydraulic components (converter, oil pump, filter, 泵、过滤器、接头、油管)。
connections, hoses).
Electrical problems 电路问题
• Check the efficiency and correct installation of the ·检查车辆电池组的效率和正确安装。
vehicle battery.
• Check the efficiency and correct installation of all ·检查变速器外所有电器元件(电线、电缆、
electrical components outside the transmission 交流发电机、电池组等)的效率和正确安装。
(wiring, cables, alternator, battery, etc.).
• Check the efficiency and correct installation of all ·检查变速器所有电器元件(电线、传感器、
transmission electrical components (wiring, sensors, 螺线管、EGM/ECU 等)的效率和正确安装。
solenoid valves, EGM/ECU, etc.)
Mod TLB1 2WD / 4WD 液力变速箱维修手册

E.2 Troubleshooting of transmission


The next table lists problems, possible causes and recommended corrective action.

E.2 变速器中发现并修理故障
下面的表格列举了问题、可能的原因和推荐的正确操作。
Mod TLB1 2WD / 4WD 液力变速箱维修手册

问题 原因 操作

车辆不动 电磁阀故障 检查/更换


变速器和车辆间连线的损坏 修理/更换
电线漏电 清洗
断电 更换
坏的螺线管 更换
坏的传感器 更换
短路或接线错误 检查/更换保险丝
仅仅 TLB2 电轮非正规功能操作(EGM/ECU) 更换 EGM/ECU
不合适的油高 加满
检查泄露 更换/加满
过滤器入口堵塞 清洗
油泵的损坏 更换
油泵减压阀的损坏 更换油泵
变速器过滤器的堵塞/损坏 更换
控制阀的损坏/阻塞 更换
损坏的变换器 更换
油温低于 0 度 等待油达到工作温度(停转检测)
更换
仅仅 TLB1 损坏的转动密封 更换
损坏的同步器 更换
锁止的换向杆 更换/修理离合器元件
过度磨损的离合器元件 检查/修理/更换
无驱动变速器(断裂齿轮、轴、轴
承等)
车 辆 简 化 不合适的油温 等待油达到工作温度(停转检测)
成电动换 恢复合适温度值
档 润滑油过热 检查油路并更换(油泵、过滤器、控制阀)
不合适的工作压力 更换
加满
损坏的变换器 更换/修理
不合适的油高 更换/修理 4WD 轴群
过度磨损的离合器元件 更换
4WD 离合器故障 修理/更换
过热螺线管 更换 EGM/ECU
变速器和车辆间的损坏电线接头 更换
仅仅 TLB2 损坏的 EGM/ECU 逻辑
损坏的传感器
Mod TLB1 2WD / 4WD 液力变速箱维修手册
Mod TLB1 2WD / 4WD 液力变速箱维修手册

问题 原因 操作
过热 损坏的液压冷却系统 修理
脏的热交换器 清洗
刹车不注意活动了 释放
轴的轮毂太脏 清洗
失灵(断裂齿轮、轴、轴承等) 检查/修理/更换
变速器外制动力:不规则车轴 检查/修理轴
运行
离合器片齿扣 修理/更换
损坏的变换器 更换
损坏的油液自动调温器 更换
不合适的油高 加满
坏油泵 更换
车升起时轮转 离合器片齿扣 修理/更换
动 降低油温(高的油粘度) 等待油达到工作温度(停转检测)
更换油液和过滤器
不合适的油规格 更换
损坏的控制阀 修理/更换
换向器锁定故障
噪音 损坏的变换器 更换
仅仅 TLB1 损坏的油泵 更换
仅仅 TLB1 通风/气蚀 检查油高/检查油的规格
失灵(断裂齿轮、轴、轴承等) 检查/修理/更换
损坏的离合器片 更换
损坏的同步器冲动元件 更换
损坏的 4WD 离合器 更换
不规范操作 损坏的控制阀 更换
电系统故障 修理/更换
损坏的离合器片 更换
损坏的变换器 更换
降低油温(高的油粘度) 等待油达到工作温度(停转检测)
看到“过热”
过热 更换 EGM/ECU
仅仅 TLB2 EGM/ECU 操作有误 修理/更换
损坏的液压系统
齿轮保持啮合 损坏/阻塞穿梭轴杆 修理/更换
电系统故障 修理/更换
损坏的控制阀 更换
损坏的液压系统 修理/更换
损坏的离合器元件 修理/更换
仅仅 TLB2 不规范的 EGM/ECU 操作 更换 EGM/ECU
仅仅 TLB1 损坏的齿轮控制杆 更换
仅仅 TLB1 损坏的同步器 更换
Mod TLB1 2WD / 4WD 液力变速箱维修手册

问题 原因 操作
无 4WD 电变速器 损坏的 4WD 离合器 更换
液压系统故障 修理/更换
损坏的控制阀 更换
刹车传感器故障 检查/更换
电系统故障 修理/更换
仅仅 TLB2 EGM/ECU 运行故障 更换 EGM/ECU
齿轮转换不能啮

仅仅 TLB1 损坏的开关 更换
仅仅 TLB1 损坏的同步器 更换
仅仅 TLB2 损坏的离合器元件 修理/更换
仅仅 TLB2 损坏的液压系统 修理/更换
仅仅 TLB2 损坏的控制阀 更换
仅仅 TLB2 损坏的压力传感器 检查/更换
仅仅 TLB2 电系统故障 修理/更换
仅仅 TLB2 不规范的 EGM/ECU 操作 更换 EGM/ECU
Mod TLB1 2WD / 4WD 液力变速箱维修手册

F SPECIAL TOOLS
特殊工具
Mod TLB1 2WD / 4WD 液力变速箱维修手册

F.1 Special tools F.1 特殊工具


The special drifts/pad used to assembly the seals, 用来装配密封、轴承和衬套的特殊冲头/衬垫
bearings and bushes should always be used with 应该总能与扳手 CA119033 互换使用的;与
the interchangeble handle CA119033; its use is 适当的安全扳手一起被
recommended togheter with a suitable security 推荐的目的是保护手。
handle in order to protect the hands.
Mod TLB1 2WD / 4WD 液力变速箱维修手册

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