WG180 Transmission Workshop Manual 20124

ADVANCE WG180 Transmission Service Manual
Preface
The Service Manual introduces the transmission removal and assembling process and offers the
transmission service process technology and standard requirements, which can help the service
personnel understand
understan d the transmission removal and assembling methods
met hods more profoundly
profoundl y as well as
lay a solid technical foundation for the service personnel to correctly judge the malfunction and do
troubleshooting.
The Service Manual mainly includes following content:
Chapter I. Introduction
The chapter mainly introduces the transmission service precautions as well as symbol meanings
and common thread tightening torque value in the text.
Chapter II. Transmission System
The chapter mainly introduces the mechanical principles of different gears of the transmission
as well as Gearbox control system Transmission Function Testing and maintenance.
Chapter III. Transmission Removal
The chapter introduces the correct parts removal steps as well as precautions during removal.
Chapter IV. Transmission Assembling
The chapter introduces the correct parts assembling steps as well as precautions during
assembling.
Chapter V. Malfunction Diagnosis and Troubleshooting
The chapter introduces the malfunction diagnosis and troubleshooting of the EST
Semi-Automatic Gear Controller and transmission.
Attention
Due to product improvements, relevant parts in the Service Manual will be subject to change without
further notice. For the newest data and information, please consult with or get them from Shandong
Lingong Construction Machinery Co., Ltd.
Contents
1 Introduction
Introduction .......................................................................................................................................................1
1.1 Safety Precautions ........................................................................................................................................

........................................................................................................................................1
1.2 Instructions of Marks and Symbols ..............................................................................................................3
1.3 Common Bolt Tightening Torque Table .......................................................................................................3
2 Transmission System ..........................................................................

.........................................................................................................................................
............................................................... 5
2.1 Transmission.................................................................................................................................................
Transmission.................................................................................................................................................5
2.1.1 Transm
Transmission
ission Introduction ...................................................................................................................
...................................................................................................................5
2.1.2 Basic Parameters

P arameters of the Transmission-torque Converter Assembly .............
....................................................
.......................................6
2.1.3 Mechanical Principles of the Gears of the Transmission.....................................................................

Transmission..................................................................... 7
2.1.4 Gearbox control system .....................................................................................................................10
2.1.5 Transm
Transmission
ission Function Te
Testing
sting ..........................................................................................................
.......................................................................................................... 20
2.1.6 Operation and Maintenance of WG200 Power Gearshift Transmission............................................22
3 Transmission Removal ....................................................................................................................................

.................................................................................................................................... 27
3.1 Transmission Assembly Removal ..............................................................................................................27
3.1.1 Torque Converter Removal ...............................................................................................................27
3.1.2 Transm
Transmission
ission Control Valve Removal .................................................................................
...............................................................................................
.............. 28
3.1.3 Oil Filter Removal .............................................................................................................................

............................................................................................................................. 29
3.1.4 Removal of the Auxiliary PTO Wheel Hub.......................................................................................29
3.1.5 Input Device Removal .......................................................................................................................30
3.1.6 Removal of the Lubricating Oil Pipe Component and Auxiliary PTO ..............................................31
3.1.7 Dismantle the three Sets of the clutch Assembly .........................................................................

..............................................................................
..... 32
3.1.8 Removal of the Parking Brake and the Output Device ..................................................................... 33
3.1.9Intermediatee Shaft Assembly Removal .............................................................................................. 37

3.1.9Intermediat
3.1.10 Removal of the Torque Converter Pressure Regulating Valve

Valve ........................................................ 38
3.2 Transmission Assembly Component Removal ...........................................................................................39
3.2.1 Main PTO Removal...........................................................................................................................39
3.2.2 Input Component Removal ............................................................................................................... 40
3.2.3Three Sets of the Clutch Removal......................................................................................................45
I
4 Transmission Assembly ..................................................................................................

...................................................................................................................................
................................. 53
4.1 Assembling of the Transmission

Transmission Assembly ................................................................................................ 53
4.1.1 Three Sets of the Clutch Assembly ...................................................................................................

................................................................................................... 53
4.1.2 Main PTO

P TO Assembly .........................................................................................................................
......................................................................................................................... 63
4.1.3 Input Part Assembly ..........................................................................................................................

.......................................................................................................................... 65
4.2 Transmission Assembly ..............................................................................................................................

.............................................................................................................................. 70
4.2.1 Output Part Assembly ....................................................................................................................... 70
4.2.2 Intermediate Shaft Component Assembly ......................................................................................... 73
4.2.3 Torque Converter Pressure

P ressure Control Valve Assembly ........................................................................ 74
4.2.4 Assembling of the K3K4 Clutch Assembly....................................................................................... 74
4.2.5 KRK2 KVK1Clutch Assembly .....................................................................................................

..................................................................................................... 76
4.2.6 Auxiliary PTO

P TO Assembly .................................................................................................................. 76
4.2.7 Input Component Assembly .............................................................................................................. 78
4.2.8 Main PTO Component Assembly ..................................................................................................... 79
4.2.9 Oil Filter Assembly ...........................................................................................................................

........................................................................................................................... 79
4.2.10 Transmission Control Valve Assembly............................................................................................

Assembly............................................................................................ 80
4.2.11 Torque Converter Assembly ............................................................................................................

............................................................................................................ 81
5 Malfunction
Malfunction Diagnosis and Troubleshooting
Troubleshooting ................................................................................................
................................................................................................ 82
5.1Malfunction Diagnosis and Troubleshooting of the EST Semi-Automatic Gear Controller ....................... 82
5.2Malfunction Diagnosis and Troubleshooting of the Transmission.............................................................. 84
II
1 Introduction
1.1 Safety Precautions
Important Safety Precautions

The maintenance and repair is very important for a safe vehicle operation. The Manual
mainly describes the correct removal and assembling technology of the transmission
assembly.
To avoid
avoid person
personal
al injur
injuries
ies,, will
will be
be made
made as the safet
safety
y mark
mark in the Manual
Manual.. The
The
precautionss with shall be paid high attention to. In case
precaution case of potential
potential dangers,
dangers, it is
is
recommended
recommende d to consider the own safety
safety first of all, and then con
consider
sider taking necessary
necessary
safety measures.
Safety Tips
During assembling and removal, wrong operation method will lead to parts damages, service
life shortening, service performance deterioration, and other unsafe factors. Accordingly, when
assembling and removing the parts, it is recommended to carefully read the Manual.
1. All parameters, figures and relevant content in the Manual are applicable for the standard
equipped product. For derivative product, please consult with us or refer to relevant materials.
2. In the repair workshop, the places special for assembling and removal operation and storing
removed parts shall be prepared, and the corresponding tools and parts shall be placed in a
proper site. In addition, the working area shall be kept clean, which shall be free from oil dirt
and pollutants. Smoking is only allowed in the specified place; smoking is not allowed during
operation, and corresponding fire extinguishers shall be prepared.
3. The welding operation can only be conducted by the trained personnel with welding
experience. During welding, welding gloves, retainer, goggles, work cap and other work
clothes applicable for welding operation.
4. Before removing the transmission-torque converter assembly, it is necessary to clean

pollutants on the surface of the transmission-torque
transmission-torqu e converter assembly, so as to av
avoid
oid polluting
the parts during removal.
5. During operation, it is necessary to wear safety boots and safety helmet. It is not allowed to
wear unqualified work clothes; it is necessary to fasten buttons of the work clothes. When
knocking the parts with the copper rod, it is necessary to wear goggles.
6. The gasoline, kerosene and water-based oil stain cleaning agent can be used to clean the
removed parts.
7. When applying the traveling crane or other hoisting equipment, check relevant spreader for
damages first of all, and such hoisting equipment with sufficient hoisting capacity shall be used.
During hoisting,
parts collision. It the appointed
is not allowed hoisting
to work positionareshall
in the area be used
a under for slow
the hoisted hoisting, so as to avoid
parts.
1
Attention
As the torque converter has no axial positioning, it is necessary to prevent its slipping in case of
removal and assembling of the transmission, as shown in Figure 1-1
Figure 1-1
8. In case of simultaneous operation with two or more persons, they shall reach an agreement in
the operation procedures before operation, so as to avoid accidents due to incompatible pace.
9. It is necessary to properly keep all tools and be familiar with their application methods.
10. In case of alignment of two holes, it is forbidden to insert hands and fingers. For parts to be
directly assembled by hand, it is necessary to pay attention that the gripping position is free
from squeezing danger.
11. It is necessary to test the removed parts; the parts whose application performance is affected
shall be replaced with a new one.
12. After assembling, the parts shall be free from interference.
13. When assembling the oil seal and seal ring through the keyway, screw hole and step, it is
necessary to apply relevant protection measures to avoid damages.
14. When assembling the parts, the applied tools shall match with the thread fastener, so as to
avoid damages.
15. When screwing down the connector body and screw plug, it is not allowed to use pneumatic
wrench and other similar tightening tools. It is necessary to screw them down by hand and then
with the torque wrench with corresponding capacity, so as to reach the corresponding torque
value.
16. When draining out fluid in the transmission, it is necessary to slowly screw off the oil drain
plug, so as to avoid fluid spraying.
spra ying.
2
1.2 Instructions of Marks and Symbols

To ensure that the Manual can play a role, it is necessary to use marks specified in Table 1-1
for aspects of the important safety and quality requirements.
Table 1-1
Mark Item Remarks

Special attention shall be given to the safety in case of
operation.
Safety
Special attention shall be given to the safety in case of
operation as there is pressure inside.
Special attention shall be given to the technical requirements
Attention
in case of operation to ensure that the operation is qualified.
Part or device weight or removal and assembling method.
Weight Attention shall be given to selection of the spreader and its
operation posture.
Tightening Special attention shall be given to the tightening torque of
torque the component in case of assembling.
The place which needs adhesive and lubricating grease
Coating
coating.
Oil
Oil and
and wate
waterr Fill
ill tthe
he engi
engine
ne oil,
oil, wate
waterr and
and fuel
fuel with
with cert
certai
ain
n cap
capac
acit
ity
y.
The place needing oil or water draining and draining

Draining
capacity.
1.3 Common Bolt Tightening Torque Table

Table 1-2
Nominal diameter of bolt mm

Bolt strength Yield
strength 6 8 10 12 14
grade
N/mm2
Tightening torque N.m
4.6 24
240 4~5 10~12 20~25 36~45 55~70
5.6 30
300 5~7 12~15 25~32 45~55 70~90
6.8 48
480 7~9 17~23 33~45 58~78 93~124
8.8 640 9~12 22~30 45~59 78~104 124~165
10.9 900 13~16 30~36 65~78 110~130 180~210
12.9 1080 16~21 38~51 75~100 131~175 209~278
Yield
Bolt strength strength 16 18 20 22 24
grade
N/mm2
3
4.6 240 90~110 120~150 170~210 230~290 300~377

5.6 300 110~140 150~190 210~270 290~350 370~450
6.8 480 145~193 199~264 282~376 384~512 488~650
8.8 640 193~257 264~354 376~502 521~683 651~868
10.9 900 280~330 380~450 540~650 740~880 940~1120
12.9 1080 326~434 448~597 635~847 864~1152 1098~1464

Yield
Bolt strength
strength 27 30 33 36 39
grade
N/mm2
4.6 240 450~530 540~680 670~880 900~1100 928~1237
5.6 300 550~700 680~850 825~1100 1120~1400 1160~1546
6.8 480 714~952 969~1293 1319~1759 1694~2259 1559~2079
8.8 640 952~1269 1293~1723 1759~2345 2259~3012 2923~3898
10.9 900 1400~1650 1700~2000 2473~3298 2800~3350 4111~5481
12.9 1080 1606~2142 2181~2908 2968~3958 3812~5082 4933~6577
4
2 Transmission System
2.1 Transmission
2.1.1 Transmission Introduction
The type WG180 (max. transmission power of 180KW) power gearshift transmission is
composed of the hydraulic torque converter and rear-mounted countershaft transmission with
multi-sheet friction clutch. The SDLG 958 959 wheel loader adopts the 4WG180 gearbox
assembly which can realize speed switching between 4 forward gears and 3 reverse gears. The
SDLG G9190 grader adopts the 6WG180 gearbox assembly which can realize speed switching
between 6 forward gears and 3 reverse gears
1 1. Transmission
Transmission control valve
2 2. Oi
Oill filter
filter
3 3. Torque
Torque converte
converterr oil tempera
temperature
ture
4 measuring port
5 4. Transmission
Transmission oil outlet
outlet
6 5. Oil suctio
suctionn pipe
7 6. Transmission housing
7. Rotation
Rotation speed
speed sensor
sensor
Figure 2-1
8 8. Torque converter
9 9. Variable-speed
Variable-speed pump
10 10. Auxiliary PTO
11 11. Clutch (3 groups in total)
12 12. Output shaft assembly
13 13. Parking brake
Figure 2-2
5
2.1.2 Basic Parameters of the Transmission-torque Converter Assembly

Table 2-1
Item 4WG180 6WG180
Single-stage and single-turbine hydraulic

Type
torque converter with three elements
Torque ratio 2.55 2.14

Torque Oil cooling method Circulating water cooling
converter
Torque converter inlet oil pressure
8.5
(bar)
Torque converter outlet oil pressure
5
(bar)
Type Countershaft electro-hydraulic gear shift
Four forward gears
Six forward gears and
Transmission gear and three reverse
three reverse gears
gears
First forward gear 4.278 5.991
Second forward gear 2.368 3.447
Third forward gear 1.126 2.596
Fourth forward gear 0.648 1.494
Transmission
Transmission
Fifth forward gear  1.179
ratio
Sixth forward gear  0.678
First reverse gear 4.278 5.991
Second reverse gear 2.368 2.596
Third reverse gear 1.126 1.179
Variable speed pump type In-built gear pump
Transmission working pressure (bar) 16~18
6
2.1.3 Mechanical Principles of the Gears of the Transmission

1. Construction Principle of Transmission
The actuating mechanism in the gearbox consists of 6 clutches, which are K1, K2, K3, K4,
KV and KR respectively and the KR is reverse clutch. Different gears can be realized through the
combinations, and there are must two clutches working simultaneously at each gear, see figure 4-4
for the working principles of the gearbox.
Figure2-3
2. Hydraulic oil system of transmission
A gear pump as the oil supply of the torque converter and pilot valve is installed within the
transmission and driven directly by engine through power taking-off shaft. With a flow rate of
Q= 35L/1000r/min, the oil pump pumps the hydraulic oil, filtered by a suction filter
(pre-filtration) in the oil circuit , into a screw-in filter (secondary filtration) at the housing top
or any other location of the vehicle, which is away from the transmission and is connected to it
fil ter area 5100cm2 .
by oil pipes. The filter accuracy is 0.025mm and filter
Oil from the filter flows into the pilot valve ; through a pressure-control valve after its working
pressure being limited by a control
contro l pressure valve (main pressure re
regulating
gulating valve).
The role of pressure control valve is to regulate the boost characteristics of clutch cylinder at
the moment of shifting, which means, oil pressure will be reduced instantaneously when
shifting and increased back to 14-18bar (pressure limited by control pressure valve) after
shifting (clutch engaged). This can reduce shift shock to improve shift quality. Hydraulic oil
through pilot valve enters into clutch directly. The shifting valve is fixed by steel balls, springs
and recesses.
Control pressure valve sends those spilled oil into torque converter and lubrication piping while
limiting the maximum working pressure.
7
A pressure limiting valve (with a response pressure of 8.5-10bar) is equipped at the inlet of
torque converter oil circuit to prevent components damage due to high internal pressure in it.
According to the working principle of hydraulic transmission, oil is the medium for conveying
energy within the torque converter. So, in order to avoid cavitation erosion of oil, the converter
cabinet should be always full of oil, which may be realized by the pressure control valve
(backpressure valve with a response pressure of 2.5bar) at the outlet of torque converter oil
circuit. Oil spilled from the converter enters directly into the oil cooler (oil-water or oil- air heat
exchanger).
When a water-cooled engine is applied, the cooler shall be installed in the engine s cooling
water pipe line. An oil-air cooler is applicable when a blower cooled engine is applied, and the
cooler is to be installed at the blasting end of the cooling fan. Cooler assembly and connecting
oil pipe assembly dose not to be supplied by our factory. A bypass valve shall be equipped for
the oil cooler to protect it at low temperature or when blocked.
Oil from the cooler enters directly into the lubrication circuit to supply adequate lubrication
cooling oil to each lubricating point. A pressure shut-off valve can be mounted if required.
The operation of the pressure cut-off valve can be easily controlled by regulating pneumatic
pressure or oil pressure through a second brake pedal. Hydraulic pressure should be not less
than 40bar, and pneumatic pressure not less than 2.5 bar.
The role of a pressure cut-off valve is to cut off the oil pressure of clutch oil circuit, and to
disengage the clutch while the shifting (reversal) valve doesn
doesn t operate. By doing so, all of the
engine power can be provided to the external pump and the shifting valve dose not need to be
positioned at neutral position
pos ition while operating pressure shut
shut-off
-off valve.
8
lo
tr
n
co
ilc
u
ra
d
y
-h
ro
tlce
e
f
o
le
icp
irn
p
ilc
u
ra
d
y
H
-4
2
ig
F
9
2.1.4 Gearb
Gearbox
ox con
control
trol system
The shift control of gearbox is electro-hydraulic control, in our machine: 4WG180
transmission is equipped with EST Semi-Automatic Gear Controller (as shown in figure 2-5),
6WG180 transmission is equipped with SG-6S gear selector (as shown in figure 2-6), the hydraulic
slide valves are controlled by the shift selector and the solenoid valves are connected with the shift
selector to realize shift control in sequence. Do not control the gears in a manner of skipping some
gear. The gear pump used for supplying oil for the torque converter and control valve is installed in
the gearbox and is directly driven by the engine through the PTO shaft, and the flow is Q=35L/min.
The hydrodynamic drive oil enters the variable-speed control valve after the suction oil filter and
pressure control
co ntrol valve in the oil line, and the control pressure
pre ssure of gearbox is 13~18bar. The function
of the pressure control valve is to adjust the pressure rising characteristic of clutch cylinder during
shifting to reduce the shifting impact and improve the shifting quality.
Figure2-5 Figure2-6
1. EST Semi-Automatic Gear Controller
(1) Princip
Principle
le
EST-series gear controller is a electric control system based on EST-4 (four valves) or EST-5
(five valves) electric control unit, as shown in Fig (2-5), having semi-automatic controlling function
of reversing and speed changing.
The system consists of following five sub-assemblies, as shown in Fig. 13-7 and 13-9:
a) Control handle DW
DW-4 (Four-gear
(Four-gear selector),
selector), installed
installed under
under the wheel,
wheel, operated
operated by
left hand
b) Electric control unit EST-4
EST-4 (or -5)
c) Specia
Speciall wire
wire harness
harness and connecto
connectors
rs
d) Solenoi
Solenoid
d valve
valvess on
on contro
controll v
valve
alve
e) Speed sensor (without
(without in current four-solenoid
four-solenoid controller)
controller)
The four subassemblies a) to d) must be used together, with the diagram as shown in Fig.
(2-10) and Fig. (2-12).
The control system is currently used to control transmission model WG180 that matches
loader.
electric Both signals
control unit,from DW-4
which selector
analyses andanddetermines
other fromsignals
vehiclecomprehensively
electric circuit areand
input to EST-4
then as per
control request to the transmission, outputs corresponding voltage to solenoid valves on
10
transmission control valve. The solenoids combination control related oil circuit, then hydraulic oil
pushes related
r elated clutch,
clu tch, thus realizing operation
ope ration on direction
dire ction and
an d gear. In addition, the EST-4 electric
control unit outputs four signals to vehicle circuit, including neutral signal AS (for starting
interlock), reverse signal RF (for reversal indication), forced gear-down indication (H1) and
alarming indication (H2). Refer to Function Sheet of EST-4 Output Signals Signals  for details. All of
them are plus output, i.e. +24V.
+24V.
EST-4 electric control unit possesses functions of measurement and protection. Before using,
connect plugs of all leading-out cables. As for those to vehicle circuit, except for positive and
negative wire of power supply, that of starting interlock signal AS must also connected and others
may depend on. If any solenoid valve did not connect, or short circuit occurred, or power supply
was abnormal, the unit would lock all outputs except alarming signal (light H2 flashing and ticking
inside). At the time, cut off the power supply and eliminate faults.
About operation of this control system, gears and direction can be changed by moving the
handle of selector DW-4, additionally, brake signal BR and emergent brake BR2 in vehicle circuit
can also affect controller output. At first and second gears in forward or backward, if any of the two
signals is connected to +24V, outputs of EST-4 are identical to neutral of corresponding gear of
DW-4.
Technical Dada: Table2-2
Rated voltage DC 24V
Working voltage range DC 2032V
Input current Max.5A
Output signal current Max. 0.5A for each
Working temperature -20+70
Storage temperature -40+80
(2) Operati
Operation
on
Before starting vehicle engine, put the handle of gear selector DW-4 at  N
N position, or the engine
cannot be started. If it is the first time to operate the selector DW-4 after being electrified, the handle should also
be put at neutral position first
first and then moved to rrequired
equired gear
gear,, or not, the EST-4
EST-4 will have no signal output.
output.
a) Push or pull handle horizontally to change moving direction, including F (forward), N (neutral) and R
(reversal); rotate the handle to change gears, anti-clockwise for gearing-up and clockwise for gearing down. The
operation force needs not too big. Numbers 1, 2, 3 and 4 on the handle indicate positions for four gears, among
which gear 1 is slowest and 4 fastest.
b) This controller has the function of forced gear-do

gear-down
wn (KD): when DW-r selector is at gear 2 in forward or
backward, press the handle forward once, the gear will be change to 1, at the same time light H1 will flash. The
function is invalid in other gears other than 2. It can be relieved by taking any of following measures: (1) press the
handle again; (2) turn the handle to change gear; (3) take reversal operation; (4) change to neutral.
c) During the vehicle running at gear 1 or 2, in case of foot braking and emergent braking, signals output from
ECU are identical to that of corresponding neutral position. Releasing the braking switch, original gear will be
back to immediately.
immediately. However
However,, if in gear 3 or 4, braking
braking is invalid.
11
d) When the vehicle parking, put the handle of gear selector DW-4
DW-4 at  N
N position.
e) If alarm occurs during vehicle running (the vehicle does not run; light H2 flashes and ECU ticks), shift the
handle to neutral (N), if the alarm is eliminated, continue to normal operate; if not, it means there are troubles in
wiring. Cut off power supply and check thoroughly.
thoroughly. Reconnect power after removing the troubles.
Measurement of Main Components

(a) Measurement of solenoid valves: the resistance of the solenoid valves is around 60 ~ 70 ohm (4-valve).
Before measuring with a multi-meter, cut off the power supply and remove the round plugs connecting to the
control valve. If the read is out of the specified range, it means the valve has failures and should be replaced.
(b) Measurement of speed sensor: use a multi-meter to measure the resistance after cutting off power supply.
supply.
Measure the resistance between two pins, which is normal if within 1.02K to 1.2K. If the read is 0 or infinite, it
means the sensor is damaged and needs to be replaced. Besides, check if its location suitable, which requiring the
space between top plane of the sensor and inspection gear top being 0.5 ~ 0.8mm. By wresting forwards to the end
and then backwards half circle, the space should be basically suitable.
(c) Measurement of brake switches: pressured switches for both foot brake and emergent brake are to use
constant-open contacts, the resistance of which is measured as infinite. When stepping on the brake switch, the
read should be 0.
(d) Measurement of gear selector DW-4: Measurement should be done with a special inspection box supplied
by the company.
company. Insert pins on DW-
DW-4 4 into 8-core sockets of the device and electrify with DC 24V (red line to
+24V and yellow one to ground). There are 8 lamps on the box, indicating respectively 8 conditions of DW-4.
Rotating the selector handle, lamps for gears 1~4 light; shifting the handle, lamps for forward
forward, neutral
neutral and
reverse
reverse light; pressing the handle, lamp KD
KD light. If normal, it means the selector has no trouble. If any does
not meet requirements mentioned above, the selector should be replaced.
(e) Measurement of EST-4 ECU
Measurement of EST is also realized with a special inspection box supplied by the company. Connect the
35-needle plug of the leading-out cable of the box to the socket of EST, by the manner that: hitch the pin at
end-cover of the inspection box with the hook at one end of the plug, aiming at the plug, press tightly until the
other end of the plug is fixed by the spring leafs. To the 8-core square plug of the leading-out wire, connect a
DW-4
DW-4 selector. Electrify the inspection box with a DC 24V power (red one to +24V and yellow one to minus). Set
DW-4 at neutral gear two, four lamps M1-M4 on the box will flash once as it is electrified and then only M2 lights.
DW-4
Rotating or shifting the selector handle, 8 lamps should change according to the function table.
Function Table of EST-4 Output Signals
Table2-3
Gear Forward Reverse Neutral
Output 1 2 3 4 1 2 3 4 01 02 03 04
M1     
M2   
M3       
M4      
AS    
12
RF    
H1 Light in KD condition
Flash when having alarm or light when the sensor is disconnected for
H2
types with speed sensor.
Indicates having signal output, lamp lights
2. SG-series Gear Selector

(1) Princ
Princip
iple
le
Shown as the outside view Fig (2-6), the selector works on the principle as follows: the handle moves the
slotted cylinder turning, thus selecting expected gear
gear.. Up- or down-ward (or left- or right-ward) movement of the
handle can determine running direction: Forward, Backward and Neutral. First, an optical sensor detects position
of the handle; the signal is amplified and combined as a code
demanded by this expected gear, and then output to a hydraulic control valve inside the transmission, thus pushing
corresponding clutch and making output speed of the transmission meeting the selected gear. Power for the
selector is supplied by vehicle electrical system, with working voltage being stable DC 24V. Gen
Generally
erally,, the storage
cell on the vehicle and the DC generator can satisfy the power demand.
Connection between selector and external circuit is realized by a 20-core cable with two plugs, one with
suspension fuse connects to vehicle electrical system and the other to control valve of the transmission. Electrical
diagrams for various selector models are shown as Fig. (2-7) and (2-8).
Technical
echni cal Data Table2-4
able2 -4
Rated voltage DC 24V
Working voltage range DC 2032V
Input current Max. 5A
Output signal current Max. 0.5A for each
Working temperature -20+70

Storage temperature -40+80
13



m
a
rg
a
i
d
g
rin
W
S
-6
G
S
-7
.2
gi
F
e
d
o
c
-
F
14
g
ni
ck
ol
h
ti
w
-6
S
G
S
f
o
m
a
rg
a i
d
g
n
rii
W
-8
.2
gi
F
15
9
-2
gi
F
16
0
-1
.2
g i
F
17
-1
.2
gi
F
18
2
1
-
.2
g
i
F
19
2.1.5 Transmission Function Testing

1. Test of electro-hydraulic controlled transmission
Attention
The test shall not be done until the transmission temperature reaches 80 95 and
the engine is at the maximum speed.
2/13
KV
K1 G
1 KR
3/14 K2
4 K4
5 K3
Figure2-13
7 12
8 11
9 10
Figure2-14
(1) Testing points for oil pressure: 1= torque converter inlet port pressure 3= torque converter outlet port
pressure 6= steering pressure 10=pressure of clutch KV 11=pressure

11=pressure of clutch KR 7=pressure
of clutch K1 8=pressure of clutch K2 9=pressure of clutch K3 12=pressure of clutch K4
(2) Testing points for temperature: 3=torque converter outlet port
20
Electrical measuring points: G=coil pick-up Steering valve (24V)
Testing points for flow rate2=filter inlet port 13=filter outlet port
(3) Testing 50L/min)
port (minimum flow rate is 50L/min)
4= cooler inlet port6=cooler outlet port (minimum flow rate is 40L/min)
Connection thread of each testing points: 161078912


M10×114

M14×1.5
213

M26×1.545

M30×1.5.
Table2-5
Figure2-15
21
2.1.6 Operation and Maintenance of WG200 Power Gearshift Transmission

1. Application precautions
(1) When checking the transmission oil level, the engine shall run at idle speed (about 1000 rpm)
and the oil temperature shall be kept at the normal working temperature;
(2) When the oil temperature is 40 , the oil level shall be between the middle and lower scale lines
of the oil dipstick.
When the oil temperature is 80 , the oil level shall be between the middle and upper scale lines of
the oil dipstick.
(3) Strictly follow the maintenance requirements and periodically replace the transmission oil and
the filter.
(4) Before starting the vehicle engine, ensure that the control handle is at the neutral gear.
(5) Before every traveling, loosen the parking brake (release the brake).
(6) In case of engaging or separating the engine and the transmission and lifting the transmission,
try to avoid torque converter detachment.
(7) During parking, the gearshift handle shall be turned to the neutral gear.
(8) The normal working oil temperature shall be kept between 80110; when bearing the heavy
load, it can rise to 120  in a short time. It is necessary to pay special attention to the control oil
pressure of the transmission. If transmission
transmissio n is discovered to be abnormal during
d uring use, it is necessary
nec essary
to stop the vehicle for check.
(9) When the vehicle has malfunction and needs electric welding maintenance, it is necessary to
remove the cable plug on EST computer controller (cut off the circuit leading to the computer
controller); or else, the computer controller may be burnt due to impact current during electric
welding.
2. Operation
(1) Preparations and maintenance before traveling
Before transmission operation, it is recommended to properly fill the lubricating oil with
specified specification. In case of initial oil filling of the transmission, it is necessary to
consider that the oil radiator, filter and connecting pipe shall be filled with oil. Accordingly, the
lubricating oil in the first filling shall be much more than that for the subsequent normal
maintenance. As the torque converter oil on the vehicle will flow to the transmission via the oil
radiator and oil pipe under a stationary state, the oil level shall be correctly controlled under the
thermal equilibrium temperature in case of neutral gear engagement upon parking, idle engine
running and normal transmission operation.
The oil level can be tested when the control handle is turned to the neutral gear. When checking
the oil level, it is necessary to insert the oil dipstick to the lower limit of the oil pipe. When
cleaning the main oil circuit filter, pay attention that no dirt and sediment can enter into the oil
circuit. In addition, it is necessary to place a cover plate to prevent the parking brake from oil
immersion.
22
When installing the filter, it shall not be screwed down too tightly.
(2) Traveling and gear shift
In case of engine start, it is necessary to confirm that the gearshift handle is turned to the
neutral gear. For the sake of safety, before engine start, the parking brake shall be in a brake
state, so as to ensure that the vehicle will not be started due to engine start. After engine start,
release the parking brake; properly select the traveling direction and gear; slowly throttle up the
vehicle for start. In case of vehicle traveling, the torque converter will replace the function of
the main clutch. When the road conditions are good, the vehicle can be driven with a high gear.
If the vehicle is stopped but the engine still runs and the transmission gear is engaged, the
engine will not be stopped. For some traction force may be produced when the engine passes
the torque converter at idle speed, the vehicle may crawl on a straight pavement. The rational
method is to turn the parking brake to a brake state upon each parking.
To park the vehicle for a long time, the control handle shall be turned to the neutral gear.
During traveling, it is recommended to loosen the parking brake of the vehicle. From
experience, we draw a conclusion that the operator is hard to immediately find out that: When
the torque converter speed changes, due to large output torque ratio of the torque converter, the
vehicle can overcome the brake torque and forcedly travel even under the normal operation
conditions. The consequence is that the torque converter oil temperature will rise and the brake
will become too hot.
Due to impact of the torque converter, when shifting to low speed gear from the high speed
gear, the engine rotation speed will increase, specially the gear shift with skipping a grade.
Accordingly, if conditions permit, when shifting to low speed gear from the high speed gear,
firstly step down the foot brake; perform deceleration slowly and then shift gear. When the
vehicle travels at high speed and the traveling direction is changed, it is necessary to reduce the
engine rotation speed.
(3) Suspension and parking
As there is no rigid connection between the engine and the torque converter output shaft, when
the vehicle is parked on the slope (upslope or downslope) while the driver wants to leave the
vehicle, to avoid vehicle sliding, we recommend to apply the parking brake and place stop
blocks under wheels.
(4) Dragging
The max. dragging speed is 10km/h and the max. dragging distance is 10km.
When the distance is longer, the vehicle with malfunction shall be placed on other vehicle for
transportation.
(5) Oil temperature
The transmission oil temperature shall be monitored with the temperature sensor. The max. oil
temperature of the torque converter outlet shall not be higher than 120 ; the normal control
component and the transmission with sufficient traveling mileage will not have higher temperature.
If the oil temperature is higher than 120, the vehicle shall be stopped for oil leakage check. And,
the transmission shall be turned to the neutral gear and the engine shall run at 1200~1500rpm. In
23
such case, the oil temperature will quickly reduce to the normal value (within about 2~3 min.). If
               
be continued after troubleshooting.
troubl eshooting.
Normal gear shift oil pressure range:

ran ge: 1.6~1.8MPa (16~18bar). To monitor the control pressure,
pres sure,
it is necessary to install a pressure gauge or pressure monitoring meter. In case of engaging
some gear and applying the clutch but the pressure drops to the min. pressure lower than the
specified
necessary pressure (the pressure Ifwill
to do troubleshooting. the quickly drop temporarily
control pressure is too low,inthecase of will
clutch gear be
shift), it is
damaged,
for the clutch without sufficient contact pressure will make the friction lining continuously slip
and become too hot.
3. Maintenance
(1) Oil level check
 Park the vehicle in a flat place
   

     
  
  
     
   
the brake position.
 Idly run the engine with about 1000rpm
 Counterclockwise loosen the oil dipstick and then

take it out and wipe it off
 Insert the oil dipstick in the oil level pipe and

screw it down; keep it for about 3s after reaching the
target position, and then take it out (twice measurement
at the least)
 At 40, the oil level shall be between the lower

     
 At 80, the oil level shall be between the upper

     
The cold vehicle oil level check is only to ensure that the
transmission and the torque converter have sufficient
circulating flow. The final standard to determine the oil
level is to meet the hot vehicle oil level requirements. Figure2-16
Attention
If the oil level is lower than the min. scale, it is necessary to fill the recommended lubricating
oil till the oil level rises to the correct scale range of the corresponding temperature (see
Figure 2-16).
(2) Oil replacement
When the vehicle reaches the first 100 working hours, the first oil replacement shall be done.
After that, the oil replacement shall be done once every 1000 working hours or every year.
During oil replacement, it is recommended to stop the vehicle in a flat place; keep the
24
transmission at the working temperature; take out the oil drain plug and seal ring, and drain out
residual oil.
Start the engine and run it at idle speed
     

     
         

   
Turn the parking brake to the safe position
Select all gears once
Check the oil level again
If necessary, fill oil again
 At 40              
At 80              
Oil Replacement Period Table: Table 2-6
First oil Normal oil Oil level

Part name Oil product standard
replacement replacement check
Upon every 1000
Upon 100
working hours,
working hours,
not longer than ADVANCE HC-WG01 Before
Transmission(WG180) the filter shall
one year, and the private oil daily use
also be
filter shall also be
replaced
replaced
Other optional oil product: Table 2-7
Specification and Standard of Permissible Oil Gradein case there is no HC-WG01 private
oil available
American petroleum institute API CF-4/CG-4/CH-4 SAE15W-40European automobile

manufacturer association ACEA E2-9615W-40ZF TE-ML03 SAE15W-40American
automobile engineer association SAE 306 SAE15W-40Caterpillar T0-4 SAE15W-40
Caterpillar
Fuchs
Fuc CF-4/ SAE15W-40
hs CF-4/
CF-4/ SAE15W-40
Mobill 1300 CF-4/
Mobi
25
(3) Oil filter replacement
In case of each oil replacement, ZF coarse filter shall also be replaced. The replacement
requirements are as follows:
Coat the seal ring with a thin layer of oil
Press down the filter till it contacts with the sealing surface of the transmission; after that,
screw it down for 1/3 to 1/2 circles by hand
Fill oil
Start the engine
When the engine idly runs (about 1000rpm) and the transmission oil has a working
temperature, check the transmission oil level.
When the oil temperature is 40          
When the oil temperature is 80          
Check if it is screwed down. If necessary, screw it down by hand again.
26
3 Tran
Transm
smis
issi
sion
on Remo
Remova
vall
3.1 Transmission Assembly Removal
3.1.1 Torque Converter Removal
1. Pull out the intermediate
intermediate ring
ring and the
the torque
converter from the transmission; completely
drain out residual oil in the torque converter and
place it aside.
about 20kg
1 2
Figure 3-1
1 Torque converter
2 Intermediate ring
2. Remove the
the bolt connecting
connecting with
with the shell and
the transmission.
1 2
Figure 3-2
1 Hexagon screw ×14
2 Tension pin
27
3.1.2 Transmission Control Valve Removal

1. Remo
Removeve socke
sockett heat
heat bolts
bolts 10-
10-M8×45 
M8×45
6-M8×75from the pilot valve with a M8 socket
head wrench.
Attention
      

      
bolts.
Pay attention to keep the valve spacer intact
while taking off the pilot valve.
Figure 3-3
1 pilot valve
2. Remove the six oiloil pipe on the oil
oil delivery
delivery
plate one by one.
one . They are K2, K1, K3, K4, KR,
KV, from the top down, among which pipe KV
and KR change according to the rotation of back

axles from different machine factories.
In addition, remove the oil passage connector on
the clutch
clutch shafts and take
take down six oil pipes.
pipes.
Attention
Do well in oil pipe connect
connector
or protecti
protection,
on, and
1 2 mark the oil pipe number with the marker.
Figure 3-4 After removing the connectors, do well in
their cleaning and protection.
1 Oil pipe connector
connector of the oil passage plate
2 Oil passage connector of the clutch shaft

shaft
3. Take
Take off
off socket
socket head bolts 3-M8  45 and
bolts 3-M8
6-M835 connecting
connecting the plate
plate and the housing,
housing,
then remove the oil delivery plate and the baffle
plate and put them aside.
Attention
      
      
bolts.
After removing the oil passage plate, do well
in its cleaning and protection.
protection.
1
Figure 3-5
1
Oil passage plate
28
3.1.3 Oil Filter Removal

1. Rotate the
the oil filter
filter with the belt
belt spanner
spanner for
removal.
Figure 3-6
1 Belt spanner
3.1.4 Removal of the Auxiliary PTO Wheel

Hub
1. Take down the bolt between
between the auxiliary
auxiliary PTO
wheel hub and the transmission body.
1 2
Figure 3-7
1 Hexagon head screw
2 Auxiliary PTO wheel hub
2. After
After pushing
pushing out
out the wheel
wheel hub
hub with
with the
crowbar and taking
taking down the
the PTO
PTO wheel
wheel hub
and its seal ring, the removal is completed.
1 2
Figure 3-8
1 Auxiliary PTO wheel hub
2 Cr
Crow
owba
barr
29
3.1.5 Input Device Removal

1. Remove the hexagon
hexagon bolts between
between thethe pump
impeller bearing seat and the oil feed flange.
1 2 3
Figure 3-9
1 Oil feed flange 2 Pump impeller
bearing seat
3 Hexagon head screw (M8*28)×8
2. Slight
Slightly
ly knock
knock the
the bearing
bearing seat
seat with
with the
the
copper rod for loosening.
Take down the bearing seat and the packing.
1 2
Figure 3-10
1 Pump impeller bearing seat
2 Packing
3. Take down
down the bolt between
between the
the main PTO
wheel hub and the transmission body.
1 2
Figure 3-11
1 Hexa
Hexag
gon head
head scre
screw
w ×10
×10
2 Main PTO wheel hub
hub
30
4. Hold
Hold one about
about mm copper rod by
left hand to
to jack up the variable speed pump
pump end
cover, and hold another copper rod by right hand
to knock out the oil feed flange and the variable
speed pump component and place them aside.
Attention
The copper rod shall be used to slightly knock
the oil feed flange and the variable speed
pump component, so as to avoid component
slipping.
1
Figure 3-12
1 The bar copper with stands the spot
3.1.6 Removal of the Lubricating Oil Pipe

Component and Auxiliary PTO
1. Respectively
Respectively screw
screw off hollow bolts (M18)
(M18) at
both ends of the transmission lubricating oil pipe
and then take out the oil pipe.
1
Figure 3-13
1 Lubricating oil pipe component
2. Take down
down the snap ring
ring from the PTO
PTO shaft
with the snap ring pliers.
1 2
Figure 3-14
1 Snap ring
2 Snap ring pliers
31
3. Knock out
out the PTO
PTO shaft with
with the copper
copper rod
and take down the PTO driving gear.
1 2 3
Figure 3-15
1 Driving gear 2 PTO shaft
3 Retainer ring
4. The auxiliary
auxiliary PTO removal
removal is completed.
completed.
1
Figure 3-16
1 Ball bearing 3.1.7 Disma
Dismantle
ntle the three Sets of the clu
clutch
tch
Assembly
1. Remove
Remove the three bolts connecting
connecting each
each clutch
shaft with the housing.
1 2 3
Figure 3-17
1 Clutch shaft K3+K4 2 Clutch shaft K2+KR
3 Clutch shaft K1+KV
32
2.Pull
2.Pu ll ou the K1K2K3 clutc
outt the clutch
h shaf
shaftt with
with
tooling
Attention
Put the clutch adjusting plate under the shaft
end after pulling out each set of clutch for
general
general assembly
assembly..
When taking out the clutch assembly, place

the transmission
transmission in a proper
proper position,
position, and the
the
operation shall be slow to avoid slipping.
1 2
Figure 3-18
1 Clutch shaft removal tooling
2938001828 2938001829
3.1.8 Remov
Removal
al of the Parkin
Parking
g Brake and the
Output Device
1. Take
ake the
the safe
safety
ty plat
plates
es 2-M1
2-M10×
0×30
30 off
off the
the
output shaft
shaft on the hand brake
brake end, screw off
off the
two bolts
bolts and remov
removee the hand
hand brake
brake and the
hand brake flange assembly together with a bob
crowbar.
Attention
1 When removing, the force shall be slow and

sufficient, and protection measures shall be
Figure 3-19
taken to avoid spring detachment.
1 Parking Brake
2. Take out the oil seal

seal from the output devi
device.
ce.
Attention
When taking out the oil seal, the force shall be
uniform and sufficient to avoid damages. And,
the special removal tooling can also be used.
1
Figure 3-20
1 Oil seal
33
3. Take down
down the lock
lock washer
washer and remove
remove the
the
bolt between the pressure plate and the output
flange.
1 2
Figure 3-21
1 Lock washer
2 Hexagon head screw×2
4. Take down the pressure
pressure plate
plate,, distance
distance washer
and O-ring in turn.
1 2 3
Figure 3-22
1 Pressure plate 2 Distance washer
3 O-ring
5. Take down
down the output
output flange.
flange.
1
Figure 3-23
1 Output flange
34
6. Take down
down the
the oil seal.
seal.
Attention
When taking out the oil seal, the force shall be
uniform and sufficient to avoid damages. And,
the special removal tooling can also be used.
1
Figure 3-24
1 Oil seal
7. Remove
Remove the front
front end bearing
bearing snap
snap ring and
and
compensation washer of the output shaft with the
snap ring pliers.
1 2
Figure 3-25
1 Snap ring
2 Compensation washer
8. Knock the rear
rear end of the output shaft with
with the
copper rod.
1 2
Figure 3-26
1 Rear end of the output shaft

2 Copper rod
35
9. Take down the

the output shaft,
shaft, bearing
bearing and shaft
sleeve.
1 2 3
Figure 3-27
1 Bearing 2 Output shaft
3 Shaft sleeve
10. Take out the output gear
gear and remove
remove the bolt
between the retainer, oil shield and transmission
body.
1 2 3
Figure 3-28
1 Output gear 2 Connecting retainer
11. Take out the

the oil shield
shield and the retainer.
retainer.
1 2 3
Figure 3-29
1 Output gear 2 Oil shield
3 Retainer
36
3.1.9Interm
3.1.9Intermediate
ediate Shaft Assembl
Assembly
y Remov
Removal
al
1. Remove the sealing
sealing washer.
washer.
Figure 3-30
1 Sealing washer
2. Remove
Remove thethe bolt betwe
between
en the int
interm
ermedia
ediate
te
shaft and the transmission body.
Figure 3-31
1 Head cap screw
3. Take out the intermediat

intermediatee shaft and the O-ring.
O-ring.
1 2
Figure 3-32
1 Intermediate shaft
2 O-ring
37
4. After taking
taking out the intermediate
intermediate shaft
shaft and the
bearing component, the removal is completed.
co mpleted.
1 2
Figure 3-33
1 Intermediate shaft gear
2 Roller bearing
3.1.10 Rem
3.1.10 Remova
ovall of the Torqu
Torquee Conv
Convert
erter
er
Pressure Regulating Valve
1. Remove the
the screw plug fixing the valve
valve sleeve
component.
1 2 3
Figure 3-34
1 Valve sleeve component
2 Screw plug (CM30*1.5) 3 O-ring
2. After taking
taking out the valve
valve sleeve
sleeve components
components
(valve sleeve, valve stem, pressure spring and
gasket) from the torque converter pressure valve
hole of the transmission body, the removal is
completed.
1 2 3
Figure 3-35
1 Pressure spring 2 Valve stem
3 Valve sleeve
38
3.2 Trans
Transmi
missssio
ion
n As
Asse
semb
mbly
ly
Compone
Com ponent
nt Removal
Removal
3.2.1 Main PTO Removal
1. Remo
Removeve the
the retai
retainer
ner rin
ring
g fixing
fixing the
the drivi
driving
ng
gear on the PTO shaft with the snap ring pliers.
1
Figure 3-36
1 Retainer ring
2. Remove thethe snap ring fixing

fixing the inner
inner ring of
the ball bearing on the PTO shaft.
1 2
Figure 3-37
1 Snap ring
2 Ball bearing
3. Expand and fix the ball

ball bearing elastic
elastic retainer
ring with the screwdriver and knock the PTO
shaft from another side.
1
Figure 3-38
1 Elastic retainer ring ×2
39
4. Take down
down the driving gear,
gear, PTO
PTO shaft
shaft and
ball bearing.
1 2 3
Figure 3-39
1 Driving gear 2 PTO shaft
3 Ball bearing
5. After taking
taking down two retainer
retainer rings fixing the
needle bearing on the PTO wheel hub and
removing two elastic retainer rings fixing the
ball bearing, the removal is completed.
complete d.
1 2
Figure 3-40
1 Retainer ring
2 Needle bearing
3.2.2 Input Component Removal

1. Remove 4 bolts between the variable
variable speed
speed
pump and the oil feed flange.
Figure 3-41
40
2. Remove 4 bolts between the variable

variable speed
speed
pump and the oil feed flange.
Figure 3-42
3. Knock the output

output shaft
shaft with the
the copper rod to
knock out the variable speed pump.
12
Figure 3-43
1 Copper rod
2 Output shaft
4. Take down
down the variable
variable speed pump,
pump, packing
packing
and output shaft and remove the bolt between the

variable speed pump cover and the variable
speed pump shell.
1 2
Figure 3-44
2 Output shaft
41
5. Take down the bearing

bearing snap ring
ring from
from the
the
output shaft with the snap ring pliers and remove
the ball bearing, piston ring and compensation
washer.
1 234
Figure 3-45
1 Ball bearing 2 Piston ring (30×2)
3 Snap ring 4 Compensation washer
6. Knock the output

output shaft with the
the copper
copper rod
and take down the variable speed pump cover,
internal gear and other component.
1 2
Figure 3-46
1 Variable speed pump shell
2 Variable speed pump cover
7. Remove the internal

internal gear of the variable speed
pump, output shaft, variable speed pump cover
and ball bearing.
1 2
Figure 3-47
1 Internal gear of the variable speed

pump
2 Variable
Variable speed pump cover
cover
42
8. Take out
out the external
external ring gear of
of the variable
variable
speed pump.
1 2
Figure 3-48
1 Variable speed pump shell
2 External ring gear
9. Take down
down the safety
safety valve of the
the oil inlet
inlet of
the torque converter on the oil feed flange, steel
ball and pressure spring.
1 2
Figure 3-49
1 Steel ball
2 Pressure spring
10. Take
Take down
down the snap
snap ring
ring fixing
fixing the
the ball
bearing on the drive shaft with the snap ring
pliers.
Figure 3-50
1 Snap ring
43
11. Knock the drive

drive shaft with the
the copper rod for
removal.
1 2
Figure 3-51
1 Drive shaft
2 Copper rod
12. Take down

down the driving gear,
gear, ball bearing
bearing and
roller bearing.
1 2 3
Figure 3-52
1 Roller bearing 2 Driving gear
3 Ball bearing
13. Remove
Remove the
the plunger
plunger ring
ring from
from the
the drive
drive
shaft.
1 2
Figure 3-53
1 Drive shaft
2 Plunger ring
44
3.2.3Three
3.2.3Three Set
Setss of the Clu
Clutch
tch Remo
Removal
val
Attention
The KVK1 and KRK2 clutch

disassembling process can follow the
K3K4 clutch assembling process, which is
omitted here.
1. Take
Take down
down the K4 clut
clutch
ch gear
gear bearing.
bearing.
Place the bearing aside.

1
Figure 3-54
1 Needle bearing
2. Take down
down the lining seal
seal ring component
component and
roller of the needle bearing of the K3 clutch gear.
1 2
Figure 3-55
1 Roller×12
2 K3 clutch gear
3. Take down
down the gear, washer
washer and thrust washer
washer
of the K3 clutch.
1 2
Figure 3-56
1 Washer
2 Thrust washer
45
4. Take down
down the gear
gear and thrust
thrust washer
washer of the
K4 clutch.
1 2 3
Figure 3-57
1 Thrust washer 2 K4 clutch gear
3 Thrust washer
5. Take down
down the elastic
elastic retainer
retainer ring of the
the K4
clutch.
Figure 3-58
1 Elastic
Elastic retainer
retainer rring
ing
6. Take out the bearing

bearing plate of the K4 clutch.
clutch.
Figure 3-59
1 Bearing plate
46
7. Take out thethe external

external and internal
internal friction
friction
linings of the K4 clutch.
1 2
Figure 3-60
1 Internal friction lining
2 External friction lining
8. Install
Install the clutch tooling
tooling onto the clutch.
clutch.
1
Figure 3-61
1 Clutch spring removal tooling
2938001826 2938001827  9. Screw down the
the tooling
tooling nut and
and press down
the clutch spring.
1 2
Figure 3-62
2 Pressure spring
47
10. Take
Take down
down the retai
retainer
ner rring
ing fixin
fixing
g the
pressure spring with the snap ring pliers.
p liers.
1
Figure 3-63
1 Retainer ring
11. Take out the retainer
retainer ring and
and the guide
guide ring
of the K4 clutch in turn.
1 2
Figure 3-64
1 Retainer ring
2 Guide ring
12. Take
Take out the
the upper
upper guide
guide ring,
ring, press
pressure
ure
spring and lower guide ring on the K4 clutch in

turn.
1 2
Figure 3-65
1 Guide ring
2 Pressure spring
48
13. Take out the piston and seal ring

ring of the
the K4
clutch.
1 2 3
Figure 3-66
1 Seal ring 2 K3 clutch piston
3 Seal ring
14. The removal
removal of the K4 clutch is completed.
completed.
Figure 3-67
15. Take out
out the elastic
elastic retainer
retainer ring of the K3
clutch bearing plate.
Figure 3-68
1 Elastic retainer ring
49
16. Take out the

the K3 clutch
clutch bearing plate.
plate.
1
Figure 3-69
1 Bearing plate
17. Take out thethe external
external and
and internal
internal friction
linings of the K3 clutch.
1 2
Figure 3-70
18. Press down the K3

K3 clutch
clutch pressure
pressure spring
with the clutch spring removal tooling.
1 2
Figure 3-71
2 Pressure spring
50
19. Take
Take down
down the retai
retainer
ner rring
ing fixin
fixing
g the
the
pressure spring with the snap ring
rin g pliers.
1
Figure 3-72
1 Retainer ring
20. Take out the retainer
retainer ring and
and guide ring
ring of
the K3 clutch in turn.
1 2
Figure 3-73
1 Retainer ring
2 Guide ring
21. Take
Take out tthe
he upper
upper guide
guide ring,
ring, pressure
pressure
spring and lower guide ring of the K3 clutch in
turn.
1 2
Figure 3-74
1 Guide ring
2 Pressure spring
51
22. Take out

out the piston
piston and seal
seal ring of the K3
clutch.
1 2 3
Figure 3-75
1 Seal ring 2 K4 clutch piston
3 Seal ring
23. Remove the needle

needle bearing
bearing and check
check valve
of the K3K4 clutch.
1 2
Figure 3-76
1 Check valve
2 Needle bearing
24. The K4 clutch

clutch removal
removal is completed.
completed.
Figure 3-77
52
4 Transm
Transmiss
ission
ion A
Asse
ssembl
mbly
y
4.1 Assembling of the Transmission
Assembly
4.1.1
4.1.1 Thre
Threee Set
Setss of the Cl
Clutc
utch
h Ass
Assemb
embly
ly
Attention
The KVK1 and KRK2 clutch assembling process
can follow the K3K4 clutch assembling process,
1 2 which is omitted here.
Figure 4-1 1. Knock

Knock the
the needle
needle beari
bearing
ng into
into the
the clutch
clutch
1 Retainer ring bearing hole and install the retainer
re tainer ring.
2 Needle bearing Attention

Before assembling, clean all parts.
2. Install the seal ring

ring into the piston
piston groove
groove and
install the piston component into the clutch
cylinder.
Attention
When installing the seal ring, the sealing
surface of the seal ring shall face towards the
pressure oil surface.
1 2
Figure 4-2
1 Seal ring
2 Seal ring
1 2
Figure 4-3
1 Pressure oil surface

2 Friction lining
53
3. Place the guide

guide ring and the pressure spring
into the clutch cylinder.
1 2 3
Figure 4-4
1 Guide ring 2 Pressure spring
3 Guide ring
4. Place the
the guide ring and
and the retainer
retainer ring into
into
the clutch cylinder.
1 2
Figure 4-5
1 Guide ring
2 Retainer ring
5. Install
Install the
the spring
spring remova
removall and assem
assemblin
bling
g
tooling onto the clutch.
1
Figure 4-6
1 Clutch spring removal and assembly

tooling
tooling (293800
(2938001826
1826)) (2938001
(2938001827)
827)
54
6. Screw down the nuts on the tooling

tooling and
and press
down the clutch spring.
Figure 4-7
7. Install
Install the retainer
retainer ring into the clutch
clutch cylinder
clip groove with the snap ring pliers.
Take down the clutch spring removal and

assembling tooling.
1 2
Figure 4-8
1 Retainer ring
2 Snap ring pliers
8. Firstly,
Firstly, place the external friction
friction lining into
into
the K3 clutch.
Attention
During use, if the external friction lining of
the clutch is worn out and more than 2/3 parts
of the pattern groove of the friction lining are
worn out, timely replacement shall be done.
Figure 4-9

55
9. Place the
the internal
internal friction
friction lining into the K3
K3
clutch.
Attention
Firstly, place the external friction lining into

into
the K3 clutch and then place the external and
internal friction linings in turn. Total:
K3 clut
lutch (10 ext nal  9 internal)friction
exteernal
linings
K4 clutch (9 external  8 in
inte
tern
rnal
al)f
)fri
rict
ctio
ion
n
linings
1
inte
tern
rnal
al)f
)fri
rict
ctio
ion
n
Figure 4-10 linings
KR clut nal 11 internal)
lutch (12 external internal)fric
friction
tion
1 Internal friction lining linings
inte
tern
rnal
al)f
)fri
rict
ctio
ion
n
linings
KV clut nal 11 internal)
lutch (12 external internal)fric
friction
tion
linings
10. Place the bearing

bearing plate into the
the K3 clutch.
Figure 4-11
1 Bearing plate
11. Install
Install the elastic
elastic retainer ring into
into the K3
clutch.
Figure 4-12
56
12. Slightly
Slightly push
push the K3 clutch
clutch friction
friction lining
lining
upwards to the upper limit position with the
screwdriver; record the clutch piston stroke
which is measured by the dial indicator, and the
K3 clutch assembling is completed.
Attention
Press the dial indicator contact onto the
bearing plate and select different positions for
three measurements at the least. The dial
indicator
indicator reading
reading is
is the
the K3
K3 clutc
clutchh piston
piston
1
stroke. Select the internal friction lining with
Figure 4-13 different thickness to ensure that 
1 Dial indicator the piston stroke Three

Three Sets of th
thee Clutc
Clutch
h are
same is 1.9mm~2.2mm.
13. Knock the

the K4 clutch needle
needle bearing
bearing into the
clutch bearing hole and install the retainer ring.
1 2
Figure 4-14
1 Retainer ring
2 Needle bearing
14. Install
Install the seal ring into the K4 clutch
clutch piston
groove.
Attention
When installing the seal ring, the sealing
surface of the seal ring shall face towards the
pressure oil surface. (Refer to Figure 4-3)
Figure 4-15
1 Seal ring
57
15. Install
Install the K4 clutch piston into
into the clutch.
Figure 4-16
16. Install the guide ring and the pressure spring

spring
into the clutch cylinder.
1 2 3
Figure 4-17
1 Guide ring 2 Pressure spring
3 Guide ring
17. Install
Install the guide ring and the retainer
retainer ring.
1 2
Figure 4-18
1 Guide ring
2 Retainer ring
58
18. Instal
Installl the
the clutc
clutch
h sprin
spring
g remo
removal
val and
assembling tooling onto the clutch.
Screw down the nuts on the clutch removal

tooling and press down the clutch spring.
Figure 4-19
1 Clutch spring removal and assembling

tooling (2938001826) (2938001827)
19. Install
Install the retainer
retainer ring into
into the cylinder
cylinder clip
groove of K4 clutch with the snap ring pliers.
Take down the clutch spring removal and

assembling tooling.
1 2
Figure 4-20
1 Retainer ring
2 Snap ring pliers

20. Firstly,
Firstly, place the external
external friction
friction lining into
the K4 clutch.
Attention
During use, if the external friction lining of
the clutch is worn out and more than 2/3 parts
of the pattern groove of the friction lining are
worn out, timely replacement shall be done.
Figure 4-21
59
21. Install the

the internal friction
friction lining
lining into the K4
clutch.
Figure 4-22

22. Place the bearing
bearing plate into the
the K4 clutch.
Figure 4-23
1 Bearing plate
23. Install
Install the elastic
elastic retainer
retainer ring into
into the K4
K4
clutch.
Figure 4-24

60
24. Slightly
Slightly push
push the K4 clutch
clutch friction
friction lining
lining
upwards with the screwdriver and record the
clutch piston stroke which is measured by the
dial indicator.
Attention
Press the dial indicator contact onto the
bearing plate and select different positions for
three measurements at the least. The dial
indicator reading is the K4 clutch piston
stroke. Select the internal friction lining with
1 different thickness to ensure that the piston
stroke is stroke: 1.9mm~2.2mm.
Figure 4-25
1 Dial indicator
25. Install
Install the thrust
thrust washer
washer into
into the K3 clutch
clutch
gear.
Attention
The thrust washer shall be coated with grease.
1 2
Figure 4-26
1 K3 clutch gear
2 Thrust washer
26. Install
Install the gasket
gasket and the thrust
thrust washer
washer into
the K3 clutch.
1 2
Figure 4-27
1 Thrust washer
2 Washer
61
27. Install
Install the K3
K3 clutch gear.
gear.
Attention
Before installin
Before installing
g the gear,
gear, it is necessary
necessary to
to
perform alignment to the internal friction
lining splines of the clutch.
Figure 4-28
1 K3 clutch gear
28. Install
Install the lining seal ring
ring component
component and
roller of the internal needle bearing of the K3
clutch gear.
Attention
The roller shall be coated with grease to
prevent the clutch assembly dropping when
being installed into the transmission
transmission body.
Figure 4-29
1 Roller×12
29. Install
Install the thrust
thrust washer
washer into the
the K4 clutch
clutch
cylinder clip and gear.
Attention
The thrust washer shall be coated with
grease.
1 2
Figure 4-30
1 Thrust washer
2 Thrust washer
62
30. Install
Install the needle
needle bearing into
into the K4 clutch
clutch
gear.
Figure 4-31
1 Needle bearing
31. Install
Install the K4
K4 clutch gear.
gear.
Attention
Befo
Before
re installin
perform inst alling
g thetogear,
alignment geathe
r, itinternal
is necessary
necesfriction
sary to
lining splines of the clutch.
Figure 4-32
1 K4 clutch gear
4.1.2 Main PTO Assembly

1. Install
Install the needle
needle bearing
bearing into the wheel
wheel hub
of the output transmission body and then install
the retainer ring.
1 2
Figure 4-33
1 Retainer ring×2
2 Needle bearing
63
2. Install the retainer

retainer ring into the transmission
transmission
gear hole and then install the gear into the wheel
hub of the output transmission body.
1 2
Figure 4-34
1 Transmission gear
2 Retainer ring
3. Insert the
the PTO shaft
shaft into the gear
gear hole; knock
knock
in the ball bearing, and insert 2 elastic retainer
rings and 1 retainer ring.
1 2
Figure 4-35
1 Ball bearing
2 Elastic retainer ring×2
4. The PTO assembli
assembling
ng is completed.
completed.
1
Figure 4-36
1 Retainer ring
64
4.1.3 Input Part Assembly

1. Knock
Knock the ball
ball bearin
bearing
g onto the
the auxiliar
auxiliary
y
driving shaft.
1 2
Figure 4-37
1 Ball bearing
2 Auxiliary driving shaft

2. Install
Install the flat key
key of the internal
internal gear
gear of the
gear pump on the shaft and cover it with the oil
pump.
Figure 4-38
1 Internal gear of the gear pump
3. Knock another
another ball bearing
bearing into
into the oil pump
pump
bearing hole.
Attention
Ensure that the auxiliary driving shaft can
flexibly rotate.
Figure 4-39
1 Ball bearing
65
4. Install
Install the clip for shaft and
and buckle
buckle seal ring.
ring.
12
Figure 4-40
1 Clip
2 Seal ring
5. Knock the needle

needle bearing into
into the bearing
bearing hole
of the pump impeller bearing seat and then
install the oil seal.

Attention
Replace the old oil seal with a new one.
1 2
Figure 4-41
   
2 Needle bearing
6. Install
Install the roller bearing
bearing into the bearing
bearing hole
of the oil feed
feed flange.
flange.
Attention
Before assembling, it is necessary to clean the
oil feed flange.
1 2
Figure 4-42
1 Roller bearing
2 Oil feed flange
66
7. Install
Install the input
input gear into the oil feed flange
and adjust the gear clearance.
1
Figure 4-43
1 Input gear
8. Install
Install the seal ring
ring onto the drive
drive shaft.
1 2
Figure 4-44
1 Drive shaft
2 Seal ring
9. Insert
Insert the
the drive
drive shaft
shaft and install
install the
the ball
ball
bearing.
1 2
Figure 4-45
1 Drive shaft
2 Ball bearing
67
10. Use the depth gauge

gauge to measure
measure : two ends
ends
distance and write down: h
1 2
Figure 4-46
1 Oi
Oill ffee
eed
d fla
flange
nge end
2 Bearing
Bearing end
11. Use the depth gauge
gauge to measure
measure : two ends
ends
distance and write down: H
Attention
the output shaft bearing isD=H-h
Install the adjustable washer into the gear
pump hole.
Ensure that the axial run-out clearance of the
output shaft
shaft bearing
bearing is: 0.2mm~0.4mm.
0.2mm~0.4mm.
1 2
Figure 4-47
1 Oil pump
pump bearing
bearing hole eend
nd
2Oil pump joint end
12. Install
Install the steel
steel ball and the pressure
pressure spring
into the safety valve hole of the torque converter
on the oil feed flange.
1 2
Figure 4-48
   
2 Pressure spring
68
13. Place the oil pump packing on on the oil

oil feed
flange oil pump surface; coat it with grease, and
insert the oil pump component into the oil feed
flange component hole.
Figure 4-49
1 Oil pump packing
14. Screw down the bolt

bolt between
between the oil pump
component and the oil feed flange component.
23N.m
1 2
Figure 4-50
15. Place
Place the
the packing
packing of thethe pump
pump impell
impeller
er
bearing seat on the oil feed flange surface.
Figure 4-51
1 Packing
69
16. After knocking

knocking in the pump
pump impeller bearing
bearing
seat and screwing down the bolt between the
pump impeller bearing seat and the oil feed
flange, the assembling is completed.
23N.m
Figure 4-52 4.2 Transmission Assembly

1 Hexagon head screw (M8*28)×8 4.2.1 Output Part Assembly
1. Place the
the output shaft
shaft gear;
gear; install
install the baffle
baffle
plate and the oil shield into the transmission
body, and then fix them with two bolts (M8*16)
and the washer.
1 2 3
Figure 4-53
1 Out
utpu
putt sh
shaf
aftt gear
gear 2 Baf
Baffl
flee plat
platee
3 Oil shield
2. Knock out the
the roller bearing
bearing and place it
it at the
output gear shaft end, and then place it into the
oil shield; install the spacer sleeve and insert the
output shaft.
Figure 4-54
70
3. Adjust the washer

washer in turn.
turn.
Attention
Select the adjustable washer with different
thic
thickn
knes
ess,
s, so as to en ensu
sure
re th
that
at th
thee ax
axia
iall
clearance of the bearing is 0.1mm~0.3mm.
1
Figure 4-55
1 Output
Output shaft
shaft
4. Install
Install the snap ring.
ring.
1 2
Figure 4-56
1 Adjustable gasket
2 Snap ring
5. Install
Install the oil seal
seal into the transmissio
transmission
n body
with the tooling.
Attention
Replace the removed oil seal with a new one.
1 2
Figure 4-57
1 Oil seal
2 Oil seal assembling tooling
(2938001833)
71
6. Instal
Installl the
the outpu
outputt flange
flange and pressure
pressure plate,
plate,
and screw tight the
the bolts 2-M10×30.
2-M10×30.
46N.m
1
Figure 4-58
1 Outp
Output
ut flan
flange
ge
7. Instal
Installl the output
output flange,
flange, O-ri
O-ring,
ng, distan
distance
ce
washer and pressure plate in turn.
1
Figure 4-59
1 Lock washer
washer assembling
assembling tooling
(2938001838)
8. Instal
Installl the parkin
parking
g brake
brake flange.
flange.
Figure 4-60
1 Parking brake flange
72
9. Lock the locking

locking plate after amounting
amounting the
brake assembly, the brake drum wheel, the
pressure plate and screwing
screwin g tight the bolts.
1
Figure 4-61
1 Parking Brake
4.2.2 Intermediate Shaft Component

Assembly
1. Install the
the roller bearing
bearing into the bearing
bearing hole
of the intermediate shaft gear and fix it with
grease for standby.
1 2 3 4
Figure 4-62
1 O-ring 2 Intermediate shaft
3 Roller bearing 4 Intermediate shaft gear
2. Place the intermedia
intermediate
te shaft
shaft gear component
component
into the gear groove of the transmission body;
insert the intermediate shaft and install the
gasket.
1 2
Figure 4-63
1 Intermediate shaft gear

2 Gasket
73
3. Install
Install the screw
screw and then
then install the sealing
sealing
washer.
80N.m
1
Figure 4-64
1 Head cap screw×1
4.2.3 Torque Converter Pressure Control

Valve Assembly
1. Install
Install the pressure
pressure spring
spring and the valve
valve core
into the valve sleeve hole.

Install the O-ring onto the screw plug, and then
install the valve sleeve component into the
pressure maintaining valve hole of the torque
converte
conv erterr of the transmis
transmissio
sion
n body and screw
screw
down the screw plug; after that, the assembling
1 2 is completed.
Figure 4-65
1 O-ring
2 Screw plug
4.2.4 Assembling of the K3K4 Clutch

Assembly
1. Install
Install the O-ring and
and piston ring on the K3K4
K3K4
clutch
clutch shaft.
shaft.
1 2
Figure 4-66
1 Piston ring×3
2 O-ring
74
2. PlPlac
acee the clut
clutch
ch assem
assembly
bly into
into the
transmission body.
about 15kg
Attention
When
jack upplacing the clutch,
the bottom of theuse the to
clutch tooling
avoidand
its
falling.
Figure 4-67
1 Clutch assembling tooling 2938001832
3. Overturn
Overturn the transmission
transmission to
to make it be
be in a
horizontal position, and then install the clutch
assembl
assembling
ing tooling
tooling..
Figure 4-68
4. Use
Use the
the dept
depth
h gaug
gaugee to meas
measur
uree :
aThe bearing step Of clutch shaft and write

down : height h
bThe housing surface to the Roller

Roller of the
needle bearing of the K3 clutch and write
down: height H.
Attention
The axial clearance of the clutch assembly:
A=H-h
1 2
Figure 4-69
thickn
thickness
ess,, so as to
to ensur
ensuree that
that the axial
axial
1 K3K4
K3K4 clutch
clutch shaft
shaft clearance of the clutch assembly is:
0.1mm~0.3mm.
2 Roller of the needle
needle bearing
bearing of the K3
clutch
75
5. Take out
out the tooling;
tooling; install
install the K4K3 clutch
clutch
shaft and screw down the nut fixing the clutch
assembly.
Attention
The K3K4 clutch

clutch gear can
can flexibly rotate.
23N.m
Figure 4-70
4.
4.2.
2.5
5 KR
KRK2
K2 KVK1Clutch Assembly
1. Amount the clutch
clutch assemblies
assemblies K2+KR
K2+KR and
K1+KV onto their separate hole on the housing
and adjust the bearing clearance to be between
0.1-0.3mm. Then insert shafts K2 and K1and fix
them with bolts 3-M8×18.
Attention

thicknes
thickness,
s, so
so as to ensure
ensure that the axial
1 2 clearance of the clutch assembly is:
Figure 4-71 0.1mm~0.3mm.
1 KVK1
KVK1 clutch assembly
2 KRK2
KRK2 clutch assem
assembly
bly
4.2.6 Auxi
Auxiliary
liary PT
PTO
O Assem
Assembly
bly
1. Place the
the transfer
transfer gear into the transmis
transmission
sion
body.
Figure 4-72
1 Transfer gear
76
2. Knock in the
the PTO shaft
shaft to make
make the retainer
retainer
ring on the shaft fits with the gear.
1 2
Figure 4-73
1 PTO shaft
2 Retainer ring
3. Install the bearing snap ring on

on the PTO shaft
with the snap ring pliers.
Figure 4-74
1 Snap ring
4. Assemble
Assemble the PTO
PTO end cover and install the
addition
additional
al pa
packing
cking.. Screwin
Screwingg down
down the bolt
between the PTO end cover
co ver and the transmission
body.
Attention
Replace the removed packing with a new one.
16N.m
Figure 4-75
1 PTO end cover

77
4.2.7 Input C
Compone
omponent
nt Assem
Assembly
bly
1. Install
Install the input
input device onto the transmission
transmission
body; install the additional packing and knock it
in with the copper rod.
Attention
Upon installation, screw in two bolt

positioning thread
thread holes.
holes. Replace the removed
packing with a new one.
1
Figure 4-76
1 Input component
2. Assemble
Assemble the lubricati
lubricating
ng oil pipe
pipe component
component
and screw down the hollow screw between the
oil pipe and the transmission body.
34±5N.m
Figure 4-77
1 PTO lubricating oil pipe component
3. Assemble
Assemb
with le therod.
the copper connecting
connecting shell and knock
knock it in
Attention
Upon assembling, align it at the positioning
pin hole. Upon knock in, ensure that the force
which is applied on the connecting shell is
uniform.
Figure 4-78
1 Torque converter connecting shell

78
4. After
After screwing
screwing down
down the
the bolt betwe
between
en the
transmission body, flange and connecting shell,
the assembling is completed.
Attention
Align at the pin position, and repeatedly
screw down
diagonal the bolt in accordance with the
sequence.
68N.m
1 2
Figure 4-79
1 Tension pin×2
4.2.8 Main PTO Co

Componen
mponentt Assembl
Assembly
y
1. After installing
installing the
the main PTO
PTO component
component and
screwing down the bolt and nut between the PTO
and the transmission body, the assembling is
completed.
Attention
Repeatedly screw down the bolt in accordance
with the diagonal sequence.
23N.m
1 2
Figure 4-80
2 Hexagonal nut (M8)×1 4.2.9 Oil F

Filter
ilter Assem
Assembly
bly
1. Screw
Screw down
down the oil filte
filter.
r.
Figure 4-81
79
4.2.
4.2.10
10 Tr
Tran
ansm
smis
issi
sion
on Con
ontr
trol
ol Val
alve
ve
Assembly
1. Place a paper gasket,
gasket, a lower
lower baffle,
baffle, a paper
gasket and a oil delivery plate onto the surface of
the valve plate on the housing and fix them with
the bolt
bolt 3-M8
3-M8×30
×30 an
and
d socke
sockett screw
screwss 3-M8×
3-M8×45
45
and 6-M8×35
6-M8×35..
Attention
Replace the removed paper pad with a new
one.
1 2 Before assembling, clean the valve plate, oil

passage plate and baffle plate of the
Figure 4-82 transmission body.
1 Oil passage plate 20N.m
2 Paper pad
2. Place a paper gasket,

gasket, a upper
upper baffle,
baffle, a paper
paper
gasket and a pilot valve onto the oil delivery
plate, and fix them with the bolt 3-M8×30 and
socket
sock et screws
screws 3-M8×4
3-M8×455 and 6-M8×3
6-M8×35.
5.
Attention
Replace the removed paper pad with a new

one.
Repeatedly screw down the bolt in accordance

Figure 4-83 with the diagonal sequence.
20N.m
3. The six
six oil-holes
oil-holes on the oil delivery plate,
from the top down, are K2,K1, K3, K4,
KR,KV.( Pipe KR and KV is determined by the
rotation direction of the differential gear on the
back axle of each engine.) Connect them
respectively with oil-line holes on shaft K1, K2
and K3.
Attention
Figure 4-84 After adjusting the hose position, screw down
the bolt again.
55±5.5N.m
80
4.2.11 Torqu
Torquee Conver
Converter
ter Assemb
Assembly
ly
1. After installin
installing
g the intermediate
intermediate ring
ring and the
the
torque converter into the connecting shell, the
assembling is completed.
About
About 20kg
20kg
Attention
As there is no axial positioning after installing
the torque converter,
converter, fixing measures
measures shall be
1 2 adopted to avoid its falling.
Figure 4-85
1 Torque converter
2 Intermediate ring
81
5 Malfunction Diagnosis and Troubleshooting

5.1Malfunction Diagnosis and Troubleshooting of the EST
Semi-Automatic Gear Controller
Table 5-1
No. Troubles Causes Remedies
1 Engine cannot be started 1) Abnormal power voltage 1) Check

Check the voltag
voltage,
e, if batter
battery
y
2) Troub
Troubles
les in star
startin
ting
g relay
relay or losses too much power, charge
other related apparatuses firstly;
3) DW-4
DW-4 handle
handle is not
not at neutra
neutrall 2) Check
Check sta
starti
rting
ng cir
circui
cuitt o
off the
the
4) Ba
Bad
d cont
contac
actt of EST
EST plu
plugs
gs or
or engine, to see any bad connection
EST troubles or damaged elements
3) Put sele
selecto
ctorr ha
handl
ndlee to neutra
neutral,
l,
when the starting relay on the
engine should be engaged
4) If AS has
has no
no ssign
ignal
al (volta
(voltage
ge
on line 0 is not +24V), it shows
outp
output
ut of EST
EST is fai
ailu
lurre.
Reconnect the plugs once, making
sure right contact. If it still does
not work, replace EST.
2 Vehicle cannot run at any 1) Open

Open or shor
shortt cir
circu
cuit
it 1) Di
Disc
scon
onne
nect
ct th
thee pl
plug
ugs,
s,
gear 2) Damage
Damaged
d sole
solenoi
noid
d valv
valves;
es; In resistance of solenoid valves
these two cases, ECU will within 60~70ohm. Replace
output alarming, lamp H2 solenoid valves if necessary;
flash and tick and tock can be 2) Che

Check any wor
orn-
n-ou
outt in
in
heard inside the box connection cables. Replace if
3) Dama
Damage
ged
d DW-4
DW-4 sel
selec
ecto
torr necessary
handle or bad contact of plugs 3) Ch

Chec
eck
k if cont
contac
actt of le
leaading
ding
4) Dama
Damage
ged
d EST
EST-4
-4 or ba
bad
d -out plugs of DW-4 and EST
contact of connectors correct, if loosened, press tightly.

tightly.
5) Troub
Troubles
les in oil
oil circ
circuit
uit or o
othe
therr 4) Re
Repl
plac
acee DW
DW-4 sele
select
ctor
or or
mechanical failures EST ECU

5) Re
Repl
plac
acee hydr
hydrau
auli
licc cont
contro
roll
valve
82
3 Vehicle cannot run at gears 1) Ch

Chok
oked
ed br
brak
akee swi
switc
tch
h BR
BR or
or 1) Ch
Chec
eck
k iiff two
two swit
switch
ch work
work
one and two but can run at emergent

emergent brake switch BR2;
B R2; freely; if not, do some treatment;
gears three and four 2) Wire

ire bet
betwe
ween
en BR an
and
d +24
+24V
V 2) Disc
Discon
onne
nect
ct lin
lines
es to
to BR or
has short circuit; BR2, if gear normal, check wiring
3) Dama
Damage
ged
d sol
solen
enoi
oid
d val
valve
ve M4 and remove troubles
3) Replace M4
4. No high-speed gears. 1) It norma

normally
lly happen
happenss iin
n ttyp
ypes
es 1) Ins
nspe
pect
ct th
thee ssen
enso
sorr as
as
Speed at gear 3 or 4 is with speed sensor. The cause is mentioned above. Replace if it
identical to that at gear 1 or unconnected or bad contacted or damaged
2 damaged sensor. 2) Ch
Chec
eck
k wiri
wiring
ng to se
sens
nsor
or..
2) Bad contac
contactt of DW-4
DW-4 plugs
plugs or Repair if damaged.
damaged selector 3) Re
Repl
plac
acee sele
select
ctor
or DW
DW-4
5. No forward gears 1, 2 and 1) Damage

Damaged
d inter
internal
nal eleme
elements
nts of 1) Re
Repl
plac
acee sele
select
ctor
or
3 selector DW-4 2) Re
Repl
plac
acee sole
soleno
noid
id val
valve
ve M3
M3
2) Dama
Damage
ged
d sole
soleno
noid
id val
valve
ve M3
M3
6. No reverse 1) Damaged solenoid valve M1 1) Re

Repl
plac
acee sole
soleno
noid
id val
valve
ve M1
M1
2) Da
Dama
mage
ged
d ssel
elec
ecto
torr 2) Re
Repl
plac
acee ssel
elec
ecto
torr
7. Vehicle is sometimes in 1) Unst

Unstab
able
le po
powe
werr sup
suppl
ply
y 1) Check
Check vehicl
vehiclee power
power supply
supply
gear and sometime out 2) Ba

Bad
d con
conta
tact
ct some
somewh
wher
eree and remove voltage fault
in connection plugs 2) Ch
Chec
eck
k all
all plug
plugs,
s, tid
tidy
y and
and
3) Unst
Unstab
able
le sole
soleno
noid
id valv
valves
es press all connectors
connectors
or electric control unit 3) Replac

Replacee ele
electr
ctric
ic cont
control
rol unit
unit
83
5.2Malfunction Diagnosis and Troubleshooting of the Transmission

Table 5-1
No. Symptom Cause Troubleshooting
Troubleshooting
1 Fail to start the circuit. 1 Check the engine circuit and refer to the
such as power supply,      
electric lock, relay or instruction.
engine. 2 Place the lever at the neutral position.
2 The lever is not placed at 3 Renew the fuse.
the neutral position. 4 Settle the connection-peg or check the
   3 Fuse on the engine to the lever circuitry for connection.
1
work. controlling circuit burnt. 5 Settle the connection-peg or handle it as
4 Loose contact of the the way for electro-control box failure.
lever plug or lever fault.
5 Loose contact of the
connection-peg in the
electric-control
electric-c ontrol box or
electro-control
electro-con trol box fault.
1 Pressure gauge failure. 1Replace the pressure gauge.
2Insuffici
Insufficient
ent tight torque 2Increase the tight torque of the bolt to M8
of the shift controlling class 20Nm.
valve bolt. 3Replace.
2 Low pressure at all 3 Broken

pressure spring
valve. of main
valve. 5Replace
4Replace the
the filter
shifting
andpump.
clean the control
the speeds.
4 Worn shifting pump. valve.
5 Chips fall in to the
transmission control
valve or the valve
blocked.
1Block the oil circuit to KV clutch after
stalling the engine, then restart the engine,
Low display pressure and shift to the ahead speed 1, 2, 3. If the
at ahead speed1,2, 3 1Internal releasing in ahead shifting pressure rise to normal value, we can
3
while the rest is gear of the clutch. draw the conclusion that internal releasing
normal. happens to the clutch of this
speed. Carry out mechanical maintenance to
the transmission.
1 Block the oil circuit to KR clutch after
Low display stalling the engine, then restart the engine,
and shift to the astern speed 1, 2, 3. If
If
pressure at astern
astern
1Internal releasing in the shifting pressure rise to normal value,
4 speed1,
astern gear of the clutch. we can draw the conclusion that internal
2, 3 while the rest
releasing happens to the clutch of this speed.
is normal.
Carry out mechanical maintenance to the
transmission.
1 Block the oil circuit to K1 clutch after
stalling the engine, then restart the engine, and
shift to the astern and ahead speed 1.
If the shifting pressure rise to normal value,
Low pressure at the we can draw the conclusion that internal
first speed of both releasing happens to the clutch of this speed.
1Internal releasing at the
5 ahead and astern Carry out mechanical maintenance to the
first speed of the clutch.
while the others transmission.
are normal.
84
1Broken O-shape ring on

the throttle plug screw.
Short shifting time 2 The tight torque of the bolt 1Replace the O-shape ring.
6
for all the speeds on pressure control valve 2M8 class tight torque of the bolt is 20Nm.
is not in the specified
range.
1Choked throttle plug 1Clean and dredge it.
Long shifting time screw. 2Clean and check it
7 for all the speeds. 2Stuck pressure control
valve.
1Replace.
2Replace.
3Check the oil level and fill in oil in correct way.
1Failed oil sensor. 4Exhaust air through the exhausting hole on the
2Failed temperature gauge. radiator.(for
radiator .(for engines with exhausting holes.)
3Insuffic
Insufficient
ient oil level. 5Check if the oil circuit from the radiator
4There are air in oil to the transmission and the radiator are
radiator. choked.
High oil temperature 5Oil circuit from the 6Check if the radiator is capable of rejecting heat.
8 of the torque torque converter to radiate For example, check the engine fan belt for
converter. or is not smooth. tightness, and check the radiate appearance
6Insufficie
Insufficient
nt rejecting for feculence.
ability of the radiator. 7Check the hose joint from the transmission

7 Choked
valve of back pressure
the torque to the radiator.
housingradiator
by an.excessive
IIff it is inserted
length, into the
it will
converter. stick to the core of backpressure valve,
thus choking the valve and resulting in
difficulty of the oil circuit.
1Insuffic
Insufficient
ient oil level. 1Check the oil level and fill in oil in the
2Elastic board between correct way.
the engine and the torque 2Replace the elastic board or corresponding
converter teared, or power broken pieces.
connection failure from the 3Check if the voltage of the power supply
torque converter to the is normal, if the cable is teared and if
transmission input gear
gear.. the cable plug is loosened.
The vehicle does rarely  4Correct it by
b y the above-mentioned.way
9 not move at any 3  Circuit failure of the 5Check the resistance value of the solenoid
speed. machine. valve, which is to be 65±5ohms. If the
4Too low pressure of the resistance value is zero or , the solenoid
transmission. valve is broken. Replace it.
5Broken solenoid valve. 6Check and replace it as the service method of
6Broken shifting lever. lever fault.
7Failed electro-control box. 7Check according to the troubleshooting of
electro-control
electro-control box or through PR68
detector.
1Disconnect the emergency brake pressure
1 Broken switch of
switch or the parking brake pressure switch
The vehicle does emergency brake pressure or
and the circuit. If the first and second speed
10 not move at speed 1 parking brake pressure.
pressure.
works under this condition, the switch is
and 2. 2  Invalid solenoid valve.
broken. Replace it.
M4
2Replace the solenoid valve.
The vehicle moves 1Measure the resistance value of the speed
at the speed of 2nd sensor which is to be 1020±100ohms. If
11 1Damaged speed sensor.

gear under 3nd or
forth gear. it is measured
need to be 0 or
replacing. it is damaged and
85
1Internal releasing at
1Follow the method of dealing with internal
ahead clutch.
releasing in clutch.
2Burnt contact points in the
2Sort the lever line or replace the lever.
internal circuit of
The vehicle has no 3Check the resistance value of the solenoid
12 the shifting lever and
ahead speeds1, 2, 3. valve, which is to be100±10 ohms. If the
loose circuit contact.
resistance value is zero or , the solenoid
3Invalid solenoid.M3 
valve is broken. Replace it.
4Choked control valve of

the transmission. 4 Clear the shifting control valve.
1Internal releasing of the
astern speed clutch. 1Handle it as internal releasing of the clutch.
2Burnt contact points in the 2Sort the lever line or replace the lever.
circuit of the shifting 3Check the resistance value of the solenoid
Astern speed does
13 lever and the circuit is valve, which is to be 65±4  ohms. If the
not work.
out of charge. resistance value is zero or , the solenoid
3  Invalid solenoid valve. valve is broken. Replace it.
M1 1 Clear the shifting control valve.
4Choked valve.
1Unsteady power supply to
electric control system.
2Loose contact of the
supply circuit for electric
control system.
 
3 Unsteady work
shifting lever ofof the
loose 1Search
2 Check the supply system
in accordance of the machine.
the engine circuit.
contact of its connection 3Sort the connection-peg of the shifting
14 Unsteady speed -peg. lever or replace it.
4Insuff
Insufficient
icient oil level of the 4Add oil by the correct method.
transmission 5Sort the connection-peg.
connection-peg.
5Unsteady work of the 6Clear.
solenoid valve or electro
-control box or loose
Contact of its
connection-peg.
6Choked valve.
1Loosened Connecting 1Check and fix it.
bold. 2Add oil to normal oil level.
2  Insufficient transmission 3Check the transmission oil.
oil level. 4Replace the elastic board.
3Transmission shaft failure 5Dismantle the transmission shaft and check
Abnormal sound of that connects th
the for abnormal sound after dismantlement. If
15
the transmission transmission. so, check the transmission for mechanical
4Elastic board between failure.
he engine and the torque
converter teared.
5Internal mechanical
failure of the transmission.
1Block the oil circuit of KR clutch after
stalling the engine, then restart it. If the
The vehicle moves
vehicle moves at astern speed, we know
back at neutral 1Fritted astern clutch.
that the astern clutch is fritted and needs
speed, keeps still 2Choked valve.
mechanical maintenance.
16 at ahead speed 1, 2, 3Invalid solenoid valve
2Clear.
3 and moves M1.
normally at astern 4Lever fault.
4Replace the lever.
speed.
86
1Block the oil circuit of KV clutch after

The vehicle moves stalling the engine, then restart it. If the
1Fritted ahead clutch.
head at neutral vehicle moves at ahead speed 1, 2, 3, we
2Choked valve.
speed, remains still know that the ahead clutch 1 is fritted and
17 3  Invalid solenoid valve.
at astern speed and needs mechanical maintenance.
M3
moves normally at 2Clear.
4Lever fault.
speed 1, 2, 3. 3Replace the solenoid valve.
1Block the oil circuit of K1 clutch after
stalling the engine, then restart it. If the
The vehicle only
1Fritted K1 clutch. vehicle moves at astern speed1 and amend
moves at ahead
2Choked valve speed 1, we know that the clutch of speed 1 is
18 speed 1 and astern
3Invalid solenoid valve. fritted and needs mechanical maintenance
speed 1. It remain
4Lever fault. 2Clear.
still at other speeds.
87

WG180 Transmission Workshop Manual 20124

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

WG180 Transmission Workshop Manual 20124

Uploaded by

Copyright:

Available Formats

ADVANCE WG180 Transmission Service Manual

The Service Manual mainly includes following content:

Chapter II. Transmission System

Chapter III. Transmission Removal

Chapter IV. Transmission Assembling

Chapter V. Malfunction Diagnosis and Troubleshooting

1.1 Safety Precautions ........................................................................................................................................

1.2 Instructions of Marks and Symbols ..............................................................................................................3

1.3 Common Bolt Tightening Torque Table .......................................................................................................3

2 Transmission System ..........................................................................

2.1.2 Basic Parameters

2.1.3 Mechanical Principles of the Gears of the Transmission.....................................................................

2.1.4 Gearbox control system .....................................................................................................................10

2.1.6 Operation and Maintenance of WG200 Power Gearshift Transmission............................................22

3 Transmission Removal ....................................................................................................................................

3.1 Transmission Assembly Removal ..............................................................................................................27

3.1.1 Torque Converter Removal ...............................................................................................................27

3.1.3 Oil Filter Removal .............................................................................................................................

3.1.4 Removal of the Auxiliary PTO Wheel Hub.......................................................................................29

3.1.5 Input Device Removal .......................................................................................................................30

3.1.7 Dismantle the three Sets of the clutch Assembly .........................................................................

3.1.9Intermediatee Shaft Assembly Removal .............................................................................................. 37

3.1.10 Removal of the Torque Converter Pressure Regulating Valve

3.2 Transmission Assembly Component Removal ...........................................................................................39

3.2.1 Main PTO Removal...........................................................................................................................39

3.2.2 Input Component Removal ............................................................................................................... 40

3.2.3Three Sets of the Clutch Removal......................................................................................................45

4 Transmission Assembly ..................................................................................................

4.1 Assembling of the Transmission

4.1.1 Three Sets of the Clutch Assembly ...................................................................................................

4.1.2 Main PTO

4.1.3 Input Part Assembly ..........................................................................................................................

4.2 Transmission Assembly ..............................................................................................................................

4.2.1 Output Part Assembly ....................................................................................................................... 70

4.2.2 Intermediate Shaft Component Assembly ......................................................................................... 73

4.2.3 Torque Converter Pressure

4.2.4 Assembling of the K3K4 Clutch Assembly....................................................................................... 74

4.2.5 KRK2 KVK1Clutch Assembly .....................................................................................................

4.2.6 Auxiliary PTO

4.2.7 Input Component Assembly .............................................................................................................. 78

4.2.8 Main PTO Component Assembly ..................................................................................................... 79

4.2.9 Oil Filter Assembly ...........................................................................................................................

4.2.10 Transmission Control Valve Assembly............................................................................................

4.2.11 Torque Converter Assembly ............................................................................................................

5.2Malfunction Diagnosis and Troubleshooting of the Transmission.............................................................. 84

Important Safety Precautions

4. Before removing the transmission-torque converter assembly, it is necessary to clean

12. After assembling, the parts shall be free from interference.

1.2 Instructions of Marks and Symbols

Mark Item Remarks

The place needing oil or water draining and draining

1.3 Common Bolt Tightening Torque Table

Nominal diameter of bolt mm

4.6 240 90~110 120~150 170~210 230~290 300~377

12.9 1080 326~434 448~597 635~847 864~1152 1098~1464

12.9 1080 1606~2142 2181~2908 2968~3958 3812~5082 4933~6577

2.1.2 Basic Parameters of the Transmission-torque Converter Assembly

Item 4WG180 6WG180

Single-stage and single-turbine hydraulic

Torque ratio 2.55 2.14

2.1.3 Mechanical Principles of the Gears of the Transmission

2. Hydraulic oil system of transmission

Rated voltage DC 24V

Working voltage range DC 2032V