ADVANCE WG180 Transmission Service Manual

ANDVANCE 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 the transmission removal and assembling methods more profoundly 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.
ADVANCE WG180 Transmission
Service Manual
880×1230 mm 16# 18pieces
1st Edition in 2014. 5 1st Print
SHANDONG LINGONG CONSTRUCTION

MACHINERY CO.，LTD
Address: Linyi Economic Development Zone

Tel: 86-0539-8785688
Fax: 86-0539-8785698
Postal code：276023
Website：www.sdlg.cn
Services Tel：8008607999 4006587999 0539-8785800
Services Fax：86-0539-8785671
Contents
1 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................................................................................................................................................. 5
2.1.1 Transmission Introduction ................................................................................................................... 5
2.1.2 Basic Parameters of the Transmission-torque Converter Assembly .................................................... 6
2.1.3 Mechanical Principles of the Gears of the Transmission..................................................................... 7
2.1.4 Gearbox control system ..................................................................................................................... 10
2.1.5 Transmission Function Testing .......................................................................................................... 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 Transmission 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
3.1.9Intermediate Shaft Assembly Removal .............................................................................................. 37
3.1.10 Removal of the Torque Converter Pressure Regulating 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 Assembly................................................................................................ 53
4.1.1 Three Sets of the Clutch Assembly ................................................................................................... 53
4.1.2 Main PTO 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 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 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............................................................................................ 80
4.2.11 Torque Converter Assembly ............................................................................................................ 81
5 Malfunction Diagnosis and 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 personal injuries, will be made as the safety mark in the Manual. The
precautions with shall be paid high attention to. In case of potential dangers, it is
recommended to consider the own safety first of all, and then consider taking 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 converter assembly, so as to avoid 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, the appointed hoisting position shall be used for slow hoisting, so as to avoid
parts collision. It is not allowed to work in the area under the hoisted 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.
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 and water Fill the engine oil, water and fuel with certain capacity.
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

Yield
Bolt strength
strength 6 8 10 12 14
grade
N/mm2
Tightening torque N.m
4.6 240 4~5 10~12 20~25 36~45 55~70
5.6 300 5~7 12~15 25~32 45~55 70~90
6.8 480 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 control valve

2 2. Oil filter
3 3. Torque converter oil temperature
4 measuring port
5 4. Transmission oil outlet
6 5. Oil suction pipe
7 6. Transmission housing
7. Rotation speed sensor
Figure 2-1
8 8. Torque converter
9 9. 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) 13~17
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
by oil pipes. The filter accuracy is 0.025mm and filter area 5100cm2 .
Oil from the filter flows into the pilot valve ; through a pressure-control valve after its working
pressure being limited by a control pressure valve (main pressure regulating 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’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 while operating pressure shut-off valve.
8
9
Fig 2-4 Hydraulic principle of electro-hydraulic control

2.1.4 Gearbox control 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 valve in the oil line, and the control pressure 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) Principle
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-4 (Four-gear selector), installed under the wheel, operated by
left hand
b) Electric control unit EST-4 (or -5)
c) Special wire harness and connectors
d) Solenoid valves on control valve
e) Speed sensor (without in current four-solenoid 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. Both signals from DW-4 selector and other from vehicle electric circuit are input to EST-4
electric control unit, which analyses and determines signals comprehensively and 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 clutch, thus realizing operation on direction and 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” for details. All of
them are plus output, i.e. +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) Operation
Before starting vehicle engine, put the handle of gear selector DW-4 at neutral ‘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 and then moved to required gear, or not, the EST-4 will have no signal 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-down (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. However, if in gear 3 or 4, braking is invalid.
11
d) When the vehicle parking, put the handle of gear selector DW-4 at neutral ‘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. 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.
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. Insert pins on DW-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’, ‘neutral’ and
‘reverse’ light; pressing the handle, lamp ‘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 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.
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) Principle
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. 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. Generally, 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 Data Table2-4
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
Fig.2-7（SG-6S）Wiring diagram “F”

F-code
F 编码
14
Wiring diagram of（SG-6S with locking

Fig.2-8
15
Fig2-9
16
Fig.2-10
17
F i g . 2 - 11
18
Fig.2-12
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 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)
(3) Testing points for flow rate：2=filter inlet port； 13=filter outlet 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 is discovered to be abnormal during use, it is necessary
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
the oil temperature doesn’t fall down, it means that the system has malfunction, and operation can
be continued after troubleshooting.
Normal gear shift oil pressure range: 1.6~1.8MPa (16~18bar). To monitor the control pressure,
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 pressure (the pressure will quickly drop temporarily in case of gear shift), it is
necessary to do troubleshooting. If the control pressure is too low, the clutch will be 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
—— Turn the transmission gearshift handle to the neutral gear (“N”) and the parking brake to
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
scale “cold” and the middle scale
—— At 80℃, the oil level shall be between the upper
scale “hot” and the middle scale
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 transmission control handle to the neutral gear (“N”)
——Fill oil till reaching the upper scale in the “cold” oil area
——Turn the parking brake to the safe position
——Select all gears once
——Check the oil level again
——If necessary, fill oil again
—— At 40℃, the oil level shall be between the lower scale “cold” and the middle scale
——At 80℃, the oil level shall be between the upper scale “hot” and the middle scale
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）；
Fuchs CF-4/ SAE（15W-40）；
Mobil 1300 CF-4/ SAE（15W-40）。
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℃, it shall be within the “cold” oil level range.
——When the oil temperature is 80℃, it shall be within the “hot” oil level range.
——Check if it is screwed down. If necessary, screw it down by hand again.
26
3 Transmission Removal
3.1 Transmission Assembly Removal
3.1.1 Torque Converter Removal
1. Pull out the intermediate ring and 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 bolt connecting 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. Remove socket heat bolts 10-M8×45 、
6-M8×75from the pilot valve with a M8 socket
head wrench.
Attention
Strictly follow the sequence of “From outside
to inside and diagonal removal” to remove
bolts.
Pay attention to keep the valve spacer intact
while taking off the pilot valve.
1
Figure 3-3
1 pilot valve
2. Remove the six oil pipe on the oil delivery
plate one by 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 shafts and take down six oil pipes.
Attention
Do well in oil pipe connector protection, 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 of the oil passage plate
2 Oil passage connector of the clutch shaft
3. Take off socket head bolts 3-M8×45 and
6-M8×35 connecting the plate and the housing,
then remove the oil delivery plate and the baffle
plate and put them aside.
Attention
Strictly follow the sequence of “From outside
to inside and diagonal removal” to remove
bolts.
After removing the oil passage plate, do well
in its cleaning and protection.
1
Figure 3-5
1 Oil passage plate
28
3.1.3 Oil Filter Removal

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

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

1. Remove the hexagon bolts between the 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. Slightly knock the bearing seat with 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 the bolt between the main PTO
wheel hub and the transmission body.
1 2
Figure 3-11
1 Hexagon head screw ×10
2 Main PTO wheel hub
30
4. Hold one about φ30*400mm copper rod by

left hand to jack up the variable speed 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 screw off hollow bolts (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 the snap ring from the PTO shaft
with the snap ring pliers.
1 2
Figure 3-14
1 Snap ring
2 Snap ring pliers
31
3. Knock out the PTO shaft with the 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 PTO removal is completed.
1
Figure 3-16
1 Ball bearing 3.1.7 Dismantle the three Sets of the clutch
Assembly
1. Remove the three bolts connecting 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 out the K1、K2、K3 clutch shaft with

tooling
Attention
Put the clutch adjusting plate under the shaft
end after pulling out each set of clutch for
general assembly.
When taking out the clutch assembly, place
the transmission in a proper position, and the
operation shall be slow to avoid slipping.
1 2
Figure 3-18
1 Clutch shaft removal tooling
（2938001828）（2938001829）
3.1.8 Removal of the Parking Brake and the

Output Device
1. Take the safety plates 2-M10×30 off the
output shaft on the hand brake end, screw off the
two bolts and remove the hand 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 from the output device.

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 the lock washer and remove 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 plate, 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 the output flange.
1
Figure 3-23
1 Output flange
34
6. Take down the oil 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 the front end bearing snap ring 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 end of the output shaft with the
copper rod.
1 2
Figure 3-26
1 Rear end of the output shaft
2 Copper rod
35
9. Take down the output shaft, bearing and shaft

sleeve.
1 2 3
Figure 3-27
1 Bearing 2 Output shaft
3 Shaft sleeve
10. Take out the output gear and 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 oil shield and the retainer.
1 2 3
Figure 3-29
1 Output gear 2 Oil shield
3 Retainer
36
3.1.9Intermediate Shaft Assembly Removal

1. Remove the sealing washer.
1
Figure 3-30
1 Sealing washer
2. Remove the bolt between the intermediate

shaft and the transmission body.
1
Figure 3-31
1 Head cap screw
3. Take out the intermediate shaft and the O-ring.
1 2
Figure 3-32
1 Intermediate shaft
2 O-ring
37
4. After taking out the intermediate shaft and the

bearing component, the removal is completed.
1 2
Figure 3-33
1 Intermediate shaft gear
2 Roller bearing
3.1.10 Removal of the Torque Converter

Pressure Regulating Valve
1. Remove the screw plug fixing the 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 out the valve sleeve 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 Transmission Assembly

Component Removal
3.2.1 Main PTO Removal
1. Remove the retainer ring fixing the driving
gear on the PTO shaft with the snap ring pliers.
1
Figure 3-36
1 Retainer ring
2. Remove the snap ring fixing the 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 bearing 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 the driving gear, PTO shaft and

ball bearing.
1 2 3
Figure 3-39
1 Driving gear 2 PTO shaft
3 Ball bearing
5. After taking down two 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.
1 2
Figure 3-40
1 Retainer ring
2 Needle bearing
3.2.2 Input Component Removal

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

pump and the oil feed flange.
1
Figure 3-42
3. Knock the output shaft with the copper rod to

knock out the variable speed pump.
12
Figure 3-43
1 Copper rod
2 Output shaft
4. Take down the variable speed pump, 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 snap ring from 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 shaft with the 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 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 speed pump cover
42
8. Take out the external ring gear of the variable

speed pump.
1 2
Figure 3-48
1 Variable speed pump shell
2 External ring gear
9. Take down the safety valve of the oil 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 down the snap ring fixing the ball
bearing on the drive shaft with the snap ring
pliers.
1
Figure 3-50
1 Snap ring
43
11. Knock the drive shaft with the copper rod for
removal.
1 2
Figure 3-51
1 Drive shaft
2 Copper rod
12. Take down the driving gear, ball bearing and

roller bearing.
1 2 3
Figure 3-52
1 Roller bearing 2 Driving gear
3 Ball bearing
13. Remove the plunger ring from the drive
shaft.
1 2
Figure 3-53
1 Drive shaft
2 Plunger ring
44
3.2.3Three Sets of the Clutch Removal

Attention
The KVK1 and KRK2 clutch
disassembling process can follow the
K3K4 clutch assembling process, which is
omitted here.
1. Take down the K4 clutch gear bearing.
Place the bearing aside.
1
Figure 3-54
1 Needle bearing
2. Take down the lining seal ring 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 the gear, washer and thrust washer
of the K3 clutch.
1 2
Figure 3-56
1 Washer
2 Thrust washer
45
4. Take down the gear and thrust washer of the

K4 clutch.
1 2 3
Figure 3-57
1 Thrust washer 2 K4 clutch gear
3 Thrust washer
5. Take down the elastic retainer ring of the K4

clutch.
1
Figure 3-58
1 Elastic retainer ring
6. Take out the bearing plate of the K4 clutch.
1
Figure 3-59
1 Bearing plate
46
7. Take out the external and internal friction

linings of the K4 clutch.
1 2
Figure 3-60
1 Internal friction lining
2 External friction lining
8. Install the clutch tooling onto the clutch.
1
Figure 3-61
1 Clutch spring removal tooling
（2938001826）（2938001827） 9. Screw down the tooling nut and press down
the clutch spring.
1 2
Figure 3-62
2 Pressure spring
47
10. Take down the retainer ring fixing the

pressure spring with the snap ring pliers.
1
Figure 3-63
1 Retainer ring
11. Take out the retainer ring and the guide ring
of the K4 clutch in turn.
1 2
Figure 3-64
1 Retainer ring
2 Guide ring
12. Take out the upper guide ring, pressure
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 of the K4

clutch.
1 2 3
Figure 3-66
1 Seal ring 2 K3 clutch piston
3 Seal ring
14. The removal of the K4 clutch is completed.
Figure 3-67
15. Take out the elastic retainer ring of the K3
clutch bearing plate.
1
Figure 3-68
49
16. Take out the K3 clutch bearing plate.
1
Figure 3-69
1 Bearing plate
17. Take out the external and internal friction
linings of the K3 clutch.
1 2
Figure 3-70
18. Press down the K3 clutch pressure spring

with the clutch spring removal tooling.
1 2
Figure 3-71
2 Pressure spring
50
19. Take down the retainer ring fixing the

pressure spring with the snap ring pliers.
1
Figure 3-72
1 Retainer ring
20. Take out the retainer ring and guide ring of
the K3 clutch in turn.
1 2
Figure 3-73
1 Retainer ring
2 Guide ring
21. Take out the upper guide ring, 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 the piston and 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 bearing and check valve
of the K3K4 clutch.
1 2
Figure 3-76
1 Check valve
2 Needle bearing
24. The K4 clutch removal is completed.
Figure 3-77
52
4 Transmission Assembly
4.1 Assembling of the Transmission
Assembly
4.1.1 Three Sets of the Clutch Assembly
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 the needle bearing into the clutch
1 Retainer ring bearing hole and install the retainer ring.
2 Needle bearing Attention

Before assembling, clean all parts.
2. Install the seal ring into the piston 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 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 guide ring and the retainer ring into
the clutch cylinder.
1 2
Figure 4-5
1 Guide ring
2 Retainer ring
5. Install the spring removal and assembling
tooling onto the clutch.
1
Figure 4-6
1 Clutch spring removal and assembly
tooling (2938001826) (2938001827)
54
6. Screw down the nuts on the tooling and press

down the clutch spring.
Figure 4-7
7. Install the retainer ring into the 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, place the external friction lining 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.
1
Figure 4-9
55
9. Place the internal friction lining into the K3

clutch.
Attention
Firstly, place the external friction lining into
the K3 clutch and then place the external and
internal friction linings in turn.
1
Figure 4-10
10. Place the bearing plate into the K3 clutch.
1
Figure 4-11
1 Bearing plate
11. Install the elastic retainer ring into the K3

clutch.
1
Figure 4-12
56
12. Slightly push the K3 clutch friction 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
1 indicator reading is the K3 clutch piston
stroke. Select the internal friction lining with
Figure 4-13 different thickness to ensure that ：
1 Dial indicator the piston stroke （Three Sets of the Clutch are
same）is 1.9mm~2.2mm.
13. Knock the K4 clutch needle bearing into the

clutch bearing hole and install the retainer ring.
1 2
Figure 4-14
1 Retainer ring
2 Needle bearing
14. Install the seal ring into the K4 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)
1
Figure 4-15
1 Seal ring
57
15. Install the K4 clutch piston into the clutch.
Figure 4-16
16. Install the guide ring and the pressure spring

into the clutch cylinder.
1 2 3
Figure 4-17
1 Guide ring 2 Pressure spring
3 Guide ring
17. Install the guide ring and the retainer ring.
1 2
Figure 4-18
1 Guide ring
2 Retainer ring
58
18. Install the clutch spring removal and

assembling tooling onto the clutch.
Screw down the nuts on the clutch removal
tooling and press down the clutch spring.
1
Figure 4-19
1 Clutch spring removal and assembling
tooling (2938001826) (2938001827)
19. Install the retainer ring into the 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, place the external 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.
1
Figure 4-21
59
21. Install the internal friction lining into the K4

clutch.
1
Figure 4-22
22. Place the bearing plate into the K4 clutch.
1
Figure 4-23
1 Bearing plate
23. Install the elastic retainer ring into the K4
clutch.
1
Figure 4-24
60
24. Slightly push the K4 clutch friction 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 the thrust washer into the K3 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 the gasket and the thrust washer into
the K3 clutch.
1 2
Figure 4-27
1 Thrust washer
2 Washer
61
27. Install the K3 clutch gear.

Attention
Before installing the gear, it is necessary to
perform alignment to the internal friction
lining splines of the clutch.
1
Figure 4-28
1 K3 clutch gear
28. Install the lining seal ring 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 body.
1
Figure 4-29
1 Roller×12
29. Install the thrust washer into the K4 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 the needle bearing into the K4 clutch

gear.
1
Figure 4-31
1 Needle bearing
31. Install the K4 clutch gear.
Attention
Before installing the gear, it is necessary to
perform alignment to the internal friction
lining splines of the clutch.
1
Figure 4-32
1 K4 clutch gear
4.1.2 Main PTO Assembly

1. Install the needle bearing into the 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 ring into the 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 PTO shaft into the gear hole; 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 assembling is completed.
1
Figure 4-36
1 Retainer ring
64
4.1.3 Input Part Assembly

1. Knock the ball bearing onto the auxiliary
driving shaft.
1 2
Figure 4-37
1 Ball bearing
2 Auxiliary driving shaft
2. Install the flat key of the internal gear of the
gear pump on the shaft and cover it with the oil
pump.
1
Figure 4-38
1 Internal gear of the gear pump
3. Knock another ball bearing into the oil pump
bearing hole.
Attention
Ensure that the auxiliary driving shaft can
flexibly rotate.
1
Figure 4-39
1 Ball bearing
65
4. Install the clip for shaft and buckle seal ring.
12
Figure 4-40
1 Clip
2 Seal ring
5. Knock the needle bearing into the 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
1 Oil seal Φ75
2 Needle bearing
6. Install the roller bearing into the bearing hole

of the oil feed 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 the input gear into the oil feed flange

and adjust the gear clearance.
1
Figure 4-43
1 Input gear
8. Install the seal ring onto the drive shaft.
1 2
Figure 4-44
1 Drive shaft
2 Seal ring
9. Insert the drive shaft and install the ball
bearing.
1 2
Figure 4-45
1 Drive shaft
2 Ball bearing
67
10. Use the depth gauge to measure : two ends’

distance and write down: h
1 2
Figure 4-46
1 Oil feed flange end
2 Bearing end
11. Use the depth gauge to measure : two 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 bearing is: 0.2mm~0.4mm.
1 2
Figure 4-47
1 Oil pump bearing hole end
2Oil pump joint end
12. Install the steel ball and the pressure spring

into the safety valve hole of the torque converter
on the oil feed flange.
1 2
Figure 4-48
1 Steel ball Φ20mm
2 Pressure spring
68
13. Place the oil pump packing on the oil feed

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

component and the oil feed flange component.
23N.m
1 2
Figure 4-50
15. Place the packing of the pump impeller

bearing seat on the oil feed flange surface.
1
Figure 4-51
1 Packing
69
16. After knocking in the pump impeller bearing

seat and screwing down the bolt between the
pump impeller bearing seat and the oil feed
flange, the assembling is completed.
23N.m
1
Figure 4-52 4.2 Transmission Assembly
1 Hexagon head screw (M8*28)×8 4.2.1 Output Part Assembly
1. Place the output shaft gear; install the 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 Output shaft gear 2 Baffle plate
3 Oil shield
2. Knock out the roller bearing and place 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 in turn.

Attention
Select the adjustable washer with different
thickness, so as to ensure that the axial
clearance of the bearing is 0.1mm~0.3mm.
1
Figure 4-55
1 Output shaft
4. Install the snap ring.
1 2
Figure 4-56
1 Adjustable gasket
2 Snap ring
5. Install the oil seal into the transmission 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. Install the output flange and pressure plate,

and screw tight the bolts 2-M10×30.
46N.m
1
Figure 4-58
1 Output flange
7. Install the output flange, O-ring, distance
washer and pressure plate in turn.
1
Figure 4-59
1 Lock washer assembling tooling
(2938001838)
8. Install the parking brake flange.
1
Figure 4-60
1 Parking brake flange
72
9. Lock the locking plate after amounting the

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

Assembly
1. Install the roller bearing into the 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 intermediate shaft gear 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 the screw and then install the sealing

washer.
80N.m
1
Figure 4-64
1 Head cap screw×1
4.2.3 Torque Converter Pressure Control

Valve Assembly
1. Install the pressure spring and the 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
converter of the transmission body and 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 the O-ring and piston ring on the K3K4
clutch shaft.
1 2
Figure 4-66
1 Piston ring×3
2 O-ring
74
2. Place the clutch assembly into the

transmission body.
about 15kg
Attention
When placing the clutch, use the tooling and
jack up the bottom of the clutch to avoid its
falling.
1
Figure 4-67
1 Clutch assembling tooling 2938001832
3. Overturn the transmission to make it be in a

horizontal position, and then install the clutch
assembling tooling.
Figure 4-68
4. Use the depth gauge to measure :

a、The bearing step Of clutch shaft and write
down : height h。
b、The housing surface to the 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
1 K3K4 clutch shaft clearance of the clutch assembly is:
0.1mm~0.3mm.
2 Roller of the needle bearing of the K3
clutch
75
5. Take out the tooling; install the K4K3 clutch

shaft and screw down the nut fixing the clutch
assembly.
Attention
The K3K4 clutch gear can flexibly rotate.
23N.m
Figure 4-70
4.2.5 KRK2 、KVK1Clutch Assembly

1. Amount the clutch assemblies 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
1 2 clearance of the clutch assembly is:
Figure 4-71 0.1mm~0.3mm.
1 KVK1 clutch assembly

2 KRK2 clutch assembly
4.2.6 Auxiliary PTO Assembly

1. Place the transfer gear into the transmission
body.
1
Figure 4-72
1 Transfer gear
76
2. Knock in the PTO shaft to make the 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 the PTO shaft

with the snap ring pliers.
1
Figure 4-74
1 Snap ring
4. Assemble the PTO end cover and install the

additional packing. Screwing down the bolt
between the PTO end cover and the transmission
body.
Attention
Replace the removed packing with a new one.
16N.m
1
Figure 4-75
1 PTO end cover
77
4.2.7 Input Component Assembly

1. Install the input device onto the transmission
body; install the additional packing and knock it
in with the copper rod.
Attention
Upon installation, screw in two bolt
positioning thread holes. Replace the removed
packing with a new one.
1
Figure 4-76
1 Input component
2. Assemble the lubricating oil pipe component

and screw down the hollow screw between the
oil pipe and the transmission body.
34±5N.m
1
Figure 4-77
1 PTO lubricating oil pipe component
3. Assemble the connecting shell and knock it in

with the copper rod.
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.
1
Figure 4-78
1 Torque converter connecting shell
78
4. After screwing down the bolt between the

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

1. After installing the main PTO 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 Filter Assembly
1. Screw down the oil filter.
Figure 4-81
79
4.2.10 Transmission Control Valve

Assembly
1. Place a paper gasket, a lower 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 3-M8×30 and socket screws 3-M8×45
and 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, a upper baffle, a paper

gasket and a pilot valve onto the oil delivery
plate, and fix them with the bolt 3-M8×30 and
socket screws 3-M8×45 and 6-M8×35.
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 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 Torque Converter Assembly

1. After installing the intermediate ring and the
torque converter into the connecting shell, the
assembling is completed.
About 20kg
Attention
As there is no axial positioning after installing
the torque converter, fixing 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 the voltage, if battery
2) Troubles in starting relay or losses too much power, charge
other related apparatuses firstly;
3) DW-4 handle is not at neutral 2) Check starting circuit of the
4) Bad contact of EST plugs or engine, to see any bad connection
EST troubles or damaged elements
3) Put selector handle to neutral,
when the starting relay on the
engine should be engaged
4) If AS has no signal (voltage
on line 0 is not +24V), it shows
output of EST is failure.
Reconnect the plugs once, making
sure right contact. If it still does
not work, replace EST.
2 Vehicle cannot run at any 1) Open or short circuit 1) Disconnect the plugs,
gear 2) Damaged solenoid valves; 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) Check any worn-out in
heard inside the box connection cables. Replace if
3) Damaged DW-4 selector necessary
handle or bad contact of plugs 3) Check if contact of leading
4) Damaged EST-4 or bad -out plugs of DW-4 and EST
contact of connectors correct, if loosened, press tightly.
5) Troubles in oil circuit or other 4) Replace DW-4 selector or
mechanical failures EST ECU
5) Replace hydraulic control
valve
82
3 Vehicle cannot run at gears 1) Choked brake switch BR or 1) Check if two switch work
one and two but can run at emergent brake switch BR2; freely; if not, do some treatment;
gears three and four 2) Wire between BR and +24V 2) Disconnect lines to BR or
has short circuit; BR2, if gear normal, check wiring
3) Damaged solenoid valve M4 and remove troubles
3) Replace M4
4. No high-speed gears. 1) It normally happens in types 1) Inspect the sensor 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) Check wiring to sensor.
2) Bad contact of DW-4 plugs or Repair if damaged.
damaged selector 3) Replace selector DW-4
5. No forward gears 1, 2 and 1) Damaged internal elements of 1) Replace selector
3 selector DW-4 2) Replace solenoid valve M3
2) Damaged solenoid valve M3
6. No reverse 1) Damaged solenoid valve M1 1) Replace solenoid valve M1

2) Damaged selector 2) Replace selector
7. Vehicle is sometimes in 1) Unstable power supply 1) Check vehicle power supply

gear and sometime out 2) Bad contact somewhere and remove voltage fault
in connection plugs 2) Check all plugs, tidy and
3) Unstable solenoid valves press all connectors
or electric control unit 3) Replace electric control unit
83
5.2Malfunction Diagnosis and Troubleshooting of the Transmission

Table 5-1
No. Symptom Cause Troubleshooting
1、 Fail to start the circuit. 1、 Check the engine circuit and refer to the
（such as power supply, “starting of engine circuit” on the
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
The engine doesn’t 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 box or
electro-control box fault.
1、 Pressure gauge failure. 1、Replace the pressure gauge.
2、Insufficient tight torque 2、Increase the tight torque of the bolt to M8
of the shift controlling class 20Nm.
valve bolt. 3、Replace.
3、 Broken spring of main 4、Replace the shifting pump.
Low pressure at all
2 pressure valve. 5、Replace the filter and 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
stalling the engine, then restart the engine,
Low display
and shift to the astern speed 1, 2, 3. If
pressure at 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 engines with exhausting holes.)
3、Insufficient 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、Insufficient rejecting for feculence.
ability of the radiator. 7、Check the hose joint from the transmission
7、Choked back pressure to the radiator. If it is inserted into the
valve of the torque housing by an excessive length, it will
converter. stick to the core of backpressure valve,
thus choking the valve and resulting in
difficulty of the oil circuit.
1、Insufficient 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. the cable plug is loosened.
The vehicle does （rarely）。 4、Correct it by 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 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.
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 it is measured to be 0 or ∝，it is damaged and
forth gear. need replacing.
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
4、Clear the shifting control valve.
the transmission.
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 of the 1、Check the supply system of the machine.
shifting lever of loose 2、Search in accordance the engine circuit.
contact of its connection 3、Sort the connection-peg of the shifting
14 Unsteady speed -peg. lever or replace it.
4、Insufficient oil level of the 4、Add oil by the correct method.
transmission。 5、Sort the 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 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

ADVANCE WG180 Transmission Service Manual

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ADVANCE WG180 Transmission Service Manual

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ANDVANCE WG180 Transmission Service Manual

SHANDONG LINGONG CONSTRUCTION

Address: Linyi Economic Development Zone

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

2.1.1 Transmission Introduction ................................................................................................................... 5

2.1.2 Basic Parameters of the Transmission-torque Converter Assembly .................................................... 6

2.1.3 Mechanical Principles of the Gears of the Transmission..................................................................... 7

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

2.1.5 Transmission Function Testing .......................................................................................................... 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 Transmission 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

3.1.7 Dismantle the three Sets of the clutch Assembly .............................................................................. 32

3.1.9Intermediate Shaft Assembly Removal .............................................................................................. 37

3.1.10 Removal of the Torque Converter Pressure Regulating 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

4 Transmission Assembly ................................................................................................................................... 53

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

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

4.1.2 Main PTO 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 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 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............................................................................................ 80

4.2.11 Torque Converter Assembly ............................................................................................................ 81

5 Malfunction Diagnosis and Troubleshooting ................................................................................................ 82

5.1Malfunction Diagnosis and Troubleshooting of the EST Semi-Automatic Gear Controller....................... 82

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

Important Safety Precautions

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

1 1. Transmission control valve

2.1.2 Basic Parameters of the Transmission-torque Converter Assembly

Item 4WG180 6WG180

2.1.3 Mechanical Principles of the Gears of the Transmission

2. Hydraulic oil system of transmission

Fig 2-4 Hydraulic principle of electro-hydraulic control

2.1.4 Gearbox control system

Rated voltage DC 24V

Working voltage range DC 20～32V

Input current Max.5A