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1

CONTENTS
Preface
Safety Information
Operating Principle
Technical Specifications

Shift
Control Valve, End Cap Group and Clutch
Assembly ........................................................ 67
Output Shaft Group .................... 115

Parts Reassembly
CV&CR Assembly .................. 122
- C1&C3 Assembly ................ 141

General
Torque Specifications

- C2&C4 Assembly ................. 159


Output Shaft Group ................... 180

Denomination of
Standard Dimensions
Conversion Table
Tool Table
Cleaning and
Inspection

Shift
Control Valve, End Cap Group and Clutch
Assembly ....................................................... 189
Connectors and Hose
Assembly ..................................................... 210
Brake ................................................ 217
Torque Converter Housing
Group ............................................................ 221
Torque Converter Group ........... 240

Parts Disassembly
Transmission and Torque
Converter Accessories ....................................29
Torque Converter Group ..............33
Torque Converter Housing
Group .............................................................40
Brake ...................................................55
Connectors and Hose
Assembly .......................................................59

Transmission and Torque


Converter Accessories ................................. 248

Check
the Machine after Repairing
Lubrication
Oil Brand................................................ 254
Transmission Oil Level--Check ...... 254
Transmission Oil--Replace .................... 254

Transimission oil Filter--Replace .255

Troubleshooting
Oil Pressure in All Gears
is Low ...........................................................256
Oil Pressure in
Certain Gears is Too Low .............................257
Shifting Intervals for All
Gears are Too Long ......................................257
Shifting Intervals for All
Gears are Too Short ...................................258
No Power Output for All
Gears ...........................................................258
Oil Temperature is Too High .........260
Troubleshooting ......................262

Appendix
Transmission Route Chart ..........265
Electrical Control Circuit ......269
PT300 Hydraulic Schematic for
PT300 Transmission ....................................271
PT300 PT300 Transmission
Measuring Points Layout ..............................272
PT300 PT300 Transmission Oil Inlet
.......................................................................273

Index

1
Preface

Preface

This service manual includes the detailed


operation instructions concerning product
disassembly and reassembly. Before performing
any service on this product, all the parts should
be kept clean and all the operations should be
carried out in correct procedures. Remove the
parts only when it is damaged and necessary to
remove. When you are going to loosen a bolt or
a screw, or remove a cover or housing where
seals are, you must tap with a plastic hammer or
copper bar and use a proper tool to remove the
parts such as bearing, bearing cup, ect which are
mounted on the shaft.

Select a clean and flat place and use special


tools to install and remove the parts. Before
assembling, all parts should be cleaned
thoroughly, no residual sealant is allowed on the
contact surface of housing and cover, and the
burnt or abrasive surface should be burnish with
an oil stone. Always use your professional
experience to judge the parts like bearing, lock
washer, etc. and see if they are damaged or
seriously fatigued. If so, replace with a new one.

Parts like seal ring, locknut, paper gasket, etc.


should be replaced at once after removing.
Replace the seal if it is burnt or its lip is
damaged. Particularly care must be taken to
ensure that no iron scurfs or foreign matters
leave inside the transmission. Check the
lubricant in the holes or grooves.

Lubricate all the bearings according to the


requirements of lubricant before assembling.

Different special tools are needed when installing


or removing different parts. All these tools are
available in "Tool Table".

:
This service manual is written for those trained
professional personnels to perform maintenance
or repair to LiuGong products. Due to product
improvement, the disassembly or reassembly
procedures or testing data presented in this
publication might be different from that on your
product when you are repairing the machine. We
recommend repairing the machine only by a
trained person. The Service Stations, established
by LiuGong all over the world, will offer you:
1.
Trained service team.
2.
Professional equipment, e.g. special tools.
3.

Newest and original Liugong Parts.

2
Preface

This service manual uses the following safety


signs:

You also can receive excellent service if you


repair or maintain the machine in a designated
Liugong Service Station.

Guangxi LiuGong accepts no liability for any


damage resulting from failure to observe the
operations and procedures stipulated in this
service manual.
Safety operation instruction:
1.

People who repair or maintain Liugong


product should bear the safety
responsibilities.

Danger: this word denotes an impending danger,


failure to observe instructions could result in
death or serious injuries.

Warning: this word denotes potential danger,


failure to observe instructions could result in
death or serious injuries.

2.

Obey the laws and regulations to prevent


personnel injury and harm to product.
3.

The repairer should be familiar with these


regulations before working.
4.

Only trained or experienced personnel is


allowed to operate or maintain this machine.
5.
The service center should provide training to
his people.

Caution: this word denotes potential danger,


failure to observe instructions could result in
minor to medium degree of injury.

All the photographs, illustrations and parts


drawings in this manual show the operating
procedures of the parts, not its exterior drawing,
dimension or weight.

CAUTION: The machine should be


rechecked by a professional person after it is
repaired.

3
Safety Information

Safety
Information

Attach a DO NOT OPERATE or similar warning


tag to start switch or control levers before
servicing or repairing the machine.

Be familiar with all safety cautions, failure to


observe could result in property damage, serious
injury or even death.

:
te
Da

O
pe
ra
te

r:

General Hazard Information

d
op o n
er ot
at
e

AR
N

IN

Do not wear loose fitting clothing, dangling


jewelry or long hair that can catch on controls or
in other moving parts of the machine.

Only trained and qualified personnel should be


allowed to operate or maintain the machine.

Do not operate the machine if you feel sick,


sleepy or after taking some medication. Check
with your doctor if unsure. Never operate
machinery while under the influence of drugs or
alchohol.

Wear relevant personal protective equipment


(PPE) such as a hard hat, ear protection, safety
glasses, safety shoes and gloves when
operating or servicing the machine.

4
Safety Information

When working under high noise conditions, wear


appropriate safety equipment to protect your
hearing, such as approved earmuffs or plugs.
Avoid the damage caused by exposure to high
noise on your hearing.

Using goggles, safety glasses or full face mask


can protect your eyes from being injured by high
pressure liquids, when maintaining storage
batteries, by flying scraps when the engine is in
operation or you are using tools to strike objects,
remove springs or resilient parts, add acid/
electrolyte to batteries, you should wear a full
face protective mask. When carrying out welding
operations or gas cutting operations with a
welding torch, wear specific safety goggles
suitable for the task being performed. Consult
your welding equipment dealer for more
information.

Make sure all protective guards and covers are


secured in place on the machine. Keep the
machine, especially the panels, accesses, step
and ladders, free of foreign material, such as
debris, oil, tools and other items which are not
part of the machine.Secure all loose items such
as lunch boxes, tools and others.

Pay attention when opening fluid compartments,


prevent foreign materials from entering the
system. Always remove loose materials from
near caps and plugs.

5
Safety Information

Know the appropriate worksite hand signals and


who gives them. Accept signals from one person
only.

No smoking and keep open flames away when


maintaining air conditioner or if there is
refrigerant gas, the flames contact the refrigerant
and the cigarette smoke will cause personal
injury or death.

Never put maintenance fluids into glass


containers.

Observe the relevant laws and regulations when


handling harmful articles such as lubricants,
fuels, coolants, solvents, filters, batteries and
other matterials.
,

Use all cleaning solutions with care. Do not use


any flammable material to wash components, for
example, diesel oil or gasoline. They may easily
catch fire.

Do not allow unauthorized personnel on or


around the machine.

Guangxi Liugong bear no resposibility for failures


caused by modifications to machine structure
without Liugongs permission.
Compressed Air

0.2MPa
Compressed air can cause personal injury. When
using compressed air for cleaning, wear a
protective face shield, protective clothing,
hearing protection and protective shoes. Never
direct compressed air at yourself or others.
Compressed air could penetrate your skin and
cause serious injury or death. The maximum air
pressure used should not exceed 25psi(0.2Mpa).
High-pressure Fluid
:

WARNING: Avoid injury from


highpressure oil. When repairing hydraulic
lines, ensure that system pressure is
completely released before beginning the
repair. Hydraulic oil under pressure
contacting the skin could cause serious
injury or damage.

Use cautiion before disconnecting hydraulic lines


or connectors. High pressure oil that is released
can cause a hose to whip.

Report all required repairs in time.

6
Safety Information

Wear safety glasses and leather gloves. Never


check for a high-pressure leaks with your
unprotected hand. Use a board or cardboard
when checking for leaks.

Prepare to collect fluids with suitable containers


before opening any compartment or
disassembling any component that contains
fluids.

Use suitable containers to collect waste fluids.


Do not use food containers or beverage bottles
as they could mislead people to drink the
contents.

Even a pin-hole size leak can cause serious


injury, If you are hit by spraying high-pressure oil,
see a doctor for treatment at once.
Asbestos Danger

Disposal of Waste Fluids

Improper handling of the waste fluid will cause


pollution of the environment. Obey all local
regulations for disposal of waste fluids.

Breathing asbestos dust can be hazardous to


your health. Equipment and replacement parts
shipped from Liugong have no asbestos in them.
Liugong recommends the use of genuine factory
spare parts only. Observe the following rules if
you are handling any spare parts that contain
asbestos or asbestos fibers:

Never use compressed air to clean up


asbestos. Use a wet method in order to clean
up asbestos materials. Water the area down
to clear asbestos dust.

Collect all waste fluids when performing


inspections, maintenance, testing, adjusting and
repairs to the machine.

A vacuum cleaner that is equipped with a


high efficiency particulate air filter (HEPA)
can also be used.

7
Safety Information

Do not grind materials that contain asbestos.

Operate the machine in upper tuyere area as


far as possible.

Obey environmental regulations for the


disposal of asbestos.

Shower after contact with asbestos.

Wear an approved respirator if there is no


other way to control the dust.

If it is necessary to remove shields in order to


perform maintenance, always install the shields
after the maintenance is performed.

Rotating or moving parts have cutting or crushing


hazard. Keep clear or stop engine before
servicing.

Crushing and Cutting Prevention

Don't put hands, arms, or any other parts of the


body in the way of removable parts.

Support equipment and attachments properly


when working beneath them. Do not depend on
hydraulic cylinders to hold up the implement/
attachment. The implement/attachment can fall if
a control lever is accidentally moved, or if a
hydraulic line breaks.

Keep hands and objects away from moving fan


blades. They can throw or cut any object that
contacts the moving blades.

Never attempt adjustments while the machine is


moving or the engine is running unless otherwise
specified.

8
Safety Information

If the machine must be repaired with engine


running, make sure that a qualified operator is
available in the cab to shut down the engine if
required.

Do not use a kinked or frayed wire cable. Wear


gloves when handling wire cables.

Relieve all residual pressure in air, oil, fuel or


cooling systems before any lines, connectors or
related items are disconnected or removed.

Retainer pins, when struck with force, can fly out


and injure nearby persons. Make sure the area is
clear of people when driving retainer pins. Wear
protective glasses when striking a retainer pin to
avoid injury to your eyes.

Chips or other debris can fly off objects when


struck. Make sure no one can be injured by flying
debris before striking any object.

Fire Extinguishers and First-aid


Kit

Burn Prevention

A fire extinguisher that meets with all local fire


extinguisher laws and regulations should be
available on the machine.

Some parts of the machine become hot during


normal operation. Use caution when maintaining
the engine and hydraulics. Allow the machine to
cool after it has been operating for a long period
of time.

A first-aid kit should be available at the work site.


Periodically check the contents of the kit and
replace used medical supplies as necessary.

Oil

Hot oil and components can cause personal


injury. Do not allow hot oil or components to
contact the skin.

Know how to use the fire extinguisher and firstaid


kit.

9
Safety Information

Keep telephone numbers of doctors, first-aid


centers or fire stations etc with you so you can
contact them in case of an emergency. Post the
contact telephone numbers in regulated places.
Ensure that all persons know where the
telephone numbers are located and know the
correct contact method.

Attachment Cautions

Attachments should only be installed by


authorized people who have been trained to
operate and maintain the attachment according
to the operators manual.

Refer to the instructions in the operation manual


and any other related information when installing
and using attachments.

Inspect and service the fire extinguisher


regularly. Obey the recommendations on the
instruction plate and all local laws and
regulations relating to fire extinguishers.

Incorrect installation of attachments or optional


parts not only will result in safety problems, but
also will negatively influence the operation and
sevice life of the machine and the attatchments.

Steering Frame Lock

It is forbidden to use unauthorized attachments.


Otherwise, product safety problems might be
involved and the machine service life could be
affected.

Connect steering frame lock when the machine


is being lifted and shipped. Also connect the
steering frame lock when performing repairs
near the articulation joint.

Disassemble the steering frame lock before


operating the machine.

It is forbidden to modify the machine or any


attachments without permission from your
Liugong dealer.

Liugong bears no responsibility for injuries,


accidents or machine damage resulting from the
use of unauthorized attachments.

10
Safety Information

Store Accessories Safely

Lifting The Parts

Store accessories and tools safely so as to


prevent them from falling and causing serious
injury or death. Keep playful children and
bystanders away from the storage area or any
area accessories are being stored while in use.

Falling of the lifting parts could hit or crush the


persons nearby. Serious personal injury or even
death could be resulted.

Never use a broken iron chain or an abrasive


steel rope, lifting tool or rope to lift parts.

Move the lifting parts slowly and carefully, never


move it suddenly.

Never hoist the parts over a person.

Support the Machine Correctly

Lower to the ground or support any attachments


with stands or other methods. Ensure that any
attachment can not move during maintenance or
repair work, use wheel chocks or other devices
to prevent machine movement.

Use stands or other measures that are secure


and can support the weight being applied to
them.

Do not work under any part of the machine or


attachment that is not adequately supported.

Keep all persons clear of the lifting parts until it


has been steadily placed on the supporting block
or safely lowered to the ground.

Welding Operation

Any personnel engaging in welding operations


must have occupational certificates and carry out
the operation at a place with appropriate devices
equipped, When carrying out the welding
operation, the personnel must follow the
instructions below:

Before carrying out the welding operation,


turn off the battery isolator switch, disconnect
the battery, disconnect the controllers, GPS
and other electrical parts.

11
Safety Information

Remove all paint from the place to be


welded, so as to prevent harmful gas from
being produced.

Do not inhale smoke produced buy burning


paint.

Never weld pipes, close to rubber hose and


electrical wires.

Always wear correct PPE for welding, protect


bystanders by using screens and signs
advising of the operation being performed.

Ensure good ventilation.

Remove all the flammable materials, supply


the work area with a fire extinguisher.

12
Operating Principle

Operating
Principle

(7) (3)
(8)
(6) (5) (1)
(2)
(4)
After the engine is started, oil is continuously
sucked out from the transmission oil sump
through suction hose (7) and coarse filter (3) of
charging pump. Then oil comes out from outlet of
charging pump (8) and passes through hose
assembly (6) and elbow (5) and filtered by oil
filter (1). Finally it is supplied to shift control valve
(4) and torque converter through hose assembly
(2).

(10) (11)

(9)

When oil flows into the torque converter, it


produces a lot of heat due to its high and
complicated flowing speed. The heated oil
passes through hose assembly (10) and reaches
torque converter oil radiator (11). After being
cooled in the oil radiator, it comes out and returns
to the transmission torque converter through
hose assembly (9) to lubricate the clutches and
bearings inside the transmission.
9

10

11

8
7
6

9.
Hose assembly
11.
Torque converter oil radiator

10.
Hose assembly

( )

1.
Oil filter
3.
Coarse filter

2.
Hose assembly
4.
Electro-hydraulic shift
control valve

5.
Elbow
7.
Suction hose

6.
Hose assembly
8.
Charging pump

The torque converter is installed between the


engine and transmission, which consists of
impeller, turbine and stator. These three
impellers are arranged in a loop system and the
fluid inside them flows circularly.

13
Operating Principle

12
13
14

12. Impeller

13. Stator

14. Turbine

The impeller is connected with the engine while


turbine is connected with the transmission. The
impeller is driven by the engine and rotates with
the same speed as the flying wheel of the
engine, forcing the oil inside the working
chamber to impact on the turbine with a fast
speed and huge pressure in the given direction.
By this way, the mechanical energy of the engine
is converted into the kinetic energy of the fluid;
then the turbine absorbs the kinetic energy of the
fluid and rotates to obtain its speed. The kinetic
energy of the working fluid is then converted into
the mechanical energy of the turbine to transmit
the power to the transmission through the gear.

Charging pump continuously supplies the


transmission oil from the oil sump to the torque
converter. After coming out from the impeller, oil
enters into the turbine. Then oil direction is
changed, oil comes out from the turbine and runs
to the stator and being baffled to run forward
continuously by the stator vane. When the oil
flows back to the impeller along the vane of the
idler, its absolute streamline strikes the front
surface of the impeller and its absolute
streamline is identical with the original one. The
residual energy of oil in the last circle helps the
impeller rotating. Therefore, the total torque of
the turbine is equal to the vector sum of the
torque from impeller impacting on the fluid and
from the stators reaction on the fluid. The torque
converter has increased the output torque of the
engine and takes away the heat through the
running fluid.

12
12. Impeller

13

14
13. Stator

14. Turbine

The output speed of the turbine of torque


converter changes accordingly as the change of
the machine work load in order to meet the
torque requirements of the machine.

PT300

14
Operating Principle

All gears inside the transmission are constant


meshing gears and running under the support of
the bearings. Gears, bearings and clutches are
lubricated by cooling oil. Four forward gears and
four reverse gears are available on PT300
transmission, which consists of six multi-plate
clutches, drive gear, shaft, bearing, transmission
housing, electro-hydraulic shift control valve and
other attachments.

The power of the engine is transferred to the


torque converter from its input end, and is finally
transferred to the transmission. The output shaft
of the transmission drives the front and rear axle
through the front and rear flange and drive shaft.

Transmission gears are controlled by the


engagement and disengagement of the clutches,
which is controlled by the electro-hydraulic shift
control valve. The pressurized oil can reach the
corresponding clutches when the solenoid valve
of the electro-hydraulic shift control valve
controls the corresponding spools.

Pressure control valve adjusts the gear pressure


of clutches. During shifting, the pressure will drop
for a very short time; after finishing shifting, it will
rise to the setting value.

The gear change signal is determined by the


speed of the machine and is sent out by a
LiuGong controller. During shifting, the pressure
control valve will be reset to its initial position by
the resetting valve and make the piston prepare
for the next shifting.

During shifting, the pressurized oil from the


electro-hydraulic shift control valve pushes the
clutch piston to move, the return spring is thus
forced to compress and the outer clutch disc is
forced to move in the axial direction and finally
engages with inner clutch disc. When the
pressure of the electro-hydraulic shift control
valve is cut off, the outer clutch disc and inner
clutch disc are forced to disengage under the
pressure of return spring. Therefore, different
gears can obtain through the engagement and
disengagement of clutches.

( 0.8MPa)

0.25MPa
A relief valve is provided at the inlet of the torque
converter to prevent the pressure produced in
the torque converter is too high (cut-in pressure
supposed to be 0.8MPa). To avoid the
occurrence of cavitations, the torque converter
should be fully filled with oil. The cut-in pressure
of the torque converter is about 0.25MPa
maintained by the backup valve.

15
Technical Specifications

Technical Specifications
Item

Unit

Qty

Rated engine input power

KW

130

Max. engine input rev. speed

rpm

2500

Max. engine input torque

N.m

800

Max. torque converter output torque

N.m

1100

The cut-in pressure of the outlet valve of torque converter

MPa

0.25

The cut-in pressure of the relief valve of torque converter

MPa

0.80

Max. torque ratio of torque converter

3.15

Working temperature of torque converter

80 100

System pressure of electro-hydraulic shift control valve

MPa

1.8 2.0

Rated voltage of electro-hydraulic shift control solenoid valve

24

Rated current of electro-hydraulic shift control solenoid valve

mA

350

Oil cleanliness of electro-hydraulic shift control valve

NAS1638 9
NAS1638 Grade 9

Speed ratio (F1)

4.020

Speed ratio (F2)

1.985

Speed ratio (F3)

1.015

Speed ratio (F4)

0.561

Speed ratio (R1)

4.017

Speed ratio (R2)

1.984

Speed ratio (R3)

1.014

Speed ratio (R4)

0.561

Rated pressure of charging pump

MPa

2.0

Rated speed of charging pump

rpm

2200

Rated displacement of charging pump

mL/r

45

SAE15W-40 1300
Transmission oil (SAE15W-40 MOBIL 1300)

40

Weight (without oil)

Kg

580

16
General Torque Specifications

General Torque Specifications


PT500
Tighten the bolts used on PT500 transmission according to the torque requirements shown in the
following table unless otherwise specified.
Standard Torque (N.m)

Nominal
Diameter

4.6
Grade 4.6
Strength

4.8
Grade 4.8
Strength

5.8
Grade 5.8
Strength

6.8
Grade 6.8
Strength

8.8 10.9 12.9


Grade 8.8 Grade 10.9 Grade 12.9
Strength
Strength
Strength

M6

4.5 0.5

4.5 0.5

61

61

10.5 1.5

14 1.5

18 2

M8

11 1

11 1

13 1.5

13 1.5

26 4

33 3

45 6

M10

22 2

22 2

28 3

28 3

52 7

72 6

90 10

M12

40 4

40 4

50 5

50 5

90 12

120 10

150 20

M14

62 7

62 7

80 10

80 10

145 20

195 15

245 30

M16

100 10

100 10

125 15

125 15

225 35

305 25

380 50

M18

135 15

135 15

170 20

170 20

310 45

415 35

520 70

M20

190 20

190 20

240 30

240 30

410 50

600 50

750 100

M22

260 30

260 30

320 30

320 30

600 80

800 70

1000 140

M24

340 35

340 35

410 40

410 40

760 100

1020 100

1280 180

M27

490 40

490 40

630 70

630 70

1100 150

1500 100

1850 250

M30

610 70

610 70

800 50

800 50

1500 200

1850 150

2500 300

M33

780 100

780 100

960 140

960 140

2050 300

2900 400

3450 500

M36

1000 100

1000 100

1260 140

1260 140

2650 350

3100 250

4500 500

M39

1100 130

1100 130

1300 240

1300 240

3400 470

4800 650

5700 800

M42

1520 140

1520 140

1900 200

1900 200

3500 350

4600 350

M48

2200 200

2200 200

2900 350

2900 350

4700 290

7100 640

17
Denomination of Standard Dimensions

Denomination of Standard Dimensions

Item

New Unit

Symbol

Old Unit

Conversion

Note

Mass

Kg(Kilogramm)

kg

Force

N (Neweton)

kp

1kp=9.81N

Work

J(Joule)

kpm

0.102kpm=1J=1N.m

Power

KW(Kilowatt)

PS(DIN)

1PS=0.7355KW

Torque

N.m(Newtonmeter) kpm

1Kpm=9.81N.m

T(N.m)=F(N)r(m)

Torque

N.m(Newtonmeter) kpm

1Kpm=9.81N.m

M(N.m)=F(N)l(m)

Pressure

bar

Speed

Min-1
Rpm
r/min

at

1KW=1.36PS

1.02at =1.02kp/cm2=1 bar=750torr

Conversion Table
25.40mm

1in(inch)

1kg(Kilogramm)

2.205Ib(pounds)

9.81N.m(1kpm)

7.233ibfft(pound force foot)

1.356N.m(0.138kpm)

1Ibfft(pound force foot)

1kg/cm

5.560Ib/in(pound per inch)

1bar(1.02kp/cm2)

14.233psi(pound force per squar inch lbf/in2)

0.070bar(0.071kp/cm2)

1psi(Ibf/in2)

1Liter

0.264Gallon(Imp.)

4.456Liter

1Gallon(Imp.)

1Liter

0.220Gallon(US)

3.785Liter

1Gallon(US)

1609.344m

1Mile(Landmeile)

0C(Celsius)

+32F(Fahrenheit)

0C(Celsius)

273.15Kelvin

18
Tool Table

Tool Table

Description

Picture

Number

A00

Mounting rack

A01

Pressing socket

Remove the oil


seal seat of
output shaft

A02

Spacer sleeve

Transmission
disassembly and
reassembly

Two-armed
puller

Note

A03

Install the circlip


of spring pressure
cap in clutch

Install the clutch


return spring

19
Tool Table

Description

Picture

Number

A04

Pressing socket

Install oil seal of


output shaft

A06

Tool for seals

Install the oil seals


of adapter sleeve

Tools for
bearings

Remove the
circlip of spring
pressure cap in
clutch

A05

Tool for seals

Note

A07

Remove and
install bearings

20
Tool Table

Description

Eye bolt

Picture

Number

A08
M10 M12

A09

Marker pen

Universal use

A10

White sisal rope

Universal use

Steel rope

Note

A11

Remove clutch
assembly

Universal use

21
Tool Table

Description

Picture

Number

A12

Hammer

A13

Tommy bar

Universal use

Universal use

Screwdriver

Gun for plane


sealant

Note

A14

Universal use

A15

Universal use

22
Tool Table

Description

Picture

Number

A16

Locker

A17

Punch

Universal use

A18

Copper bar

Universal use

Copper bar

Note

A19

Install the clutch


piston assembly

Universal use

23
Tool Table

Description

Torque spanner

Picture

Number

A20
20~100N.M
60~300N.M

A21

Open spanner

Universal use

A22
9/16 14 17

19 21 22 24
27 32 36 41 Universal use
55

Adjustable
wrench

Universal use

Impact wrench

Note

A23

Universal use

24
Tool Table

Description

Ring spanner

Inner hexagon
spanner

Air gun

Socket

Picture

Number

Note

A24
9/16 14 17
19 21 22 27 Universal use
41

A25
S8

A26

Universal use

Universal use

A27

9/16 14 17
Universal use
19 22

25
Tool Table

Description

Socket

Socket

Picture

Number

A28
S6

A29
50

Socket
extension

A30

Remove and
install the shift
control valve

Remove and
install the locknut
of output shaft

Universal use

Three-armed
puller

Note

A31

Universal use

26
Tool Table

Description

Picture

Number

Pliers for inner


circlip

A32

Depthometer

Dial caliper

Universal use

Pliers for outer


circlip

Note

A33

Universal use

A34
(0~300mm)

A35
(0~200mm)

Universal use

Universal use

27
Cleaning and Inspection

Cleaning
and Inspection
Cleaning

Clean all parts thoroughly using solvent type


cleaning fluid. It is recommended that parts be
immersed in cleaning fluid and moved up and
down slowly until all old lubricant and foreign
material is dissolved and parts are thoroughly
cleaned.

CAUTION: Care should be exercised to


avoid skin rashes, fire hazards and inhalation
of vapors when using solvent type cleaners.
Bearings

Remove bearings from cleaning fluid and strike


flat against a block of wood to dislodge solidified
particles of lubricant. Immerse again in cleaning
fluid to flush out particles. Repeat above
operation until bearings are thoroughly clean.

Dry bearings using moisture-free compressed


air. Be careful to direct air stream across bearing
to avoid spinning. Do not spin bearings when
drying.
Housings

Clean interior and exterior of housings, bearing


caps,etc., thoroughly.

Cast parts may be cleaned in hot solution tanks


with mild alkali solutions providing these parts do
not have ground or polished surfaces. Parts
should remain in solution long enough to be
thoroughly cleaned and heated. This will aid the
evaporation of the cleaning solution and rinse
water. Parts cleaned in solution tanks must be
thoroughly rinsed with clean water to remove all
traces of alkali. Cast parts may also be cleaned
with steam cleaner.

CAUTION: Care should be exercised to


avoid inhalation of vapors and skin rashes
when using alkali cleaners.

All parts cleaned must be thoroughly dried


immediatley by using moisture-free compressed
air or soft, lintless absorbent wiping rags free of
abrasive materials such as metal filings,
contaminated oil or lapping compound.

Inspection

The importance of careful and thorough


inspection of all parts cannot be overstressed.
Replacement of all parts showing indication of
wear or stress will eliminate costly and avoidable
failures at a later date.

28
Cleaning and Inspection

Bearings

Bearings Carefully inspect all rollers; cages and


cups for wear, chipping or nicks to determine
fitness of bearings for further use. Do not replace
a bearing cone or cup individually without
replacing the mating cup or cone at the same
time. After inspection, dip bearings in Automatic
Transmission Fluid and wrap in clean lintless
cloth or paper to protect them until installed.
Oil seals, gaskets, etc.

Replacement of spring load oil seals, "0" rings,


metal sealing rings, gaskets and snap rings is
more economical when unit is disassembled
than premature overhaul to replace these parts
at a future time. Further loss of lubricant through
a worn seal may result in failure of other more
expensive parts of the assembly.

Sealing members should be handled carefully,


particularly when being installed. Cutting,
scratching, or curling under of lip of seal
seriously impairs its efficiency. Apply a thin coat
of Permatex No. 2 on the outer diameter of the
oil seal to assure an oil tight fit into the retainer.
When assembling new metal type sealing rings,
same should be lubricated with coat of chassis
grease to stabilize rings in their grooves for ease
of assembly of mating members. Lubricate all "0"
rings and seals with recommended type
Automatic Transmission Fluid before assembly.
Gears and shafts

If magna-flux process is available, use process


to check parts. Examine teeth on all gears
carefully for wear, pitting, chipping, nicks, cracks
or scores. If gear teeth show spots where case
hardening is worn through or cracked, replace
with new gear. Small nicks may be removed with
suitable hone. Inspect shafts and quills to make
certain they are not sprung, bent, or splines
twisted, and that shafts are true.
Housing, covers, etc.

Inspect housings, covers and bearing caps to be


certain they are thoroughly clean and that mating
surfaces, bearing bores, etc., are free from nicks
or burrs. Check all parts carefully for evidence of
cracks or condition which would cause
subsequent oil leaks or failures.

29
Parts Disassembly
Transmission and Torque Converter Accessories

Parts Disassembly
Transmission and Torque Converter Accessories

15
14

14
14

16

14

15

7
6
10

5
4

11

12

13

8
1

Transmission and Torque Converter Accessories


No.

Description

Qty

No.

Description

Qty

Hose assembly

Coarse filter

Connector

10

O O-ring

Oil drain plug

11

Cover plate

O O-ring

12

Washer

Magnet

13

Bolt

Sight glass

14

Gasket

O O-ring

15

Connector

Adjustable connector

16

Hose assembly

30
Parts Disassembly
Transmission and Torque Converter Accessories

CAUTION: Cleanliness is quite important. Clean the component surface before


disassembling to prevent mud and dust etc. coming inside.
1.

Place the transmission levelly on the mounting


rack, lock the locking device of the mounting rack.

2. (3)

Remove the oil drain plug (3) from the oil outlet to
release transmission oil, and collect with a
container.

CAUTION: Recycle all waste transmission


oil with suitable containers to avoid polluting
the environment.
3. (3) (5) O (4)
Remove the magnet (5) and O-ring (4) from the oil
drain plug (3).

31
Parts Disassembly
Transmission and Torque Converter Accessories

4. (9)
(9)
Loosen the coarse filter (9), and remove it from the
transmission.

5. (6)
Remove the sight glass (6).

6. (6) O (7)
Remove the O-ring (7) from the sight glass (6).

7. (1)
(1)
Unscrew the hose assembly (1) connectors at both
ends, remove the hose assembly (1).

32
Parts Disassembly
Transmission and Torque Converter Accessories

8. (8)
Remove the adjustable connector (8) from the
torque converter.

9. (2)
Remove the connector (2) from the transmission.

10. (16)
(15) (14)
Remove the hose assembly (16) connector (15)
and gaskets (14) from the torque converter.

11. (16)
(15) (14) (16)
Remove the hose assembly (16) connector (15)
and gaskets (14) from the shift control valve, and
then remove the hose assembly (16).

33
Parts Disassembly
Torque Converter Group

Torque Converter Group


24
23

22
20

19

21
20

18
17
16
15
14
13

12

11
9
8
10
7
6
5

4
4
3
4
2
1

34
Parts Disassembly
Torque Converter Group

Torque Converter Group


No.

Description

Qty No.

Description

Qty

Bolt

12

13

Gear

Washer

12

14

Circlip

Adjusting sleeve

15

Paper gasket

Flexible plate

16

Cover plate

Bolt

17

Washer

Washer

18

Bolt

Shaft

19

Lifting eye

O O-ring

20

Washer

Seal

21

Bolt

10

Housing

22

Bolt

10

11

Paper gasket

23

Rivet

12

Torque converter

24

Nameplate

12

CAUTION: Cleanliness is quite important. Clean the component surface before


disassembling to prevent mud and dust etc. coming inside.

35
Parts Disassembly
Torque Converter Group

Flexible Plate, Housing and Shaft


1. (3) (1) (2)
Remove bolts (1) and washers (2) from the
adjusting sleeve (3).

2. (3)
Remove the adjusting sleeve (3).

3. (4)
Remove the flexible plates (4).

36
Parts Disassembly
Torque Converter Group

4. (7) (5) (6)


Remove bolts (5) and washers (6) from shaft (7).

5. (7) (7)
Tap the shaft (7) with a copper bar, and then
remove the shaft (7).

6. (7) O (8)
Remove the O-ring (8) from shaft (7).

7. (10) (22) (20)


Remove bolts (22) and washers (20) from housing
(10).

37
Parts Disassembly
Torque Converter Group

8. (19) (21) (20)


(19)
Remove bolts (21) and washers (20) from lifting
eye(19), and then remove the lifting eye (19).

9. (10) (10)
Lift up the housing (10) and remove it.

10. (11)
Remove the paper gasket (11).

38
Parts Disassembly
Torque Converter Group

11. (16) (18) (17)


Remove bolts (18) and washers (17) from cover
plate (16).

12. (16) (15)


Remove cover plate (16) and paper gasket (15).

13. (10) (9)


Remove seal (9) from housing (10).

39
Parts Disassembly
Torque Converter Group

Torque Converter
1. (12)
(12) (12)
(12)
Screw two eye bolts onto the opposite angles of
the torque converter (12), lift the torque converter
(12) upward to separate it from the torque
converter housing, and then remove it.

2. (12) (14)
Remove the gear circlip (14) from the torque
converter (12).

3. (12) (13)
Remove the gear (13) from the torque converter
(12).

40
Parts Disassembly
Torque Converter Housing Group

Torque Converter Housing Group


37
14

34
35

38
14

36
33
28
14

26

30
27

25
20

31

26

32

25

23

20

22

24

13
14

23

21
20

29

22

19
14

21

18

20

7
17

5
4

16
15

12

11

10

9
8

13

14

41
Parts Disassembly
Torque Converter Housing Group

Torque Converter Housing Group


No.

Description

Qty No.

Description

Qty

Casting iron seal

20

Ball bearing

Stator seat

21

Spacer

Turboshaft

22

P.T.O gear

Casting iron seal

23

Circlip

Ball bearing

24

P.T.O shaft

Circlip

25

Shim

Circlip

26

Circlip

Bolt

27

O O-ring

Washer

28

Bolt

10

Inlet valve

29

Flange

11

O O-ring

30

O O-ring

12

Torque converter housing

31

Connector

13

Bolt

24

32

P.T.O shaft

14

Washer

40

33

Paper gasket

15

O O-ring

34

Connector

16

Plug

35

Gasket

17

Pin

36

Charging pump

18

Outlet valve

37

Bolt

19

Bolt

38

Bolt

CAUTION: Cleanliness is quite important. Clean the component surface before


disassembling to prevent mud and dust etc. coming inside.

42
Parts Disassembly
Torque Converter Housing Group

Charging Pump, Flange, Outlet Valve


1. (34) (35)
Remove connector (34) and gasket (35) from the
charging pump.

2. (31) O (30)
Remove connector (31) and O-ring (30) from the
charging pump.

3. (36) (38) (14)


Remove bolts (38) and washers(14) from the
charging pump (36).

4. (36) (37) (14)


Remove bolts (37) and washers (14) from the
charging pump (36).

43
Parts Disassembly
Torque Converter Housing Group

5. (36)
(36) (12)
(36)
Tap the edges around the charging pump (36) with
a copper bar until the pump and the torque
converter housing (12) are separated, remove the
charging pump (36).

6. (33)
Remove paper gasket (33) from the charging
pump.

7. (29) (28)
(14)
Remove bolts (28) and washers (14) from the
steering pump flange (29).

8. (29)
(29) (12)
(29)
Tap the edges around the steering pump flange
(29) with a copper bar until the flange (29) and the
torque converter housing (12) are separated,
remove the flange (29).

44
Parts Disassembly
Torque Converter Housing Group

9. (29) O (27)
Remove the O-ring (27) from the steering pump
flange (29).

10. (18) (19) (14)


Remove the outlet valve (18) bolts (19) and
washers (14).

11. (18)
Remove the outlet valve (18).

45
Parts Disassembly
Torque Converter Housing Group

Torque Converter Housing


1. (13) (14)
Remove bolts (13) and washers (14) from the
transmission.

2. (12) (13)
(14)
Remove bolts (13) and washers (14) from the
torque converter housing (12).

3. (12)
(12)
(12)
Lift up the torque converter housing (12).
Meanwhile, tap the torque converter housing (12)
upward with a copper bar to separate it from the
transmission, and then remove the torque
converter housing (12).

46
Parts Disassembly
Torque Converter Housing Group

Stator Seat Group


1. (2) (8) (9)
Remove bolts (8) and washers (9) from the stator
seat (2).

2. (2)
(2) (12)
(2)
Screw the bolts into the bolt holes of the stator seat
(2) until the stator seat (2) is separated from the
torque converter housing (12), remove the stator
seat (2).

3. (2) (5) (6)


Remove the ball bearing (5) outer circlip (6) from
the stator seat (2).

47
Parts Disassembly
Torque Converter Housing Group

4. (3) (2)
(3)
Tap the turboshaft (3) downwards with a copper
bar until it is separated from the stator seat (2).

5. (2) (1)
Remove the casting iron seal (1) from the stator
seat (2).

6. (5) (7)
Remove the ball bearing (5) circlip (7).

48
Parts Disassembly
Torque Converter Housing Group

7. (3) (5)
Remove the ball bearing (5) from the turboshaft
(3).

8. (3) (4)
Remove the casting iron seal (4) from the
turboshaft (3).

49
Parts Disassembly
Torque Converter Housing Group

Inlet Valve, P.T.O Gear, P.T.O Shaft


1. (10)
Remove the inlet valve (10).

2. (10) O (11)
Remove the O-ring (11) from the inlet valve (10).

3. (26)
Remove the P.T.O shaft circlip (26) from the
steering pump.

4. (25)
Remove the shim (25).

50
Parts Disassembly
Torque Converter Housing Group

5. (26)
Remove the P.T.O shaft circlip (26) from the
charging pump.

6. (25)
Remove the shim (25).

7. (22)
(20) (12)
Tap the side surface of the charging pump P.T.O
gear (22) with a copper bar until the ball bearing
(20) is separated from the torque converter
housing (12).

8. (20) (32)

Separate the ball bearing (20) from the P.T.O shaft


(32) with a punch.

51
Parts Disassembly
Torque Converter Housing Group

9. (32)
(20)
Remove the ball bearing (20) from the P.T.O shaft
(32).

10. (32)
(21)
Remove the spacer (21) from the P.T.O shaft (32).

11. (32)
(32) (22)

Tap the steps around the P.T.O shaft (32)


downwards with a punch until the P.T.O shaft (32)
is separated from the P.T.O gear (22).

12. (32)
(22)
Remove the P.T.O gear (22) from the P.T.O shaft
(32).

52
Parts Disassembly
Torque Converter Housing Group

13. (12)
(32)
Remove the P.T.O shaft (32) from the torque
converter housing (12).

14. (32)
(26)
Remove the shaft circlip (26) from the P.T.O shaft
(32).

15. (32) (20)


Remove the ball bearing (20) from the P.T.O shaft
(32).

16. (22)
(20) (12)
Tap the side surface of the steering pump P.T.O
gear (22) with a copper bar until the ball bearing
(20) is separated from the torque converter
housing (12).

53
Parts Disassembly
Torque Converter Housing Group

17. (20) (24)

Separate the ball bearing (20) from the steering


pump P.T.O shaft (24) with a punch.

18. (24)
(20)
Remove the ball bearing (20) from the steering
pump P.T.O shaft (24).

19. (24)
(21)
Remove the shaft spacer (21) from the steering
pump P.T.O shaft (24).

20. (24)
(24) (22)

Tap the steps around the steering pump P.T.O


shaft (24) downwards with a punch until the P.T.O
shaft (24) is separated from the P.T.O gear (22).

54
Parts Disassembly
Torque Converter Housing Group

21. (24)
(22)
Remove the P.T.O gear (22) from the steering
pump P.T.O shaft (24).

22. (12)
(24)
Remove the steering pump P.T.O shaft (24) from
the torque converter housing (12).

23. (24) (23)


Remove the circlip (23) from the steering pump
P.T.O shaft (24).

24. (24) (20)


Remove the ball bearing (20) from the steering
pump P.T.O shaft (24).

55
Parts Disassembly
Brake

Brake

12
11
13
10
9
8
7
6
5
1
4
3
2

Brake
No.

Description

Qty No.

Description

Qty

Brake group

Bolt

Flange

Washer

Bolt

10

Bolt

Washer

11

Washer

Brake hub

12

Nut

Locknut

13

Handle

O O-ring

CAUTION: Cleanliness is quite important. Clean the component surface before


disassembling to prevent mud and dust etc. coming inside.

56
Parts Disassembly
Brake

1. (5) (3) (4).


Remove the brake hub (5) bolts (3) and washers
(4).

2. (5)
Remove brake hub (5).

3. (6)
Remove locknut (6).

57
Parts Disassembly
Brake

4. O (7)
Take out the O-ring (7).

5. (2)
Remove the flange(2).

6. (1) (8) (9)


Remove the brake group (1) bolts (8) and washers
(9).

58
Parts Disassembly
Brake

7. (1)
Remove brake group (1).

8. (13) (10) (11)


(12) (13)
Remove the handle (13) bolt (10), washer (11),
and nut (12). Then remove handle (13).

59
Parts Disassembly
Connectors and Hose Assembly

Connectors and Hose Assembly


24

23

G
10

18

10

10

12
13

F 17 18

12
13

13
10

10

10
10

12

12

12

12

13

F
C

13
16

19

13

22
21

18
15

17
10
9

14

6
5
4

20

18

D
7

B
11

10

25

26
2

18

9
8

17

18
2
1

2
2
1

60
Parts Disassembly
Connectors and Hose Assembly

Connectors and Hose Assembly


No.

Description

Qty No.

Description

Qty

Connector

14

Hose assembly

Gasket

15

Hose assembly

Hose assembly

16

Hose assembly

O O-ring

17

Connector

Connector

18

Gasket

O O-ring

19

Breather

Hose assembly

20

Breather pipe

O O-ring

21

O O-ring

Connector

22

Connector

10

O O-ring

23

Hose assembly

11

Hose assembly

24

Hose assembly

12

Connector

25

O O-ring

13

Gasket

26

Connector

CAUTION: Cleanliness is quite important. Clean the component surface before


disassembling to prevent mud and dust etc. coming inside.
1. (20)
Remove breather pipe (20).

2. (20) (19)
Remove breather (19) from breather pipe (20).

61
Parts Disassembly
Connectors and Hose Assembly

3. (22) O (21)
Remove connector (22) and O-ring (21).

4. (7)
(1) (2)
Remove the hose assembly (7) connector (1) and
gaskets (2) from the cover of the CV&CR
assembly.

5. - (7)
(1) (2) (7)
Remove the hose assembly (7) connector (1) and
gaskets (2) from C1&C3 cover. Take off hose
assembly (7).

6. - (3)
(1) (2)
Remove the hose assembly (3) connector (1) and
gaskets (2) from C2&C4 cover.

62
Parts Disassembly
Connectors and Hose Assembly

7. (3)
(3)
Disconnect hose assembly (3) and remove it from
cover of the CV&CR assembly.

8. (11) (14)
(15) (16)

Disconnect hose assembly (11), (14), (15) and (16)


in sequence from the shift control valve.

9. - (11)
(11)
Disconnect hose assembly (11) and remove it from
cover of C2&C4.

10. - (14)
(17) (18) (14)
Remove the hose assembly (14) connector (17)
and gaskets (18) from C2&C4 cover. Take off hose
assembly (14).

63
Parts Disassembly
Connectors and Hose Assembly

11. - (15)
(15)
Disconnect hose assembly (15) and remove it from
C1&C3 cover.

12. - (16)
(17) (18) (16)
Remove the hose assembly (16) connector (17)
and gaskets (18) from C1&C3 cover. Take off hose
assembly (16).

13. (23) (24)

Disconnect hose assembly (23) and (24) in


sequence from shift control valve.

64
Parts Disassembly
Connectors and Hose Assembly

14. (23)
(23)
Disconnect hose assembly (23) and remove it from
cover of the CV&CR assembly.

15. (24)
(17) (18) (24)
Remove the hose assembly (24) connector (17)
and gaskets (18) from cover of the CV&CR
assembly. Take off hose assembly (24).

16. (26) O
(25)
Remove connector (26) and O-ring (25) from cover
of the CV&CR assembly.

65
Parts Disassembly
Connectors and Hose Assembly

17. O (8) (9)


O (10)
Remove O-ring (8), connector (9) and O-ring (10)
from cover of the CV&CR assembly.

18. O (4) (5)


O (6)
Remove O-ring (4), connector (5) and O-ring (6)
from cover of the CV&CR assembly.

19. - O (8)
(9) O (10)
Remove O-ring (8), connector (9) and O-ring (10)
from cover of C1&C3.

20. - O (10)
(9) O (8)
Remove O-ring (10), connector (9) and O-ring (8)
from cover of C2&C4.

66
Parts Disassembly
Connectors and Hose Assembly

21. (11) (14)


(15) (16)
(12) O (10) (13)
Remove the hose assembly (11), (14), (15) and
(16) connectors (12), O-rings (10) and gaskets
(13) in sequence from shift control valve.

22. (23) (24)


(12) O (10)
(13)
Remove the hose assembly (23) and (24)
connectors (12), O-rings (10) and gaskets (13)
from shift control valve.

67
Parts Disassembly
Shift Control Valve, End Cap Group and Clutch Assembly

Shift Control Valve, End


Cap Group and Clutch Assembly
25
24

23

22

26

21

24
5

15
14
13

12

12

29

11

28

17

1
16

6
5

18
16

4
10
9
2
1
2
1

20
19

6
5

2
7

3
2

5
4
3
2
1

27

68
Parts Disassembly
Shift Control Valve, End Cap Group and Clutch Assembly

Shift Control Valve, End Cap Group and Clutch Assembly


No.

Description

Qty No.

Description

Qty

Bolt

18

16

Roller bearing

Washer

53

17

CV&CR assembly

Cover assembly

18

-
C1&C3 assembly

Gasket

19

Roller bearing

Circlip

20

-
C2&C4 assembly

Shim

21

Pin

Bolt

29

22

Gasket

End cap

23

Gasket

Shaft

24

Washer

10

Cover assembly

25

Bolt

11

Lifting eye

26

Bolt

12

Ball bearing

27

Gasket

13

Gear

28

Cover

14

Circlip

29

Bolt

15

Shift control valve

15

CAUTION: Cleanliness is quite important. Clean the component surface before


disassembling to prevent mud and dust etc. coming inside.

69
Parts Disassembly
Shift Control Valve, End Cap Group and Clutch Assembly

Shift Control Valve


1. (15)
(25) (24)
Remove bolts (25) and washers (24) from shift
control valve body.

2. (15)
Remove the body of shift control valve (15).

3. (23)
Remove gasket (23).

4. (15)
(26) (24)
Remove oil transfer plate bolts (26) and washers
(24) from shift control valve (15).

70
Parts Disassembly
Shift Control Valve, End Cap Group and Clutch Assembly

5. (15)
Remove the oil transfer plate.

6. (22)
Remove gasket (22).

71
Parts Disassembly
Shift Control Valve, End Cap Group and Clutch Assembly

End Cap Group and Idler Shaft


1. - (3) (1)
(2)
Remove bolts (1) and washers (2) from C2&C4
cover assembly (3).

2. - (3)
M22 70 (3)
(8) - (3)
(4)
Screw bolt M22 70 into the lubricating oil inlet of
C2&C4 cover assembly (3) until the cover
assembly (3) and end cap (8) are separated.
Remove cover assembly (3) and gasket (4).

3. - (3) (1)
(2)
Remove bolts (1) and washers (2) from C1&C3
cover assembly (3).

4. - (3)
M22 70 (3)
(8) - (3)
(4)
Screw bolt M22 70 into the lubricating oil inlet of
C1&C3 cover assembly (3) until the cover
assembly (3) and end cap (8) are separated.
Remove cover assembly (3) and gasket (4).

72
Parts Disassembly
Shift Control Valve, End Cap Group and Clutch Assembly

5. (9) (1) (2)


Remove bolts (1) and washers (2) from idler shaft
(9).

6. (10) (1)
(2)
Remove bolts (1) and washers (2) from CV&CR
cover assembly (10).

7. (10)
M22 70 (10)
(8) (10)
(4)
Screw bolt M22 70 into the lubricating oil inlet of
CV&CR cover assembly (10) until the cover
assembly (10) and end cap (8) are separated.
Remove the cover assembly (10) and gasket (4).

73
Parts Disassembly
Shift Control Valve, End Cap Group and Clutch Assembly

8. (11) (1) (2)


(11)
Remove bolts (1) and washers (2) from lifting
eye(11). Remove lifting eye (11).

9. (8) (7) (2)


Remove bolts (7) and washers (2) from end cap
(8).

10. (8)
(8)
Screw two bolts into the bolt holes of end cap (8)
until end cap (8) is separated from the
transmission housing.

CAUTION: Interlacely and evenly screw


the bolts into the holes. Do not screw one bolt
into the end immediately to prevent damaging
other parts.
11. (8)
(8)
Screw an eye bolt into the end cap (8), fasten the
eye bolt by wire rope and then lift up the end cap
(8) and move it away.

74
Parts Disassembly
Shift Control Valve, End Cap Group and Clutch Assembly

12. (9) (14).


Remove the idler shaft (9) circlip (14).

13. (13)
Remove gear (13).

14. (13) (12)


Remove ball bearing (12) from gear (13).

75
Parts Disassembly
Shift Control Valve, End Cap Group and Clutch Assembly

15. (9) (12)


Remove ball bearing (12) from idler shaft (9).

16. (9)
Remove idler shaft (9).

17. - (20) (19)


(5)
Remove the roller bearing (20) circlip (5) from the
C2&C4 assembly (20).

18. - (20) (19)


(6)
Remove the roller bearing (19) shim (6) from the
C2&C4 assembly (20).

76
Parts Disassembly
Shift Control Valve, End Cap Group and Clutch Assembly

19. - (18) (16)


(5)
Remove the roller bearing (16) circlip (5) from the
C1&C3 assembly (18).

20. - (18) (16)


(6)
Remove the roller bearing (16) shim (6) from the
C1&C3 assembly (18).

21. (17) (16)


(5)
Remove the roller bearing (16) circlip (5) from the
CV&CR assembly (17).

22. (17) (16)


(6)
Remove the roller bearing (16) shim (6) from the
CV&CR assembly (17).

77
Parts Disassembly
Shift Control Valve, End Cap Group and Clutch Assembly

23. - (20) (19)

Remove roller bearing (19) cup from the C2&C4


assembly (20).

24. - (18) (16)

Remove roller bearing (16) cup from the C1&C3


assembly (18).

25. (17) (16)

Remove roller bearing (16) cup from the CV&CR


assembly (17).

78
Parts Disassembly
Shift Control Valve, End Cap Group and Clutch Assembly

Clutch Assembly
1. (17)

Tap the CV&CR assembly (17) with a copper bar


to separate it from the transmission housing.

2. A10
(17) (17)

Tie up the CV&CR assembly (17) firmly with white


sisal rope A10 (See Tool Table), lift the CV&CR
assembly up and then move it away.

3. (28) (29) (2)


Remove bolts (29) and washers (2) from cover
(28).

79
Parts Disassembly
Shift Control Valve, End Cap Group and Clutch Assembly

4. (28) (27)
Remove cover (28) and gasket (27).

5. - (18) -
(20) - (18) (20)
Alternately tap the C1&C3 assembly (18) and
C2&C4 assembly (20) with a copper bar until both
of them are separated from the transmission
housing.

6. A10 (18) - (20)


- (18) -
(20)
Tie up the C1&C3 assembly (18) and the C2&C4
assembly (20) firmly with white sisal rope A10
(See Tool Table), lift them up and move them
away.

7. (17)
(5)
Remove the ball bearing circlip (5) in the CV&CR
assembly (17) from the transmission housing.

80
Parts Disassembly
Shift Control Valve, End Cap Group and Clutch Assembly

8. - (18)
(5)
Remove the ball bearing circlip (5) in the C1&C3
assembly (18) from the transmission housing.

9. - (20)
(5)
Remove the ball bearing circlip (5) in the C2&C4
assembly (20) from the transmission housing.

81
Parts Disassembly
Shift Control Valve, End Cap Group and Clutch Assembly

CV&CR Assembly

10
1
11
12
13
14
15

16

17

4
20
4
6

19
8

21
8
18

18

18

18

7
10

6
4
5

17
16
4

15
14
13

3
9
2

12
11

82
Parts Disassembly
Shift Control Valve, End Cap Group and Clutch Assembly

CV&CR Assembly
No.

Description

Outer clutch disc

Qty No.

Description

Qty

18

12

Retaining cap

Carrier plate

13

Return spring

Circlip

14

Retaining cap

Ball bearing

15

Piston

Gear

16

Inner seal ring

Circlip

17

Outer seal ring

Ball bearing

18

Casting iron seal

Circlip

19

CV&CR shaft assembly

Inner clutch disc

16

20

Gear

10

Inner clutch disc

21

Roller bearing

11

Circlip

. CR Assembly
1. (19)
(8)
Remove circlip (8) from the CV&CR shaft
assembly (19).

2. (7) (7)
(19)
(7)
Pull the ball bearing (7) up with three-armed puller
to separate the ball bearing (7) from the CV&CR
shaft assembly (19). Remove ball bearing (7).

83
Parts Disassembly
Shift Control Valve, End Cap Group and Clutch Assembly

3. (4) (6)
Remove the ball bearing (4) circlip (6).

4. (5) (5)
(19) (5)
Pull the gear (5) up with three-armed puller to
separate gear (5) from the CV&CR shaft assembly
(19). Remove the gear (5).

5. (5) (4)
Remove ball bearing (4) from two ends of the gear
(5).

84
Parts Disassembly
Shift Control Valve, End Cap Group and Clutch Assembly

6. (3)
Remove the circlip (3).

7. (2)
Take out the carrier plate (2).

8. 1 (1)
Take out one piece of outer clutch disc (1).

85
Parts Disassembly
Shift Control Valve, End Cap Group and Clutch Assembly

9. (10)
Take out the inner clutch disc (10).

10. (1)
(9)
Take out the outer clutch disc (1) and inner clutch
disc (9) from CR chamber in turn and make
alignment mark.

11. A04
(11)
(12) (13)
Fasten tool A04 (See Tool Table) to the press
machine, take the circlip (11) out from the circlip
groove. Tap the retaining cap (12) with a copper
bar to make the return spring (13) loose steadily.
:

CAUTION: The pre&Compressive force of


the return spring is very strong. Disassemble
the circlip with press machine and tool instead
of hand, otherwise personnel injury may result.

86
Parts Disassembly
Shift Control Valve, End Cap Group and Clutch Assembly

12. (11) (12) (13)


(14)
Remove the circlip (11), retaining cap (12), return
spring (13) and retaining cap (14).

13. (15)
Screw in the screw and take out the piston (15).

14. (15) (16)


(17)
Remove the inner seal ring (16) and outer seal ring
(17) from the piston (15).

87
Parts Disassembly
Shift Control Valve, End Cap Group and Clutch Assembly

. CV Assembly
1. (19)
(18)
Remove the casting iron seal (18) from the
CV&CR shaft assembly (19).

2. (19)
(21) (8)
Remove the roller bearing (21) circlip (8) from the
CV&CR shaft assembly (19).

3. (21)
(21)
(19) (21)

Pull the roller bearing (21) cone up with threearmed puller until it is separated from the CV&CR
shaft assembly (19). Remove the roller bearing
(21) cone.

88
Parts Disassembly
Shift Control Valve, End Cap Group and Clutch Assembly

4. (4) (6)
Remove the ball bearing (4) circlip (6).

5. (20) (20)
(19)
(20)
Pull the gear (20) up with three-armed puller until it
is separated from the CV&CR shaft assembly (19).
Remove the gear (20).

6. (20) (4)
Remove ball bearing (4) from two ends of the gear
(20).

89
Parts Disassembly
Shift Control Valve, End Cap Group and Clutch Assembly

7. (3)
Remove the circlip (3).

8. (2)
Take out the carrier plate (2).

9. 1 (1)
Take out one piece of outer clutch disc (1).

90
Parts Disassembly
Shift Control Valve, End Cap Group and Clutch Assembly

10. (10)
Take out the inner clutch disc (10).

11. (1)
(9)
Take out the outer clutch disc (1) and inner clutch
disc (9) from CV chamber in turn and make
alignment mark.

12. A04
(11)
(12) (13)
Fasten tool A04 (See Tool Table) to the press
machine, take the circlip (11) out from the circlip
groove. Tap the retaining cap (12) with a copper
bar to make the return spring (13) loose steadily.
:

CAUTION: The pre&Compressive force of


the return spring is very strong. Disassemble
the circlip with press machine and tool instead
of hand, otherwise personnel injury may result.

91
Parts Disassembly
Shift Control Valve, End Cap Group and Clutch Assembly

13. (11) (12) (13)


(14)
Remove the circlip (11), retaining cap (12), return
spring (13) and retaining cap (14).

14. (15)
Screw in the screw and take out the piston (15).

15. (15) (16)


(17)
Remove inner seal ring (16) and outer seal ring
(17) from the piston (15).

- C1&C3 Assembly

92
Parts Disassembly
Shift Control Valve, End Cap Group and Clutch Assembly

10

23
24

11

12
13
14

2
15

16

17

20
4
21
19

22

18

18

18
10

18

17

16

15
4

14
13
12

9
2

11

93
Parts Disassembly
Shift Control Valve, End Cap Group and Clutch Assembly

- C1&C3 Assembly
No.

Description

Outer clutch disc

Qty No.

Description

Qty

18

13

Return spring

Carrier plate

14

Retaining cap

Circlip

15

Piston

Ball bearing

16

Inner seal ring

Gear

17

Outer seal ring

Circlip

18

Casting iron seal

Ball bearing

19

-
C1&C3 shaft assembly

Circlip

20

Gear

Inner clutch disc

16

21

Washer

10

Inner clutch disc

22

Gear

11

Circlip

23

Circlip

12

Retaining cap

24

Roller bearing

- C1&C3 Assembly
1. - (19)
(8)
Remove circlip (8) from C1&C3 shaft assembly
(19).

2. (7) (7)
- (19)
(7)
Pry ball bearing (7) up with tommy bar to separate
it from C1&C3 shaft assembly (19). Remove ball
bearing (7).

94
Parts Disassembly
Shift Control Valve, End Cap Group and Clutch Assembly

3. (4) (6)
Remove the ball bearing (4) circlip (6).

4. (5) (5) -
(19) (5)
Pry gear (5) up with tommy bar to separate it from
C1&C3 shaft assembly (19). Remove gear (5).

5. (5) (4)
Remove ball bearing (4) from two ends of the gear
(5).

6. (3)
Remove the circlip (3).

95
Parts Disassembly
Shift Control Valve, End Cap Group and Clutch Assembly

7. (2)
Take out C3 carrier plate (2).

8. 1 (1)
Take out one piece of outer clutch disc (1).

9. (10)
Take out inner clutch disc (10).

10. (1)
(9)
Take out the outer clutch disc (1) and inner clutch
disc (9) from C3 chamber in turn and make
alignment mark.

96
Parts Disassembly
Shift Control Valve, End Cap Group and Clutch Assembly

11. A04
(11)
(12) (13)
Fasten tool A04 (See Tool Table) to the press
machine, take the circlip(11) out from the circlip
groove. Tap the retaining cap (12) with a copper
bar to make the return spring (13) loose steadily.
:

CAUTION: The pre&Compressive force of


the return spring is very strong. Disassemble
the circlip with press machine and tool instead
of hand, otherwise personnel injury may result.
12. (11) (12) (13)
(14)
Remove the circlip (11), retaining cap (12), return
spring (13) and retaining cap (14).

13. (15)
Screw in the screw and take out the piston (15).

97
Parts Disassembly
Shift Control Valve, End Cap Group and Clutch Assembly

14. (15) (16)


(17)
Remove inner seal ring (16) and outer seal ring
(17) from the piston (15).

C2, C1 Assembly
1. - (19)
(18)
Remove casting iron seal (18) from C1&C3 shaft
assembly (19).

2. - (19)
(8)
Remove circlip (8) from C1&C3 shaft assembly
(19).

98
Parts Disassembly
Shift Control Valve, End Cap Group and Clutch Assembly

3. (24)
(24) -
(19) (24)
Pull the roller bearing (24) cone up with threearmed puller until it is separated from the C1&C3
shaft assembly (19). Remove the roller bearing
(24) cone.

4. (22) (23)
Remove the gear (22) circlip (23).

5. (22) (23)
Remove the gear (22) and washer (23).

99
Parts Disassembly
Shift Control Valve, End Cap Group and Clutch Assembly

6. (20) (20) (19)


(20)
Pry gear (20) up with tommy bar to separate it from
C1&C3 shaft assembly (19). Remove gear (20).

7. (20) (4)
Remove ball bearing (4) from two ends of the gear
(20).

8. (3)
Remove the circlip (3).

100
Parts Disassembly
Shift Control Valve, End Cap Group and Clutch Assembly

9. (2)
Take out C1 carrier plate (2).

10. 1 (1)
Take out one piece of outer clutch disc (1).

11. (10)
Take out inner clutch disc (10).

101
Parts Disassembly
Shift Control Valve, End Cap Group and Clutch Assembly

12. (1)
(9)
Take out the outer clutch disc (1) and inner clutch
disc (9) from C1 chamber in turn and make
alignment mark.

13. A04
(11)
(12) (13)
Fasten tool A04 (See Tool Table) to the press
machine, take the circlip(11) out from the circlip
groove. Tap the retaining cap (12) with a copper
bar to make the return spring (13) loose steadily.
:

CAUTION: The pre&Compressive force of


the return spring is very strong. Disassemble
the circlip with press machine and tool instead
of hand, otherwise personnel injury may result.
14. (11) (12) (13)
(14)
Remove the circlip (11), retaining cap (12), return
spring (13) and retaining cap (14).

102
Parts Disassembly
Shift Control Valve, End Cap Group and Clutch Assembly

15. (15)
Screw in the screw and take out the piston (15).

16. (15) (16)


(17)
Remove the inner seal ring (16) and outer seal ring
(17) from the piston (15).

103
Parts Disassembly
Shift Control Valve, End Cap Group and Clutch Assembly

- C2&C4 Assembly

6
24

23
12

22
13

11

14
15
16
17
18
4
5
6
20
21

19

19

19

19
11

18

10

17
9
16
15

8
6

14
13
12

7
6

1
5
4

104
Parts Disassembly
Shift Control Valve, End Cap Group and Clutch Assembly

- C2&C4 Assembly
No.

Description

Qty No.

Description

Qty

Inner clutch disc

13

13

Retaining cap

Outer clutch disc

15

14

Return spring

Inner clutch disc

15

Retaining cap

Carrier plate

16

Piston

Circlip

17

Inner seal ring

Ball bearing

18

Outer seal ring

Gear

19

Casting iron seal

Spacer

20

-
C2&C4 shaft assembly

Gear

21

Gear

10

Ball bearing

22

Roller bearing

11

Circlip

23

Pinion

12

Circlip

24

Spacer

C1, C4 Assembly
1. - (20)
(11)
Remove circlip (11) from the C2&C4 shaft
assembly (20).

2. (10) (10)
- (20)
(10)
Pry ball bearing (10) up with tommy bar to
separate it from C2&C4 shaft assembly (20).
Remove ball bearing (10).

105
Parts Disassembly
Shift Control Valve, End Cap Group and Clutch Assembly

3. - (20)
(9) (8)
Remove gear (9) and spacer (8) from C2&C4 shaft
assembly (20).

4. (7) (7) -
(20) (7)
Pull the gear (7) up with three-armed puller until it
is separated from the C2&C4 shaft assembly (20).
Remove gear (7).

5. (7) (6)
Remove ball bearing (4) from two ends of the gear
(7).

106
Parts Disassembly
Shift Control Valve, End Cap Group and Clutch Assembly

6. (5)
Remove the circlip (5).

7. (4)
Take out the carrier plate (4).

8. 1 (2)
Take out one piece of outer clutch disc (2).

107
Parts Disassembly
Shift Control Valve, End Cap Group and Clutch Assembly

9. (3)
Take out the inner clutch disc (3).

10. (2)
(1)
Take out the outer clutch disc (2) and inner clutch
disc (1) from C4 chamber in turn and make
alignment mark.

11. A04
(12)
(13) (14)
Fasten tool A04 (See Tool Table) to the press
machine, take the circlip(12) out from the circlip
groove. Tap the retaining cap (13) with a copper
bar to make the return spring (14) loose steadily.
:

CAUTION: The pre&Compressive force of


the return spring is very strong. Disassemble
the circlip with press machine and tool instead
of hand, otherwise personnel injury may result.

108
Parts Disassembly
Shift Control Valve, End Cap Group and Clutch Assembly

12. (12) (13) (14)


(15)
Remove circlip (12), retaining cap (13), return
spring (14) and retaining cap (15).

13. (16)
Screw in the screw and take out the piston (16).

14. (16) (17)


(18)
Remove the inner seal ring (17) and outer seal ring
(18) from the piston (16).

109
Parts Disassembly
Shift Control Valve, End Cap Group and Clutch Assembly

C2, C4 Assembly
1. - (20)
(19)
Remove casting iron seals (19) from C2&C4 shaft
assembly (20).

2. - (20)
(22) (11)
Remove ball bearing (22) circlip (11) from C2&C4
shaft assembly (20).

3. (23) (23) (20)


Pull the gear (23) up with three-armed puller until it
is separated from the C2&C4 shaft assembly (20).
Remove gear (23).

110
Parts Disassembly
Shift Control Valve, End Cap Group and Clutch Assembly

4. - (20)
(22)
Remove ball bearing (22) cone from C2&C4 shaft
assembly (20).

5. - (20)
(23)
Remove gear (23) from C2&C4 shaft assembly
(20).

6. - (20)
(24)
Remove spacer (24) from C2&C4 shaft assembly
(20).

111
Parts Disassembly
Shift Control Valve, End Cap Group and Clutch Assembly

7. (21) (21) (20)


(21)
Pry gear (21) up with tommy bar to separate it from
C2&C4 shaft assembly (20). Remove gear (21).

8. (21) (6)
Remove ball bearing (6) from two ends of the gear
(21).

9. (5)
Remove the circlip (5).

112
Parts Disassembly
Shift Control Valve, End Cap Group and Clutch Assembly

10. (4)
Take out carrier plate (4).

11. 1 (2)
Take out one piece of outer clutch discs (2).

12. (3)
Take out the inner clutch disc (3).

113
Parts Disassembly
Shift Control Valve, End Cap Group and Clutch Assembly

13. (2)
(1)
Take out the outer clutch discs (2) and inner clutch
discs (1) from C2 chamber in turn and make
alignment mark.

14. A04
(12)
(13) (14)
Fasten tool A04 (See Tool Table) to the press
machine, take the circlip(12) out from the circlip
groove. Tap the retaining cap (13) with a copper
bar to make the return spring (14) loose steadily.
:

CAUTION: The pre&Compressive force of


the return spring is very strong. Disassemble
the circlip with press machine and tool instead
of hand, otherwise personnel injury may result.
15. (12) (13) (14)
(15)
Remove circlip (12), retaining cap (13), return
spring (14) and retaining cap (15).

114
Parts Disassembly
Shift Control Valve, End Cap Group and Clutch Assembly

16. (16)
Screw in the screw and take out the piston (16).

17. (16) (17)


(18)
Remove the inner seal ring (17) and outer seal ring
(18) from the piston (16).

115
Parts Disassembly
Output Shaft Group

Output Shaft Group

1
2
1
3

22

21

4
5
6
7

12
13

11
9
10

14

12
13

15
16
17

4
3
1
2
1
18
19

20

Output Shaft Group


No.

Description

Qty No.

Description

Qty

O O-ring

12

O O-ring

Seal seat

13

Plug

Seal

14

Output shaft

Circlip

15

Bush

Roller bearing

16

Ball bearing

Sleeve

17

Shim

Gear

18

Flange

Oil shield

19

O O-ring

Washer

20

Locknut

10

Bolt

21

Nameplate

11

Transmission housing

22

Rivet

116
Parts Disassembly
Output Shaft Group

CAUTION: Cleanliness is quite important. Clean the component surface before


disassembling to prevent mud and dust etc. coming inside.
1. A01
(11) (2)
Remove seal seat (2) from the rear output end of
transmission housing (11) with tool A01(see Tool
Table)
O

CAUTION: The seal and O-ring on the seal


seat can not be reused.

2. (2) O (1)
Remove O-ring (1) from seal seat (2).

3. (2) (3)
Remove seal (3) from seal seat (2).

117
Parts Disassembly
Output Shaft Group

4. (5) (4)
Remove the roller bearing (5) circlip (4).

5. (18)
(20) (20) (14)
(20)
Unscrew output flange (18) locknut (20)
counterclockwise with a socket until it is separated
from output shaft (14). Remove locknut (20).

CAUTION: The locknut can not be reused


as that will cause looseness.

6. O (19)
Remove O-ring (19).

118
Parts Disassembly
Output Shaft Group

7. (18)
Remove output flange (18).

8. A01
(2)
Remove seal seat with Tool A01(See Tool Table).
O

CAUTION: The seal and O-ring on the seal


seat can not be reused.
9. (2) O (1)
Remove O-ring (1) from seal seat (2).

10. (2) (3)


Remove seal (3) from seal seat (2).

119
Parts Disassembly
Output Shaft Group

11. (4)
Remove the circlip (4).

12. (17)
Take out shim (17).

13. (13) O (12)


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

14. (13) (8)


(10) (9)
Remove bolt (10) and washer (9) from oil shield (8)
through the mounting hole of plug (13).

120
Parts Disassembly
Output Shaft Group

15. (14) (14)


(11) (14)
(5)
Tap output shaft (14) with a copper bar until it is
separated from transmission housing (11). Then
remove the output shaft (14) and roller bearing (5)
cup.

16. (14) (6)


(5)
Remove sleeve (6) and roller bearing (5) cone
from output shaft (14).

17. (11) (7)


Take out gear (7) from transmission housing (11).

121
Parts Disassembly
Output Shaft Group

18. (11) (16)


Take out oil shield (16) from transmission
housing(11).

19. (11) (15)


Take out bush (15) from transmission housing (11).

20. (11) (16)


Remove ball bearing (16) from transmission
housing (11).

122
Output Shaft Group

123
Parts Reassembly
CV&CR Assembly

Parts Reassembly
CV&CR Assembly

10

1
11
12
13
14
15

2
16

3
4

17

19
4
6
8

18

21
8

7
10

6
4

17
16

15
4

14
13

3
9
2

12
11

124
Parts Reassembly
CV&CR Assembly

CV&CR Assembly
No.

Description

Outer clutch disc

Qty No.

Description

Qty

18

11

Circlip

Carrier plate

12

Retaining cap

Circlip

13

Return spring

Ball bearing

14

Retaining cap

Gear

15

Piston

Circlip

16

Inner seal ring

Ball bearing

17

Outer seal ring

Circlip

18

CV&CR shaft assembly

Inner clutch disc

16

19

Gear

10

Inner clutch disc

CAUTION: It is quite important to clean the components before assembling. Wash the
components with detergent and prevent contaminants and foreign matter coming inside. Check
the components carefully. Replace the component with a new one if it is damaged.

CAUTION: Check the oil passage before assembling CV&CR shaft assembly and clear iron
slags etc. in it.

CV Assembly
1. (16) (17)
(16) (17)
(15)
Coat the piston inner seal ring (16) and outer seal
ring (17) with adequate transmission oil and install
them onto the piston (15).

125
Parts Reassembly
CV&CR Assembly

2. (15)
(18)
Install the piston (15) into the CV chamber of
CV&CR shaft assembly (18).

3. A18
(15)
Tap the piston (15) with a copper bar A18 (See
Tool Table) into the bottom of CV chamber
horizontally.

4. (12) (13) (14)


Install the retaining cap (12), return spring (13) and
the retaining cap (14).

126
Parts Reassembly
CV&CR Assembly

5. (11) A02

Install the circlip (11) onto tool A02 (See Tool


Table).

6. A02
(18)
Install tool A02 onto the CV&CR shaft assembly
(18).

7. A03
(11) (11)
(11) (11)

Connect tool A03 (See Tool Table) to the press


machine, press the circlip (11) down quickly to
install it into the groove. Check and adjust the
circlip (11) to ensure that it is assembled in the
groove.
:

CAUTION: The pre&Compressive force of


the return spring is very strong. Reassemble
the circlip with press machine and tool instead
of hand, otherwise personnel injury may result.

127
Parts Reassembly
CV&CR Assembly

8. 8 (9)
8 (1)
Put 8 pieces of inner clutch discs (9) and 8 pieces
of outer clutch discs (1) into the CV chamber
alternately.

CAUTION: The part that contacts the


piston in the CV chamber is inner clutch disc,
not outer clutch disc.

Use the old and new inner clutch discs and outer
clutch discs as follows:
(a)

Check the inner clutch disc and outer clutch disc


with a ruler to ensure that all parts are horizontal. If
not, use new parts when assembling.
(b)

0.15mm
0.30mm
2.20 0.05mm
Check the outer clutch disc for wear. Use new
parts if its surface is smooth or almost smooth. If
one side is abraded over 0.15mm, two sides are
abraded over 0.3mm, use new parts when
assembling. The new outer clutch disc thickness
is 2.20 0.05mm.
(c)

Check the outer clutch disc. Use new parts if the


friction material is damaged or burnt.
(d)

Check the outer clutch disc spline for wear, the


inner clutch disc for corrosion, scrape or other
damage. Use new parts if any one of these occurs.
(e)

Coat the contact surface of the outer clutch disc


with clean transmission oil before assembling.

128
Parts Reassembly
CV&CR Assembly

9. (10)
Install inner clutch disc (10).
(10) 132 , "
(10) "
Refer to "How to choose CV inner clutch disc (10)"
on page 132 for inner clutch disc (10) selection.

10. 1 (1)
Install one piece of outer clutch disc (1).

11. (2)
Install carrier plate (2).

129
Parts Reassembly
CV&CR Assembly

12. (3)
Install the circlip (3).

13. (19) (1)


(19)
Rotate the gear (19) back and forth downwards to
make all the spline teeth of the outer clutch disc (1)
align with each other, then take out the gear (19).

14. (4)
Install the ball bearing (4).

130
Parts Reassembly
CV&CR Assembly

15. (19)
Install the gear (19).

16. (4)
Install the ball bearing (4).

17. (4) (6)


Install the ball bearing (4) circlip (6).

131
Parts Reassembly
CV&CR Assembly

18. 0.15MPa
(19)
(15)
(19) (18)

Inject 0.15 MPa compressed air into the CV


passage and rotate the gear (19). When you hear
the piston (15) moves and locks the parts and the
gear (19) can rotate successfully on CV&CR shaft
assembly (18), it indicates that the CV assembly is
in good condition and can work normally. If not,
disassemble it and check it.

132
Parts Reassembly
CV&CR Assembly

(10)
How to choose CV inner clutch disc (10)
No.

Description

Thickness
(mm)

Inner clutch disc

1.7

Inner clutch disc

2.3

Inner clutch disc

2.9

Inner clutch disc

3.4

(a) (10)
(1) (2) (3)
Choose one of the inner clutch discs (10) in the left
table to preassemble with outer clutch disc (1), carrier
plate (2) and circlip (3).

(b) (2)
100N.m
(2)
L1
Press the carrier plate (2) down with screwdriver to the
limit position (The pressure is about 100N.m), measure
the depth L1 from the upper surface of carrier plate (2)
to the CV outer hub end face with a depthometer.

(c) (2)
(3)
L2
Measure the depth L2 from the upper surface of circlip
(3) to the CV outer hub end face with a depthometer
when the carrier plate (2) returns to the natural state.

(d) (15) ,
3.4 3.6mm

L L1 L2 3
According to the measured value, calculate the stroke
of piston (15) and see if it is within 3.4-3.6mm. If not,
choose another inner clutch disc.
L L1 L2 3

133
Parts Reassembly
CV&CR Assembly

CR Assembly
1. (16) (17)
(16) (17)
(15)
Coat the piston inner seal ring (16) and outer seal
ring (17) with adequate transmission oil and Install
them onto the piston (15).

2. (15)
(18)
Install the piston (15) into the CR chamber of
CV&CR shaft assembly (18).

3. A18
(15)
Tap the piston (15) with a copper bar A18 (See
Tool Table) into the bottom of CR chamber
horizontally.

134
Parts Reassembly
CV&CR Assembly

4. (12) (13) (14)


Install the circlip (12), return spring (13) and the
retaining cap (14).

5. (11) A02

Install the circlip (11) onto tool A02 (See Tool


Table).

6. A02
(18)
Install tool A02 onto the CV&CR shaft assembly
(18).

135
Parts Reassembly
CV&CR Assembly

7. A03
(11) (11)
(11) (11)

Connect tool A03 (See Tool Table) to the press


machine, press the circlip (11) down quickly to
install it into the groove. Check and adjust the
circlip (11) to ensure that it is assembled in the
groove.
:

CAUTION: The pre&Compressive force of


the return spring is very strong. Reassemble
the circlip with press machine and tool instead
of hand, otherwise personnel injury may result.

136
Parts Reassembly
CV&CR Assembly

8. 8 (9)
8 (1)
Put 8 pieces of inner clutch discs (9) and 8 pieces
of outer clutch discs (1) into the CR chamber
alternately.

CAUTION: The part that contacts the


piston in the CR chamber is inner clutch disc,
not outer clutch disc.

Use the old and new inner clutch discs and outer
clutch discs as follows:
(a)

Check the inner clutch disc and outer clutch disc


with a ruler to ensure that all parts are horizontal. If
not, use new parts when assembling.
(b)

0.15mm
0.30mm
2.20 0.05mm
Check the outer clutch disc for wear. Use new
parts if its surface is smooth or almost smooth. If
one side is abraded over 0.15mm, two sides are
abraded over 0.3mm, use new parts when
assembling. The new outer clutch disc thickness
is 2.20 0.05mm.
(c)

Check the outer clutch disc. Use new parts if the


friction material is damaged or burnt.
(d)

Check the outer clutch disc spline for wear, the


inner clutch disc for corrosion, scrape or other
damage. Use new parts if any one of these occurs.
(e)

Coat the contact surface of the outer clutch disc


with clean transmission oil before assembling.

137
Parts Reassembly
CV&CR Assembly

9. (10)
Install inner clutch disc (10).
(10) 141 , "
(10) "
Rrefer to "How to choose CR inner clutch disc
(10)" on page 141 for inner clutch disc (10)
selection.

10. 1 (1)
Install one piece of outer clutch disc (1).

11. (2)
Install carrier plate (2).

138
Parts Reassembly
CV&CR Assembly

12. (3)
Install the circlip (3).

13. (5) (1)


(5)
Rotate the gear (5) back and forth downwards to
make all the spline teeth of the outer clutch disc (1)
align with each other, then take out the gear (5).

14. (4)
Install the ball bearing (4).

139
Parts Reassembly
CV&CR Assembly

15. (5)
Install the gear (5).

16. (4)
Install the ball bearing (4).

17. (4) (6)


Install the ball bearing (4) circlip (6).

140
Parts Reassembly
CV&CR Assembly

18. (7)
Install the ball bearing (7).

19. (8)
Install the circlip (8).

20. 0.15MPa
(5)
(15)
(5) (18)

Inject 0.15 MPa compressed air into the CR


passage and rotate the gear (19). When you hear
the piston (15) moves and locks the parts and the
gear (19) can rotate successfully on CV&CR shaft
assembly (18), it indicates that the CR assembly is
in good condition and can work normally. If not,
disassemble it and check it.

141
Parts Reassembly
CV&CR Assembly

(10)
How to choose CR inner clutch disc (10)

No.

Description

Thickness
(mm)

Inner clutch disc

1.7

Inner clutch disc

2.3

Inner clutch disc

2.9

Inner clutch disc

3.4

(a) (10)
(1) (2) (3)
Choose one of the inner clutch discs (10) in the left
table to preassemble with outer clutch disc (1), carrier
plate (2) and circlip (3).

(b) (2)
100N.m
(2)
L3
Press the carrier plate (2) down with a screwdriver to
the limit position (The pressure is about 100N.m),
measure the depth L3 from the upper surface of carrier
plate (2) to the CR outer hub end face with a
depthometer.
(c) (2)
(3)
L4
Measure the depth L4 from the upper surface of circlip
(3) to the CR outer hub end face with a depthometer
when the carrier plate (2) returns to the natural state.

(d) (15)
3.4 3.6mm

L L3 L4 3
According to the measured value, calculate the stroke
of piston (15) and see if it is within 3.4-3.6mm. If not,
choose another inner clutch disc.
L L3 L4 3

142
Parts Reassembly
- C1&C3 Assembly

- C1&C3 Assembly

10

11
12
13
14

2
15

3
16

4
17
19
4
20
21

18

22
17

10

7
6

16

4
5

15
14
4

13
12

9
2

11

143
Parts Reassembly
- C1&C3 Assembly

- C1&C3 Assembly
No.

Description

Outer clutch disc

Qty No.

Description

Qty

18

12

Retaining cap

Carrier plate

13

Return spring

Circlip

14

Retaining cap

Ball bearing

15

Piston

Gear

16

Inner seal ring

Circlip

17

Outer seal ring

Ball bearing

18

-
C1&C3 shaft assembly

Circlip

19

Gear

Inner clutch disc

16

20

Circlip

10

Inner clutch disc

21

Gear

11

Circlip

22

Circlip

CAUTION: It is quite important to clean the components before assembling. Wash the
components with detergent and prevent contaminants and foreign matter coming inside. Check
the components carefully. Replace the component with a new one if it is damaged.
-
CAUTION: Check the oil passage before assembling C1&C3 shaft assembly and clear iron
slags, etc. in it.

C1 Assembly
1. (16) (17)
(16) (17)
(15)
Coat the piston inner seal ring (16) and outer seal
ring (17) with adequate transmission oil and install
them onto the piston (15).

144
Parts Reassembly
- C1&C3 Assembly

2. (15) -
(18)
Install the piston (15) into C1 chamber of C1&C3
shaft assembly (18).

3. A18 (15)

Tap the piston (15) with a copper bar A18 (See


Tool Table) into the bottom of C1 chamber
horizontally.

4. (12) (13) (14)


Install the retaining cap (12), return spring (13) and
the retaining cap (14).

145
Parts Reassembly
- C1&C3 Assembly

5. (11) A02

Install the circlip (11) onto tool A02 (See Tool


Table).

6. A02 -
(18)
Install tool A02 onto the C1&C3 shaft assembly
(18).

7. A03
(11) (11)
(11) (11)

Connect tool A03 (See Tool Table) to the press


machine, press the circlip (11) down quickly to
install it into the groove. Check and adjust the
circlip (11) to ensure that it is assembled in the
groove.
:

CAUTION: The pre&Compressive force of


the return spring is very strong. Reassemble
the circlip with press machine and tool instead
of hand, otherwise personnel injury may result.

146
Parts Reassembly
- C1&C3 Assembly

8. 8 (9)
8 (1)
Put 8 pieces of inner clutch discs (9) and 8 pieces
of outer clutch discs (1) into C1 chamber
alternately.

CAUTION: The part that contacts the


piston in C1 chamber is inner clutch disc, not
outer clutch disc.

Use the old and new inner clutch discs and outer
clutch discs as follows:
(a)

Check the inner clutch disc and outer clutch disc


with a ruler to ensure that all parts are horizontal. If
not, use new parts when assembling.
(b)

0.15mm
0.30mm
2.20 0.05mm
Check the outer clutch disc for wear. Use new
parts if its surface is smooth or almost smooth. If
one side is abraded over 0.15mm, two sides are
abraded over 0.3mm, use new parts when
assembling. The new outer clutch disc thickness
is 2.20 0.05mm.
(c)

Check the outer clutch disc. Use new parts if the


friction material is damaged or burnt.
(d)

Check the outer clutch disc spline for wear, the


inner clutch disc for corrosion, scrape or other
damage. Use new parts if any one of these occurs.
(e)

Coat the contact surface of the outer clutch disc


with clean transmission oil before assembling.

147
Parts Reassembly
- C1&C3 Assembly

9. (10)
Install inner clutch disc (10).
(10) 151 , "
(10) "
Refer to "How to choose inner clutch disc (10) for
C1" on page 151 for inner clutch disc (10)
selection.

10. 1 (1)
Install one piece of outer clutch disc (1).

11. (2)
Install carrier plate (2).

148
Parts Reassembly
- C1&C3 Assembly

12. (3)
Install the circlip (3).

13. (19) (1)


(19)
Rotate the gear (19) back and forth downwards to
make all the spline teeth of the outer clutch disc (1)
align with each other, then take out the gear (19).

14. (4)
Install ball bearing (4).

149
Parts Reassembly
- C1&C3 Assembly

15. (19)
Install gear (19).

16. (4)
Install ball bearing (4).

17. (21) (20)


Install gear (21) and washer (20).

150
Parts Reassembly
- C1&C3 Assembly

18. (21) (22)


Install the gear (21) circlip (22).

19. 0.15MPa
(21)
(15)
(21) - (18)

Inject 0.15 MPa compressed air into C1 passage


and rotate the gear (21). When you hear the piston
(15) moves and locks the parts and the gear (21)
can rotate successfully on C1&C3 shaft assembly
(18), it indicates that the C1 assembly is in good
condition and can work normally. If not,
disassemble it and check it.

151
Parts Reassembly
- C1&C3 Assembly

(10)
How to choose inner clutch disc (10) for C1

No.

Description

Thickness
(mm)

Inner clutch disc

1.7

Inner clutch disc

2.3

Inner clutch disc

2.9

Inner clutch disc

3.4

(a) (10)
(1) (2) (3)
Choose one of the inner clutch discs (10) in the left
table to preassemble with outer clutch disc (1), carrier
plate (2) and circlip (3) .

(b) (2)
100N.m
(2)
L1
Press the carrier plate (2) down with a screwdriver to
the limit position (The pressure is about 100N.m),
measure the depth L1 from the upper surface of carrier
plate (2) to the outer hub end face of C1 with a
depthometer.
(c) (2)
(3)
L2
Measure the depth L2 from the upper surface of circlip
(3) to the outer hub end face of C1 with a depthometer
when the carrier plate (2) returns to the natural state.

(d) (15)
3.4 3.6mm

L L1 L2 3
According to the measured value, calculate the stroke
of piston (15) and see if it is within 3.4-3.6mm. If not,
choose another inner clutch disc.
L L1 L2 3

152
Parts Reassembly
- C1&C3 Assembly

C3 Assembly
1. (16) (17)
(16) (17)
(15)
Coat the piston inner seal ring (16) and outer seal
ring (17) with adequate transmission oil and install
them onto the piston (15).

2. (15) -
(18)
Install the piston (15) into C3 chamber of C1&C3
shaft assembly (18).

3. A18 (15)

Tap the piston (15) with a copper bar A18 (See


Tool Table) into the bottom of C3 chamber
horizontally.

4. (12) (13) (14)


Install the retaining cap (12), return spring (13) and
the retaining cap (14).

153
Parts Reassembly
- C1&C3 Assembly

5. (11) A02

Install the circlip (11) onto tool A02 (See Tool


Table).

6. A02 -
(18)
Install tool A02 onto the C1&C3 shaft assembly
(18).

7. A03
(11) (11)
(11) (11)

Connect tool A03 (See Tool Table) to the press


machine, press the circlip (11) down quickly to
install it into the groove. Check and adjust the
circlip (11) to ensure that it is assembled in the
groove.
:

CAUTION: The pre&Compressive force of


the return spring is very strong. Reassemble
the circlip with press machine and tool instead
of hand, otherwise personnel injury may result.

154
Parts Reassembly
- C1&C3 Assembly

8. III 8 (9)
8 (1)
Put 8 pieces of inner clutch discs (9) and 8 pieces
of outer clutch discs (1) into C3 chamber
alternately.
III

CAUTION: The part that contacts the


piston in C3 chamber is inner clutch disc, not
outer clutch disc.

Use the old and new inner clutch discs and outer
clutch discs as follows:
(a)

Check the inner clutch disc and outer clutch disc


with a ruler to ensure that all parts are horizontal. If
not, use new parts when assembling.
(b)

0.15mm
0.30mm
2.20 0.05mm
Check the outer clutch disc for wear. Use new
parts if its surface is smooth or almost smooth. If
one side is abraded over 0.15mm, two sides are
abraded over 0.3mm, use new parts when
assembling. The new outer clutch disc thickness
is 2.20 0.05mm.
(c)

Check the outer clutch disc. Use new parts if the


friction material is damaged or burnt.
(d)

Check the outer clutch disc spline for wear, the


inner clutch disc for corrosion, scrape or other
damage. Use new parts if any one of these occurs.
(e)

Coat the contact surface of the outer clutch disc


with clean transmission oil before assembling.

155
Parts Reassembly
- C1&C3 Assembly

9. (10)
Install inner clutch disc (10).
(10) 159 , "
(10) "
Refer to "How to choose inner clutch disc (10) for
C3" on page 159 for inner clutch disc (10)
selection.

10. 1 (1)
Install one piece of outer clutch disc (1).

11. (2)
Install carrier plate (2).

12. (3)
Install the circlip (3).

156
Parts Reassembly
- C1&C3 Assembly

13. (5) (1)


(5)
Rotate the gear (5) back and forth downwards to
make all the spline teeth of the outer clutch disc (1)
align with each other, then take out the gear (5).

14. (4)
Install ball bearing (4).

15. (5)
Install gear (5).

157
Parts Reassembly
- C1&C3 Assembly

16. (4)
Install ball bearing (4).

17. (4) (6)


Install the ball bearing (4) circlip (6).

18. (7)
Install ball bearing (7).

158
Parts Reassembly
- C1&C3 Assembly

19. (8)
Install the circlip (8).

20. 0.15MPa
(5) (15)
(5)
- (18)

Inject 0.15 MPa compressed air into C3 passage


and rotate the gear (5). When you hear the piston
(15) moves and locks the parts and the gear (5)
can rotate successfully on C1&C3 shaft assembly
(18), it indicates that the C3 assembly is in good
condition and can work normally. If not,
disassemble it and check it.

159
Parts Reassembly
- C1&C3 Assembly

(10)
How to choose inner clutch disc (10) for C3

No.

Description

Thickness
(mm)

Inner clutch disc

1.7

Inner clutch disc

2.3

Inner clutch disc

2.9

Inner clutch disc

3.4

(a) (10)
(1) (2) (3)
Choose one of inner clutch discs (10) in the left table to
preassemble with outer clutch disc (1), carrier plate (2)
and circlip (3).

(b) (2)
100N.m
(2)
L3
Press the carrier plate (2) down with a screwdriver to
the limit position (The pressure is about 100N.m),
measure the depth L3 from the upper surface of carrier
plate (2) to the outer hub end face of C3 with a
depthometer.
(c) (2)
(3)
L4
Measure the depth L4 from the upper surface of circlip
(3) to the outer hub end face of C3 with a depthometer
when the carrier plate (2) returns to the natural state.

(d) (15)
3.4 3.6mm

L L3 L4 3
According to the measured value, calculate the stroke
of piston (15) and see if it is within 3.4-3.6mm. If not,
choose another inner clutch disc.
L L3 L4 3

160
Parts Reassembly
- C2&C4 Assembly

- C2&C4 Assembly

6
24

23
12

22
13

11

14
15
16
17
18
4
5
6
20
21

19

19

19

19
11

18

10

17
9
16
15

8
6

14
13
12

7
6

1
5
4

161
Parts Reassembly
- C2&C4 Assembly

- C2&C4 Assembly
No.

Description

Qty No.

Description

Qty

Inner clutch disc

13

13

Retaining cap

Outer clutch disc

15

14

Return spring

Inner clutch disc

15

Retaining cap

Carrier plate

16

Piston

Circlip

17

Inner seal ring

Ball bearing

18

Outer seal ring

Gear

19

Casting iron seal

Spacer

20

-
C2&C4 shaft assembly

Gear

21

Gear

10

Ball bearing

22

Roller bearing

11

Circlip

23

Pinion

12

Circlip

24

Spacer

CAUTION: It is quite important to clean the components before assembling. Wash the
components with detergent and prevent contaminants and foreign matter coming inside. Check
the components carefully. Replace the component with a new one if it is damaged.
-
CAUTION: Check the oil passage before assembling C2&C4 shaft assembly and clear iron
slags, etc. in it.

C2 Assembly
1. (17) (18)
(17) (18)
(16)
Coat the piston inner seal ring (17) and outer seal
ring (18) with adequate transmission oil and install
them onto the piston (16).

162
Parts Reassembly
- C2&C4 Assembly

2. (16) -
(20)
Install the piston (16) into C2 chamber of C2&C4
shaft assembly (20).

3. A18 (16)

Tap the piston (16) with a copper bar A18 (See


Tool Table) into the bottom of C2 chamber
horizontally.

4. (13) (14) (15)


Install the retaining cap (13), return spring (14) and
the retaining cap (15).

163
Parts Reassembly
- C2&C4 Assembly

5. (12) A02

Install the circlip (12) onto tool A02 (See Tool


Table).

6. A02 -
(20)
Install tool A02 onto the C2&C4 shaft assembly
(18).

7. A03
(11) (12)
(12) (12)

Connect tool A03 (See Tool Table) to the press


machine, press the circlip (12) down quickly to
install the circlip (12) into the groove. Check and
adjust the circlip (12) to ensure that it is assembled
in the groove.
:

CAUTION: The pre&Compressive force of


the return spring is very strong. Reassemble
the circlip with press machine and tool instead
of hand, otherwise personnel injury may result.

164
Parts Reassembly
- C2&C4 Assembly

8. 10 (1)
10 (2)
Put 10 pieces of inner clutch discs (1) and 10
pieces of outer clutch discs (2) into C2 chamber
alternately.

CAUTION: The part that contacts the


piston in C2 chamber is inner clutch disc, not
outer clutch disc.

Use the old and new inner clutch discs and outer
clutch discs as follows:
(a)

Check the inner clutch disc and outer clutch disc


with a ruler to ensure that all parts are horizontal. If
not, use new parts when assembling.
(b)

0.15mm
0.30mm
2.20 0.05mm
Check the outer clutch disc for wear. Use new
parts if its surface is smooth or almost smooth. If
one side is abraded over 0.15mm, two sides are
abraded over 0.3mm, use new parts when
assembling. The new outer clutch disc thickness
is 2.20 0.05mm.
(c)

Check the outer clutch disc. Use new parts if the


friction material is damaged or burnt.
(d)

Check the outer clutch disc spline for wear, the


inner clutch disc for corrosion, scrape or other
damage. Use new parts if any one of these occurs.
(e)

Coat the contact surface of the outer clutch disc


with clean transmission oil before assembling.

165
Parts Reassembly
- C2&C4 Assembly

9. (3)
Install inner clutch disc (3).
(10) 170 , "
(3) "
Refer to "How to choose inner clutch disc (3) for
C2" on page 170 for inner clutch disc (3) selection.

10. 1 (2)
Install one piece of outer clutch disc (2).

11. (4)
Install carrier plate (4).

166
Parts Reassembly
- C2&C4 Assembly

12. (5)
Install the circlip (5).

13. (21) (2)


(21)
Rotate the gear (21) back and forth downwards to
make all the spline teeth of the outer clutch disc (2)
align with each other, then take out the gear (21).

14. (6)
Install ball bearing (6).

167
Parts Reassembly
- C2&C4 Assembly

15. (21)
Install gear (21).

16. (6)
Install ball bearing (6).

17. (24)
Install spacer (24).

168
Parts Reassembly
- C2&C4 Assembly

18. (23)
Install pinion (23).

19. (22)
Install roller bearing (22) cone.

20. (22) (11)


Install the roller bearing (22) circlip (11).

169
Parts Reassembly
- C2&C4 Assembly

21. - (20)
(19)
Install casting iron seals (19) onto C2&C4 shaft
assembly (20).

22. 0.15MPa
(21)
(16)
(21) - (20)

Inject 0.15 MPa compressed air into C2 passage


and rotate the gear (21). When you hear the piston
(16) moves and locks the parts and the gear (21)
can rotate successfully on C2&C4 shaft assembly
(20), it indicates that the C2 assembly is in good
condition and can work normally. If not,
disassemble it and check it.

170
Parts Reassembly
- C2&C4 Assembly

(3)
How to choose inner clutch disc (3) for C2

No.

Description

Thickness
(mm)

Inner clutch disc

1.7

Inner clutch disc

2.3

Inner clutch disc

2.9

Inner clutch disc

3.4

(a) (3)
(2) (4) (5)
Choose one of the inner clutch discs (3) in the left table
to preassemble with outer clutch disc (2), carrier plate
(4) and circlip (5).

(b) (4)
100N.m
(4) L1
Press the carrier plate (4) down with a screwdriver to
the limit position (The pressure is about 100N.m),
measure the depth L1 from the upper surface of carrier
plate (4) to the outer hub end face of C2 with a
depthometer.

(c) (4)
(5)
L2
Measure the depth L2 from the upper surface of circlip
(5) to the outer hub end face of C2 with a depthometer
when the carrier plate (4) returns to the natural state.

171
Parts Reassembly
- C2&C4 Assembly

(d) (16)
3.9 4.1mm

L L1 L2 3
According to the measured value, calculate the stroke
of piston (16) and see if it is within 3.9-4.1mm. If not,
choose another inner clutch disc.
L L1 L2 3

C4 Assembly
1. (17) (18)
(17) (18)
(16)
Coat the piston inner seal ring (17) and outer seal
ring (18) with adequate transmission oil and install
them onto the piston (16).

2. (16) -
(20)
Install the piston (16) into C4 chamber of C2&C4
shaft assembly (20).

172
Parts Reassembly
- C2&C4 Assembly

3. A18 (16)

Tap the piston (16) with a copper bar A18 (See


Tool Table) into the bottom of C4 chamber
horizontally.

4. (13) (14) (15)


Install the retaining cap (13), return spring (14) and
the retaining cap (15).

5. (12) A02

Install the circlip (12) onto tool A02 (See Tool


Table).

173
Parts Reassembly
- C2&C4 Assembly

6. A02 -
(20)
Install tool A02 onto the C2&C4 shaft assembly
(20).

7. A03
(12) (12)
(12) (12)

Connect tool A03 (See Tool Table) to the press


machine, press the circlip (12) down quickly to
install the circlip (12) into the groove. Check and
adjust the circlip (12) to ensure that it is assembled
in the groove.
:

CAUTION: The pre&Compressive force of


the return spring is very strong. Reassemble
the circlip with press machine and tool instead
of hand, otherwise personnel injury may result.

174
Parts Reassembly
- C2&C4 Assembly

8. 3 (2)
3 (1)
Put 3 pieces of inner clutch discs (2) and 3 pieces
of outer clutch discs (1) into C4 chamber
alternately.

CAUTION: The part that contacts the


piston in C4 chamber is inner clutch disc, not
outer clutch disc.

Use the old and new inner clutch discs and outer
clutch discs as follows:
(a)

Check the inner clutch disc and outer clutch disc


with a ruler to ensure that all parts are horizontal. If
not, use new parts when assembling.
(b)

0.15mm
0.30mm
2.20 0.05mm
Check the outer clutch disc for wear. Use new
parts if its surface is smooth or almost smooth. If
one side is abraded over 0.15mm, two sides are
abraded over 0.3mm, use new parts when
assembling. The new outer clutch disc thickness
is 2.20 0.05mm.
(c)

Check the outer clutch disc. Use new parts if the


friction material is damaged or burnt.
(d)

Check the outer clutch disc spline for wear, the


inner clutch disc for corrosion, scrape or other
damage. Use new parts if any one of these occurs.
(e)

Coat the contact surface of the outer clutch disc


with clean transmission oil before assembling.

175
Parts Reassembly
- C2&C4 Assembly

9. (3)
Install inner clutch disc (3).
(3) 179 , "
(3) "
Refer to "How to choose inner clutch disc (3) for
C4" on page 179 for inner clutch disc (3) selection.

10. 1 (2)
Install one piece of outer clutch disc (2).

11. (4)
Install carrier plate (4).

176
Parts Reassembly
- C2&C4 Assembly

12. (5)
Install the circlip (5).

13. (7) (2)


(7)
Rotate the gear (7) back and forth downwards to
make all the spline teeth of the outer clutch disc (2)
align with each other, then take out the gear (7).

14. (6)
Install ball bearing (6).

177
Parts Reassembly
- C2&C4 Assembly

15. (7)
Install gear (7).

16. (6)
Install ball bearing (6).

17. (8) (9)


Install spacer (8) and gear (9).

178
Parts Reassembly
- C2&C4 Assembly

18. (10)
Install ball bearing (10).

19. (11)
Install the circlip (11).

20. 0.15MPa
(9) (16)
(9)
- (20)

Inject 0.15 MPa compressed air into C4 passage


and rotate the gear (9). When you hear the piston
(16) moves and locks the parts and the gear (9)
can rotate successfully on C2&C4 shaft assembly
(20), it indicates that the C4 assembly is in good
condition and can work normally. If not,
disassemble it and check it.

179
Parts Reassembly
- C2&C4 Assembly

(3)
How to choose inner clutch disc (3) for C4

No.

Description

Thickness
(mm)

Inner clutch
disc

1.7

Inner clutch disc

2.3

Inner clutch disc

2.9

Inner clutch disc

3.4

(a) (3)
(2) (4) (5)
Choose one of the inner clutch discs (3) in the left table
to preassemble with outer clutch disc (2), carrier plate
(4) and circlip (3).

(b) (4)
100N.m
(4)
L3
Press the carrier plate (4) down with a screwdriver to
the limit position (The pressure is about 100N.m),
measure the depth L3 from the upper surface of carrier
plate (4) to the outer hub end face of C4 with a
depthometer.

(c) (4)
(5)
L4
Measure the depth L4 from the upper surface of circlip
(5) to the outer hub end face of C4 with a depthometer
when the carrier plate (4) returns to the natural state.

180
Parts Reassembly
- C2&C4 Assembly

(d) (16)
1.6 1.8mm

L L3 L4 3
According to the measured value, calculate the stroke
of piston (16) and see if it is within 1.6-1.8mm. If not,
choose another inner clutch disc.
L L1 L2 3

181
Parts Reassembly
Output Shaft Group

Output Shaft Group

1
2
1
3

21

22

5
6
7

12
13

11
9
10

14

12
13

15
16
17

4
3
1
2
1
18
19

20

Output Shaft Group


No.

Description

Qty No.

Description

Qty

O O-ring

12

O O-ring

Seal seat

13

Plug

Seal

14

Output shaft

Circlip

15

Bush

Roller bearing

16

Ball bearing

Sleeve

17

Shim

Gear

18

Flange

Oil shield

19

O O-ring

Washer

20

Locknut

10

Bolt

21

Nameplate

11

Transmission housing

22

Rivet

182
Parts Reassembly
Output Shaft Group

CAUTION: It is quite important to clean the components before assembling. Wash the
components with detergent and prevent contaminants and foreign matter coming inside. Check
the components carefully. Replace the component with a new one if it is damaged.
1. (5) (4)
Install the roller bearing (5) circlip (4).

2. (11) (5)
(18)
(5)
Coat the mounting hole of roller bearing (5) in
transmission housing (11) with transmission oil.
Install the roller bearing (5) through the mounting
hole of rear output flange (18).

183
Parts Reassembly
Output Shaft Group

3. (8) (11)
Install oil shield (8) into transmission housing (11).

4. (8)
(10) (9) (10) 52
7N.m
Install oil shield (8) bolt (10) and washer (9) with an
air gun. Tightening torque of bolt (10) is 52
7N.m.

5. 45
(6) (5) (7)
(8)
Rotate the transmission housing to make it
maintain an angle of 45horizontally so as to let
the big opening partially face downwards. Put
sleeve (6) onto roller bearing (5) and install output
gear (7) into oil shield (8), then rotate the
transmission housing to let the big opening face
downwards completely.
7

184
Parts Reassembly
Output Shaft Group

6. (7) (6)
(14) (14)
(7) (14)

Align the center hole of output gear (7) with sleeve


(6) and install input shaft (14) through the
mounting hole of front flange, then align the
rectangular teeth of output shaft (14) and output
gear (7), finally install output shaft (14) in place.

7. (15)
Install bush (15).

8. (11) (16)
(16)
Coat the mounting hole of ball bearing (16) in
transmission housing (11) with transmission oil,
install ball bearing (16).

185
Parts Reassembly
Output Shaft Group

9. (13) O (12)
Install plug (13) and O-ring (12).

10. (17)
Install shim (17).
(17) 188 , "
(17) "
Refer to "How to choose shim (17)" on page 188
for shim (17) selection.

11. (4)
Install the circlip (4).

12. (2) O (1)


Install O-ring (1) onto seal seat (2).

186
Parts Reassembly
Output Shaft Group

13. (3) (
1596) (2)
A05
(3)
Apply silicone rubber sealant (No. 1596) to seal (3)
and grease the seal lip. Install seal (3) onto the
seal seat (2) with Tool A 05(See Tool Table)

14. (18) (2)


Install seal seat (2) through the mounting hole of
rear output flange (18).

15. (18)
Install rear output flange (18).

187
Parts Reassembly
Output Shaft Group

16. O (19)
Install O-ring (19).

17.
(20) (20) 2010
300N.m
Install locknut (20) with an air gun or torque
spanner. Tightening torque of locknut (20) is 2010
300N.m.

18. (2)
Install seal seat (2) through the mounting hole of
front output flange.

188
Parts Reassembly
Output Shaft Group

(17)
How to choose shim (17)
(a) (18)
(16) L1
Measure depth L1 from the mounting hole top surface
of output flange (18) to ball bearing (16) with a
depthometer.

No.

Description

Thickness
(mm)

Shim

0.6

Shim

0.7

Shim

0.8

Shim

0.9

Shim

1.0

Shim

1.1

Shim

1.2

Shim

1.3

Shim

1.4

10

Shim

1.5

11

Shim

1.6

(b) (17)
(4)
Choose one of the shims (17) in the left table to
preassemble with circlip (4)

(c) (18)
(4) L2
Measure depth L2 from the mounting hole top surface
of output flange (18) to circlip (4) with a depthometer.

189
Parts Reassembly
Output Shaft Group

(d) (16) (4)


L 0 0.15mm

L L1 L2 2.5 S
S:
According to the measured value, calculate clearance L
between bearing (16) and circlip (4) and see if it is
within 0~0.15mm. If not, select another shim.
L L1 L2 2.5 S
S: Thickness of the shim being selected

190
Parts Reassembly
Shift Control Valve, End Cap Group and Clutch Assembly

Shift Control Valve, End


Cap Group and Clutch Assembly
26
25

24

23

27

22

25
5

28
14

12
13

11

12

18

10

15

15

15

15

16

17
2
30
29

1
19

15

15

15

15

16

17

6
5
4
21
9

20

2
1

16

6
5
8

2
1

6
5
4
3
2
1

31

191
Parts Reassembly
Shift Control Valve, End Cap Group and Clutch Assembly

Shift Control Valve, End Cap Group and Clutch Assembly


NO.

Name

Qty NO.

Name

Qty

Bolt

18

17

Roller bearing

Washer

53

18

CV&CR assembly

Cover assembly

19

- C1&C3 assembly

Gasket

20

Roller bearing

Circlip

21

- C2&C4 assembly

Shim

22

Pin

Bolt

29

23

Gasket

End cap

24

Gasket

Cover assembly

25

Washer

10

Idler shaft

26

Bolt

11

Lifting eye

27

Bolt

12

Ball bearing

28

Shift control valve

13

Gear

29

Gasket

14

Circlip

30

Cover plate

15

Casting iron seal

31

Bolt

16

Circlip

15

CAUTION: It is quite important to clean the components before assembling. Wash the
components with detergent and prevent contaminants and foreign matter coming inside. Check
the components carefully. Replace the component with a new one if it is damaged.

Clutch Assembly
1. (18) (5)
Install CV&CR assembly (18) ball bearing circlip
(5).

192
Parts Reassembly
Shift Control Valve, End Cap Group and Clutch Assembly

2. - (19) (5)
Install C1&C3 assembly (19) ball bearing circlip
(5).

3. - (21) (5)
Install C2&C4 assembly (21) ball bearing circlip
(5).

4. A10 (19) - (21)

- (19) -
(21)
, - (21)

19

21

Tie up C1&C3 assembly (19) and C2&C4


assembly (21) firmly with white sisal rope A10
(See Tool Table) to let the gears engage with each
other, Meanwhile, lift them up to put them into the
transmission housing to let the bearings fit into the
mounting hole. The C2&C4 assembly should
contact the output shaft gear tightly.
5. - (19) -
(21)
Alternately tap C1&C3 assembly (19) and C2&C4
assembly (21) until they are mounted in place.
-
(18) - (20)
CAUTION: Tap C1&C3 assembly (19) first ,
C2&C4 assembly (21) the second.

193
Parts Reassembly
Shift Control Valve, End Cap Group and Clutch Assembly

6. A10
(18) (18)

Tie up CV&CR assembly (18) firmly with white


sisal rope A10 (See Tool Table), lift it up to put it
into the transmission housing to let the bearing fit
into the mounting hole.

7. (18)
Tap CV&CR assembly (18) until it is mounted in
place.

194
Parts Reassembly
Shift Control Valve, End Cap Group and Clutch Assembly

End Cap Group and Idler Shaft


1. (10)
InstalI the idler shaft (10).

2. (10) (1) (2)


(1) 52 7N.m
Install idler shaft (10) bolts (1) and washers (2).
Tightenning torque is: 52 7N.m.

3. (10) (12)
Install ball bearing (12) onto the idler shaft (10).

195
Parts Reassembly
Shift Control Valve, End Cap Group and Clutch Assembly

4. (10) (13)
Install gear (13) onto the idler shaft (10).

5. (12)
Install ball bearing (12).

6. (14)
Install the circlip (14).

196
Parts Reassembly
Shift Control Valve, End Cap Group and Clutch Assembly

7. (8)
( 1515)
Coat the end cap mounting surface with sealant
(No. 1515).

3 4mm

CAUTION: Apply sealant evenly, the


diameter of sealant cross section is 3~4mm,
the sealant should be applied in continuous
line and no break off.
8. (8)
(8)
Screw eyebolt A08 (See Tool Table) on the end
cap (8) and fasten it with a wire rope, then lift it up
and install it to the housing.

9. (8) (1) (2)


(1) 52 7N.m
Install the end cap (8) bolts (1) and washers (2).
Tightening torque of bolts (1) is 52 7N.m.

10. (11) (1) (2)


(1) 52 7N.m
Install lifting eye (11) and install bolts (1) and
washers (2) that hold lifting eye (11) in place.
Tightening torque of bolts (1) is 52 7N.m.

197
Parts Reassembly
Shift Control Valve, End Cap Group and Clutch Assembly

11. - (21) (20)

Install the roller bearing (20) cup onto C2&C4


assembly (21).

12. - (21) (20)


(6)
Install the roller bearing (20) shim (6) into C2&C4
assembly (21).
(6) 203 , " -
(6) "
Refer to "How to choose shim (6) for C2&C4
assembly" on page 203 for shim (6) selection.
13. (5)
Install the circlip (5).

14. - (3) (4)


Install cover assembly (3) and gasket (4).

198
Parts Reassembly
Shift Control Valve, End Cap Group and Clutch Assembly

15. - (3) (1)


(2) (1) 52 7N.m
Install the cover assembly (3) bolts (1) and
washers (2) for C2&C4 assembly. Tightening
torque of bolts (1) is 52 7N.m.

16. - (19)
(17)
Install roller bearing (17) onto C1&C3 assembly
(19).

17. (17) (16)


Install the roller bearing (17) circlip (16).

18. - (19)
(17) (6)
Install the roller bearing (17) shim (6) into C1&C3
assembly (19).
(6) 205 , " -
(6) "
Refer to "How to choose shim (6) for C1&C3
assembly" on page 205 for shim (6) selection.

199
Parts Reassembly
Shift Control Valve, End Cap Group and Clutch Assembly

19. (5)
Install the circlip (5).

20. - (19) (15)


15

Install casting iron seals (15) onto C1&C3


assembly (19).

21. - (3) (4)


Install cover assembly (3) and gasket (4).

22. - (3) (1)


(2) (1) 52 7N.m
Install the cover assembly (3) bolts (1) and
washers (2) for C1&C3 assembly. Tightening
torque of bolts (1) is 52 7N.m.

200
Parts Reassembly
Shift Control Valve, End Cap Group and Clutch Assembly

23. (18) (17)


Install roller bearing (17) onto CV&CR assembly.

24. (18) (17)


(16)
Install the roller bearing (17) circlip (16) onto
CV&CR assembly.

25. (18) (17)


(6)
Install the roller bearing (17) shim (6) onto CV&CR
assembly (18).
(6) 207 , "
(6) "
Refer to "How to choose shim (6) for CV&CR
assembly" on page 207 for shim (6) selection.

201
Parts Reassembly
Shift Control Valve, End Cap Group and Clutch Assembly

26. (5)
Install the circlip (5).

27. (18) (15)


15

Install casting iron seals (15) onto F-R assembly


(18).

28. (9) (4)


Install cover assembly (9) and gasket (4).

29. (9) (1)


(2) (1) 52 7N.m
Install the cover assembly (9) bolts (1) and
washers (2) for CV&CR assembly. Tightening
torque of bolts (1) is 52 7N.m.

202
Parts Reassembly
Shift Control Valve, End Cap Group and Clutch Assembly

30. (30) (29)


Install cover plate (30) and gasket (29).

31. (30) (31) (2)


(31) 52 7N.m
Install the cover plate (30) bolts (31) and washers
(2). Tightening torque of bolts (31) is 52 7N.m.

203
Parts Reassembly
Shift Control Valve, End Cap Group and Clutch Assembly

- (6)
How to choose shim (6) for C2&C4 assembly
(a) (20)
(4) L1
Measure the distance L1 from roller bearing (20) to
gasket (4) mounting surface with a depthometer.

NO.

Name

Thickness
(mm)

Shim

0.75

Shim

0.85

Shim

1.00

Shim

1.15

Shim

1.30

Shim

1.45

Shim

1.60

Shim

1.75

Shim

1.90

10

Shim

2.00

(b) (6)
(5)
Choose one of the shims(6) in the left table to
preassemble with circlip (5)

(c) (5) (4)


L2
Measure the distance L2 from the top side of the circlip
(5) to gasket (4) mounting surface with a depthometer.

204
Parts Reassembly
Shift Control Valve, End Cap Group and Clutch Assembly

(d) (20) (5)


L 0 0.15mm

L L1 L2 2.5 S
S:
According to the measured value, calculate the
clearance L between the roller bearing (20) and the
circlip (5) and see if it is within 0 ~ 0.15mm, if not,
choose aother shim.
L = L1 - L2 - 2.5 - S
S: Thickness of the shim being selected

205
Parts Reassembly
Shift Control Valve, End Cap Group and Clutch Assembly

- (6)
How to choose shim (6) for C1&C3 assembly
(a) (17)
(4) L3
Measure the distance (L3) from roller bearing (17) to
gasket (4) mounting surface with a depthometer.

NO.

Name

Thickness
(mm)

Shim

0.75

Shim

0.85

Shim

1.00

Shim

1.15

Shim

1.30

Shim

1.45

Shim

1.60

Shim

1.75

Shim

1.90

10

Shim

2.00

(b) (6)
(5)
Choose one of the shims (6) in the left table to
preassemble with circlip (5).

(c) (5) (4)


L4
Measure the distance L4 from the top side of the circlip
(5) to gasket (4) mounting surface with a depthometer.

206
Parts Reassembly
Shift Control Valve, End Cap Group and Clutch Assembly

(d) (17) (5)


L 0 0.15mm

L L3 L4 2.5 S
S:
According to the measured value, calculate the
clearance L between the roller bearing (17) and the
circlip (5) and see if it is within 0 ~ 0.15mm, if not,
choose aother shim.
L = L3 - L4 - 2.5 - S
S: Thickness of the shim being selected

207
Parts Reassembly
Shift Control Valve, End Cap Group and Clutch Assembly

(6)
How to choose shim (6) for CV&CR assembly
(a) (17)
(4) L5
Measure the distance L5 from roller bearing (17) to
gasket (4) mounting surface with a depthometer.

NO.

Name

Thickness
(mm)

Shim

0.75

Shim

0.85

Shim

1.00

Shim

1.15

Shim

1.30

Shim

1.45

Shim

1.60

Shim

1.75

Shim

1.90

10

Shim

2.00

(b) (6)
(5)
Choose one of the shims(6) in the left table to
preassemble with circlip (5)

(c) (5) (4)


L6
Measure the distance L6 from the top side of the circlip
(5) to gasket (4) mounting surface with a depthometer.

208
Parts Reassembly
Shift Control Valve, End Cap Group and Clutch Assembly

(d) (17) (5)


L 0 0.15mm

L L5 L6 2.5 S
S:
According to the measured value, calculate the
clearance L between the roller bearing (17) and the
circlip (5) and see if it is within 0 ~ 0.15mm, if not,
choose aother shim.
L = L5 - L6 - 2.5 - S
S: Thickness of the shim being selected

209
Parts Reassembly
Shift Control Valve, End Cap Group and Clutch Assembly

Shift Control Valve


1.

Install two pins into the position where the shift


control valve is installed to the transmission
housing.

2. (23)
Install gasket (23).

3. (28)
Install the shift control valve (28) oil transfer plate.

4. (28)
(27) (25) (27) 28
4N.m
Install the oil transfer plate bolts (27) and washers
(25) onto the shift control valve(28). Tightening
torque of bolts (27) is 28 4N.m.

210
Parts Reassembly
Shift Control Valve, End Cap Group and Clutch Assembly

5. (24)
Install gasket (24).

6. (28)
Install the shift control valve(28) body.

7. (28)
(26) (25) (26) 28
4N.m
Install bolts (26) and washers (25). Tightening
torque of bolts (26) is 28 4N.m.

211
Parts Reassembly
Connectors and Hose Assembly

Connectors and Hose Assembly


24

23

G
10

18

10

10

12
13

F 17 18

12
13

13
10

10

10
10

12

12

12

12

13

F
C

13
16

19

13

22
21

18
15

17
10
9

14

6
5
4

20

18

D
7

B
11

10

25

26
2

18

9
8

17

18
2
1

2
2
1

212
Parts Reassembly
Connectors and Hose Assembly

Connectors and Hose Assembly


No.

Description

Qty No.

Description

Qty

Connector

14

Hose assembly

Gasket

15

Hose assembly

Hose assembly

16

Hose assembly

O O-ring

17

Connector

Connector

18

Gasket

O O-ring

19

Breather

Hose assembly

20

Breather pipe

O O-ring

21

O O-ring

Connector

22

Connector

10

O O-ring

23

Hose assembly

11

Hose assembly

24

Hose assembly

12

Connector

25

O O-ring

13

Gasket

26

Connector

CAUTION: It is quite important to clean the components before assembling. Wash the
components with detergent and prevent contaminants and foreign matter coming inside. Check
the components carefully. Replace the component with a new one if it is damaged.
1. (23) (24)
(12) O (10)
(13)
Install hose assembly (23) and (24) connectors
(12), O-rings (10) and gaskets (13) onto the shift
control valve in sequence.

213
Parts Reassembly
Connectors and Hose Assembly

2. (11) (14)
(15) (16)
(12) O (10) (13)
Install hose assembly (11), (14), (15) and (16)
connectors (12), O-rings (10) and gaskets (13)
onto the shift control valve in sequence.

3. - O (10)
(9) O (8)
Install O-ring (10), connector (9) and O-ring (8)
onto the C2&C4 cover.

4. - O (8)
(9) O (10)
Install O-ring (8), connector (9) and O-ring (10)
onto the C1&C3 cover.

5. O (4) (5)
O (6)
Install O-ring (4), connector (5) and O-ring (6) onto
the cover of CV&CR assembly.

214
Parts Reassembly
Connectors and Hose Assembly

6. O (8) (9)
O (10)
Install O-ring (8), connector (9) and O-ring (10)
onto the cover of CV&CR assembly.

7. (26) O
(25)
Install connector (26) and O-ring (25) onto the
cover of CV&CR assembly.

8. (24) (17) (18)


Install hose assembly (24), connector (17) and
gaskets (18).

215
Parts Reassembly
Connectors and Hose Assembly

9. (23)
Connect hose assembly (23).

10. (16) (17) (18)


Install hose assembly (16), connector (17) and
gaskets (18).

11. (15)
Connect hose assembly (15).

12. (14) (17) (18)


Install hose assembly (14), connector (17) and
gaskets (18).

216
Parts Reassembly
Connectors and Hose Assembly

13. (11)
Connect hose assembly (11).

14. (3) (1) (2)


Install hose assembly (3), connector (1) and
gaskets (2).

15. (7) (1) (2)


Install hose assembly (7), connector (1) and
gaskets (2).

16. (22) O (21)


Install connector (22) and O -ring (21).

217
Parts Reassembly
Connectors and Hose Assembly

17. (19) (20)


Connect breather (19) to breather pipe (20).

18. (20)
Connect breather pipe (20).

218
Parts Reassembly
Brake

Brake

12
11
13
10
9
8
7
6
5
1
4
3
2

Brake
No.

Description

Qty No.

Description

Qty

Brake group

Bolt

Flange

Washer

Bolt

10

Bolt

Washer

11

Washer

Brake hub

12

Nut

Locknut

13

Handle

O O-ring

CAUTION: It is quite important to clean the components before assembling. Wash the
components with detergent and prevent contaminants and foreign matter coming inside. Check
the components carefully. Replace the component with a new one if it is damaged.

219
Parts Reassembly
Brake

1. (13) (10) (11)


(12) (10) 145
20N.m
Install the handle (13) bolt (10), washer (11) and
nut (12). Tightening torque of bolt (10) is 145
20N.m.

2. (1)
Install brake group (1).

3. (1) (8) (9)


(8) 90 12N.m
Install brake group (1) bolts (8) and washers (9).
Tightening torque of bolts (8) is 90 12N.m.

4. (2)
Install output flange (2).

220
Parts Reassembly
Brake

5. O (7)
Install O-ring (7)

6. (6)
(6) 2010 300N.m
Install locknut (6) with an air gun or torque
spanner. Tightening torque of locknut (6) is 2010
300N.m.

7. (5)
Install brake hub (5).

221
Parts Reassembly
Brake

8. (5) (3) (4)


(3) 90 12N.m
Install brake hub (5) bolts (3) and washers (4).
Tightening torque of bolts (3) is 90 12N.m.

222
Parts Reassembly
Torque Converter Housing Group

Torque Converter Housing Group


37
14

34
35

38
14

36
33
28
14

26

30
27

25
20

31

26

32

25

23

20

22

24

13
14

23

21
20

29

22

19
14

21

18

20

7
6
17

5
4

16
15

12

11

10

9
8

13

14

223
Parts Reassembly
Torque Converter Housing Group

Torque Converter Housing Group


No.

Description

Qty No.

Description

Qty

Casting iron seal

20

Ball bearing

Stator seat

21

Spacer

Turboshaft

22

P.T.O gear

Casting iron seal

23

Circlip

Ball bearing

24

P.T.O shaft

Circlip

25

Shim

Circlip

26

Circlip

Bolt

27

O O-ring

Washer

28

Bolt

10

Inlet valve

29

Flange

11

O O-ring

30

O O-ring

12

Torque converter housing

31

Connector

13

Bolt

24

32

P.T.O shaft

14

Washer

40

33

Paper gasket

15

O O-ring

34

Connector

16

Plug

35

Gasket

17

Pin

36

Charging pump

18

Outlet valve

37

Bolt

19

Bolt

38

Bolt

CAUTION: Cleanliness is quite important. Clean the component surface before


disassembling to prevent mud and dust etc. coming inside.

224
Parts Reassembly
Torque Converter Housing Group

P.T.O Gear, P.T.O Shaft, Inlet Valve


1. (12)
(20)
Install the P.T.O shaft ball bearing (20) for the
charging pump in the bottom of the torque
converter housing (12).

2. (12) (21)
(22) (21) (22)
(20)
Put the spacer (21) and the P.T.O gear (22) into the
torque converter housing (12) from its opening,
align them with the P.T.O shaft ball bearing (20)
bore.

3. (32) (23)
Install the circlip (23) onto P.T.O shaft (32).

225
Parts Reassembly
Torque Converter Housing Group

4. (32)
(32) (22)
Install P.T.O shaft (32), align it with the P.T.O gear
(22) spline.

5. (32)
Install P.T.O shaft (32) in place with tool.

6. (20)
Install the P.T.O shaft ball bearing (20).

226
Parts Reassembly
Torque Converter Housing Group

7. (25)
Install the P.T.O shaft shim (25).
(25) 230 , "
(25) "
Refer to "How to choose P.T.O shaft shim (25) for
charging pump" on page 230 for shim (25)
selection.

8. (26)
Install the P.T.O shaft circlip (26).

9. (12)
(20)
Install the P.T.O shaft ball bearing (20) for the
steering pump in the bottom of the torque
converter housing (12).

10. (12) (21)


(22) (21) (22)
(20)
Put the spacer (21) and the P.T.O gear (22) into the
torque converter housing (12) from its opening,
align them with the P.T.O shaft ball bearing (20)
bore.

227
Parts Reassembly
Torque Converter Housing Group

11. (24) (23)


Install the circlip (23) onto P.T.O shaft (24).

12. (24)
(24) (22)
Install P.T.O shaft (24), align it with the P.T.O gear
(22) spline.

13. (24)
Install P.T.O shaft (24) in place with tool.

228
Parts Reassembly
Torque Converter Housing Group

14. (20)
Install the P.T.O shaft ball bearing (20).

15. (25)
Install the P.T.O shaft shim (25).
(25) 232 , "
(25) "
Refer to "How to choose P.T.O shaft shim (25) for
steering pump" on page 232 for shim (25)
selection.

16. (26)
Install the P.T.O shaft circlip (26).

17. (10) O (11)


Install the O-ring (11) on the inlet valve (10).

229
Parts Reassembly
Torque Converter Housing Group

18. (10)
Install the inlet valve (10).

230
Parts Reassembly
Torque Converter Housing Group

(25)
How to choose P.T.O shaft shim (25) for charging pump
(a) (33)
(20) L1
Measure the depth L1 from the mounting surface of the
paper gasket (33) to the ball bearing (20) with a
depthometer.

No.

Name

Thickness
(mm)

Shim

1.3

Shim

1.4

Shim

1.5

Shim

1.6

Shim

1.7

Shim

1.8

Shim

1.9

Shim

2.0

Shim

2.1

10

Shim

2.2

(b) (25)
(26)
Choose one of the shims(25) in the left table to
preassemble with circlip (26).

(c) (33) (26)


L2
Measure the depth L2 from the mounting surface of the
paper gasket (33) to the upper edge of circlip (26) with
a depthometer.

231
Parts Reassembly
Torque Converter Housing Group

(d) (20) (26)


L 0.05 0.10mm

L L1 L2 2.5 S
S:
According to the measured value, calculate the
clearance L between the ball bearing (20) and the
circlip (26) to see if it is within 0.05 ~ 0.10mm; if not,
select another shim.
L = L1 - L2 - 2.5 - S
S: Thickness of the shim being selected

232
Parts Reassembly
Torque Converter Housing Group

(25)
How to choose P.T.O shaft shim (25) for steering pump
(a) (29)
(20) L3
Measure the depth L3 from the mounting surface of the
flange (29) to the ball bearing (20) with a depthometer.

No.

Name

Thickness
(mm)

Shim

1.3

Shim

1.4

Shim

1.5

Shim

1.6

Shim

1.7

Shim

1.8

Shim

1.9

Shim

2.0

Shim

2.1

10

Shim

2.2

(b) (25)
(26)
Choose one of the shims(25) in the left table to
preassemble with circlip (26).

(c) (29) (26)


L4
Measure the depth L4 from the mounting surface of the
flange (29) to the upper edge of circlip (26) with a
depthometer.

233
Parts Reassembly
Torque Converter Housing Group

(d) (20) (26)


L 0.05 0.10mm

L L3 L4 2.5 S
S:
According to the measured value, calculate the
clearance L between the ball bearing (20) and the
circlip (26) to see if it is within 0.05 ~ 0.10mm; if not,
select another shim.
L = L3 - L4 - 2.5 - S
S: Thickness of the shim being selected

234
Parts Reassembly
Torque Converter Housing Group

Torque Converter Housing


1. (12)
( 1515)
Coat the mounting surface of the torque converter
housing (12) with a layer of sealant (No. 1515).

3 4mm

CAUTION: Apply sealant evenly, the


diameter of sealant cross section is 3~4mm,
the sealant should be applied in continuous
line and no break off.
2. (12)
(12)
Lift up the torque converter housing (12) to the top
of the transmission housing, install it in place with
a copper bar.

3. (12) (13)
(14) (13) 52 7N.m
Install the bolts (13) and washers (14) on the
torque converter housing (12). Tightening torque of
bolts (13) is 52 7N.m.

4. (13)
(14) (13) 52 7N.m
Install the bolts (13) and washers (14) on the
transmission housing. Tightening torque of bolts
(13) is 52 7N.m.

235
Parts Reassembly
Torque Converter Housing Group

Charging Pump, Flange, Outlet Valve


1. (18)
Install the outlet valve (18).

2. (18) (19) (14)


(19) 52 7N.m
Install the outlet valve (18) bolts (19) and washers
(14). Tightening torque of bolts (19) is 52 7N.m.

3. (29) O (27)
Install the O-ring (27) onto the steering pump
flange (29).

4. (29)
Install the steering pump flange (29).

236
Parts Reassembly
Torque Converter Housing Group

5. (29) (28)
(14) (28) 52 7N.m
Install the steering pump flange (29) bolts (28) and
washers (14). Tightening torque of bolts (28) is 52
7N.m.

6. (33)
Install the charging pump paper gasket (33).

7. (36)
Install the charging pump (36).

8. (36) (37) (38)


(14) (37) (38)
52 7N.m
Install the charging pump (36) bolts (37), (38) and
washers (14). Tightening torque of bolts (37), (38)
is 52 7N.m.

237
Parts Reassembly
Torque Converter Housing Group

9. (31) O (30)
Install the charging pump fitting (31) and O-ring
(30).

10. (34) (35)


Install the charging pump connector (34) and
gasket (35).

238
Parts Reassembly
Torque Converter Housing Group

Stator Seat Group


1. (3) (4)
Install the casting iron seal (4) onto the turboshaft
(3).

2. (3) (5)
Install the ball bearing (5) onto the turboshaft (3).

3. (5) (7)
Install the ball bearing (5) circlip (7).

239
Parts Reassembly
Torque Converter Housing Group

4. (2) (1)
Install the casting iron seal (1) onto the stator seat
(2).

5. (3) (2)
Install the turboshaft (3) onto the stator seat (2).

6. (5) (6)
Install the ball bearing (5) circlip (6).

240
Parts Reassembly
Torque Converter Housing Group

7. (2)
Install the stator seat (2).

CAUTION: The threaded holes and the oil


inlet and outlet between the stator seat and the
torque converter housing should be aligned
during assembling.

8. (2) (8) (9)


(8) 92 12N.m
Install the bolts (8) and washers (9) onto the stator
seat (2). Tightening torque of bolts (8) is 92
12N.m.

241
Parts Reassembly
Torque Converter Group

Torque Converter Group


24
23

22
20

19

21
20

18
17
16
15
14
13

12

11
9
8
10
7
6
5

4
4
3
4
2
1

242
Parts Reassembly
Torque Converter Group

Torque Converter Group


No.

Name

Qty No.

Name

Qty

Bolt

12

13

Gear

Washer

12

14

Circlip

Adjusting sleeve

15

Paper gasket

Flexible plate

16

Cover plate

Bolt

17

Washer

Washer

18

Bolt

Shaft

19

Lifting eye

O O-ring

20

Washer

Seal

21

Bolt

10

Housing

22

Bolt

10

11

Paper gasket

23

Rivet

12

Torque converter

24

Nameplate

12

CAUTION: Cleanliness is quite important. Clean the component surface before


disassembling to prevent mud and dust etc. coming inside.

243
Parts Reassembly
Torque Converter Group

Torque Converter
1. (12) (13)
Install the gear (13) onto the torque converter (12).

2. (14)
Install the gear circlip (14).

3. (12)
(12)
Screw two eye bolts on the opposite angles of the
torque converter (12), lift up the torque converter
(12) and install it into the torque converter housing.

244
Parts Reassembly
Torque Converter Group

4. (12) (12)

(12)
Shake the torque converter (12) gently to let the
stator of the torque converter (12) engage with the
teeth of the stator seat, install the torque converter
(12) in place with a copper bar.

5. (11)
Install the paper gasket (11).

6. (9) (
1596) A06
(10)
(9)
Apply silicone rubber sealant (No. 1596) to seal (9)
and grease the seal lip. Install seal (9) into housing
(10) with Tool A 06(See Tool Table).

245
Parts Reassembly
Torque Converter Group

7. (10)
Install the housing (10).

8. (10) (22) (20)


(22) 52 7N.m
Install the bolts (22) and washers (20) onto the
housing (10). Tightening torque of bolts (22) is 52
7N.m.

9. (19) (21) (20)


(21) 52 7N.m
Install the bolts (21) and washers (20) onto the
lifting eye (19). Tightening torque of bolts (21) is 52
7N.m.

246
Parts Reassembly
Torque Converter Group

10. O (8)
(7)
Grease the O-ring (8), and then install it onto the
shaft (7).

11. (7)
Install the shaft (7).

12. (7) (5) (6)


(5) 90 12N.m
Install the bolts (5) and washers (6) onto the shaft
(7). Tightening torque of bolts (5) is 90 12N.m.

247
Parts Reassembly
Torque Converter Group

13. (4)
Install the flexible plates (4).

14. (3)
Install the adjusting sleeve (3).

15. (3) (1) (2)


(1) 90 12N.m
Install the bolts (1) and washers (2) onto the
adjusting sleeve (3). Tightening torque of bolts (1)
is 90 12N.m.

16. (16) (15)


Install the cover plate (16) and the paper gasket
(15).

248
Parts Reassembly
Torque Converter Group

17. (16) (18) (17)


(18) 26 4N.m
Install the bolts (18) and washers (17) onto the
cover plate (16). Tightening torque of bolts (18) is
26 4N.m.

249
Parts Reassembly
Transmission and Torque Converter Accessories

Transmission and Torque Converter Accessories

15
14

14
14

16

14

15

7
6
10

5
4

11

12

13

8
1

Transmission and Torque Converter Accessories


No.

Description

Qty

No.

Description

Qty

Hose assembly

Coarse filter

Connector

10

O O-ring

Oil drain plug

11

Cover plate

O O-ring

12

Washer

Magnet

13

Bolt

Sight glass

14

Gasket

O O-ring

15

Connector

Adjustable connector

16

Hose assembly

250
Parts Reassembly
Transmission and Torque Converter Accessories

CAUTION: Cleanliness is quite important. Clean the component surface before


disassembling to prevent mud and dust etc. coming inside.
1. (6) O (7)
Install the O-ring (7) onto the sight glass (6).

2. (6)
Install the sight glass (6).

3. (3) (5) O (4)


Install the magnet (5) and O-ring (4) onto the oil
drain plug (3).

4. (3)
Install the oil drain plug (3).

251
Parts Reassembly
Transmission and Torque Converter Accessories

5. (9)
Install the coarse filter (9).

6. (2)
Screw the connector (2) to the transmission.

7. (8) (1)
Install the adjustable connector (8) and the hose
assembly (1).

8. (16)
(15) (14)
Install the hose assembly (16) connector (15) and
gaskets (14) onto the torque converter.

252
Parts Reassembly
Transmission and Torque Converter Accessories

9. (16)
(15) (14)
Install the hose assembly (16) connector (15) and
gaskets (14) onto the shift control valve.

253
Transmission and Torque Converter Accessories

254
Check the Machine after Repairing
Transmission and Torque Converter Accessories

Check the Machine after


Repairing

The transmission, torque converter, and their


pipings that connect to hydraulic system are
important links for power transmitting between
engine and wheels. The proper operation of
either unit depends greatly on the condition and
operation of the other components; therefore,
whenever repairing or checking of one unit, the
balance of the system must be considered
before the work is completed.

If a checked or repaired transmission has been


installed in the machine, the torque converter oil
cooler, and those pipings that connect to
hydraulic system must be thoroughly cleaned by
a trained and experienced person.

Check the machine as follows after the


transmission is checked and repaired:
1.

Before installing the transmission, check oil


filter pipings, cooling pipings, torque
converter and oil filter for blockage, damage,
leakage or other abnormalities. If have, drain
out the torque converter oil in hydraulic
pipings, torque converter cooler and oil filter.
Remove the hydraulic hoses and oil filter
from the machine, clean or replace them
when necessary.
2.
Clean torque converter oil radiator grids.
3.

Install clean hydraulic hoses and oil filter on


the machine.
4.
Install all oil drain plugs.
5.

Replenish transmission oil through


transmission oil filling pipes. Check the
transmission oil level.
(a) "N"
Turn the shift control lever to NEUTRAL
position.
(b) 750 /
Start the engine and run at idle speed about
750rpm.
(c)

Check sight glass, the oil level should reach


the middle position.

255
Check the Machine after Repairing
Transmission and Torque Converter Accessories

NOTICE: The transmission oil level will


rise when the engine stops running. The
rising degree relates with the mounting
condition of the transmission.
6.

1.8~2.0MPa

Connect a pressure gauge separately to the


pressure measuring joints of the shift control
valve. Operate the shift control lever to get
different gears and check the system
pressure in forward and reverse gears. The
pressure is supposed to be 1.8~2.0MPa. If
not, check the transmission again and
remove the problem.

CAUTION: Contact related service


person to repair transmission when the oil
pressure is abnormal.

256
Lubrication
Oil Brand

Lubrication

Transmission Oil--Replace

Oil Brand
PT300 SAE15W-40
1300

100
1000
,

SAE15W-40 MOBIL 1300 Hydraulic transmission


oil is used on PT300 transmission.

Replace the transmission oil at the first 100


service hours. After that, change the
transmission oil every 1000 service hours at
least once a year.

Replace the transmission oil as follows:

Transmission Oil Level-Check


1.

1.

Park the machine on flat ground. When the


transmission reaches the work temperature,
remove the oil drain plug to drain oil.

Park the machine on flat ground.


2. "N"

Turn the shift control lever to NEUTRAL


position.

CAUTION: Only drain oil at the top end of


the transmission and torque converter.

3.
750 / 40C

2.

When the transmission reaches the work


temperature, start the engine and let it run at
idle speed about 750rpm. Loosen the oil
filling cap, the transmission oil level should
reach the middle position of the sight glass
when the temperature is 40C.

Loosen the charging pump suction pipes at


the bottom of the transmission housing,
remove the coarse filter and clean it.
3.

Clean the oil drain plug and mounting surface


of the housing, then install with seal ring.
4.
Start the engine and let it run at idle speed.
5. "N"
Turn the shift control lever to NEUTRAL
position.
6.
Replenish transmission oil to the middle
position of the sight glass.

257
Lubrication

CAUTION: Use clean transmission oil


and filter to prolong the service life of the
transmission.
7.
Engage the parking parke.
8.
Operate the shift control lever to get each
gear in turn.
9.
Check the oil level again and replenish oil
when necessary.

Transimission oil Filter-Replace

When replacing transmission oil, replace


transmission coarse filter and oil filter
simultaneously. Do not reuse the damaged oil
filter.

Replace the oil filter as follows:


1.
Coat the seal ring with transmission oil.
2.
Fill the oil filter with clean transmission oil.
3.
1/3 1/2
Install the oil filter until it contacts with the
seal surface of the transmission, then
manually tighten it by 1/3 to 1/2 turn.

258
Troubleshooting
Oil Pressure in All Gears is Low

Troubleshooting
70~90C
Precondition for performance testing: transmission temperature should be within 70~90C.

Oil brands and oil quantity must meet oil requirements used for transmission.

All the procedures must strictly follow the operation regulations.

Oil Pressure in All Gears is Low


Pg
(1.8 2.0MPa)

K1K2K3
K4

27Nm

Check oil press. on


Check oil press. at Pg Low press. measuring point
if it is 1.8 2.0MPa?
K1, K2, K3, and K4
Normal

Replace oil press.


gauge

Low press.

Check bolt torque of


control valve if it is
27Nm?

Normal

Check press. control valve


Replace press. control valve

Check press. control


valve & oil filter

Check torque
converter & oil pump

259
Troubleshooting
Oil Pressure in Certain Gears is Too Low

Oil Pressure in Certain Gears is Too


Low

Pg
1.8 2.0MPa

Check oil press. at Pg Low oil press. in some gears


if it is 1.8~2.0MPa?

Block the presumable damaged clutch


hose, control oil press. to prescribed value
Normal

Repair transmission

Shifting Intervals for All Gears are Too


Long
Pg

Measure time for


pressure build up at Pg

Too long

Clean & check press. control


valve housing and body

260
Troubleshooting
Shifting Intervals for All Gears are Too Short

Shifting Intervals for All Gears are Too


Short
Pg

Too short
Measure time for
pressure build up at Pg

32Nm

Check max. bolt torque of


control valve if it is 32Nm?

Clean & check control


valve housing & body

No Power Output for All Gears

261
Troubleshooting
No Power Output for All Gears

Check oil level (idling


speed of engine)

Over low

Replenish oil to set


level

Normal

Check connection of
engine & torque con.

Damaged
Repair

Normal

Check oil press.

No oil press. Oil pump faults,


repair it

Normal

Check control
circuit
Normal

Transmission
faults, repair it

No current
Check fuse
Normal

Cable faults, repair it

Fuse faults, replace it

262
Troubleshooting
Oil Temperature is Too High

Oil Temperature is Too High

6~8C

0.25 0.50MPa

263
Troubleshooting
Oil Temperature is Too High

Improper operation
Drive at the set speed

Normal
Check oil level

Normal Check if radiator temp of Normal Check if outlet oil pressure of


torque con. is 0.25~0.50MPa?
inlet & outlet differs 6~8C

Abnormal oil level

Replenish oil to the


correct mark

Dirty transmission
surface
Clean

Too low

Check outlet valve


of torque converter

Too high

Repair outlet valve


of torque converter

Note ventilation

Repair

Replace seals of
torque converter

264
Troubleshooting
Troubleshooting

Troubleshooting

No

Feature

Possible Reason

Solutions

Engine is unable to
start.

Machine start circuit (such as power


voltage, start switch, start relay, start
motor, etc.) faults.
2
Shift control lever is not placed in neutral
position.
3
Fuse to control circuit is flameout.
4
Shift control lever plugs contact poorly or
shift control lever faults.
5 .
Controller plugs contact poorly or
controller faults.

1
Check machine circuit.
2
Shift control lever is placed in neutral
position.
3
Replace fuse.
4
Check plugs.
5
Check plugs.

Pressure for shifting


in all gears is low.

1
Oil pressure gauge faults.
2
Insufficient tightening torque for bolts of
shift control valve.
3
Spring of main pressure valve is broken.
4
Charging pump is abraded.
5
Scraps comes into shift control valve or
valve is blocked.

1
Replace oil pressure gauge.
2 M8-8.8
27Nm
The torque of M8-8.8 strength bolts of shift
control valve is 27Nm.
3
Replace it.
4
Replace charging pump.
5
Replace oil filter, clean shift control valve.

Shifting intervals for


all gears are too
short.

1 O
O-ring on the throttling plugs is damaged.
2

Tightening torque of pressure control


valve bolts is not in set range.

1 O
Replace O-ring.
2 M8-8.8
27Nm.
The torque of M8-8.8 strength bolts of shift
control valve is 27Nm.

Shifting intervals for


all gears are too long.

Throttling plug blockage.

Pressure control valve blockage.

1
Clean and dredge.
2
Clean and check.

265
Troubleshooting
Troubleshooting

No

Feature

Oil temperature of
torque converter is
high.

Machine cannot move


in each gear.

Possible Reason

Solutions

1
Oil temperature sensor faults.
2
Oil temperature gauge faults.
3
Insufficient oil level.
4
Air exists in torque converter oil radiator.
5
Oil path from torque converter to oil
radiator is blocked.
6
Low gear pressure.
7
Transmission faults.

1
Replace it.
2
Replace it.
3
Check oil level as correct method.
4
Drain out the air.
5

Check oil path from torque converter to oil


radiator for blockage.
6
Follow the above troubleshooting methods.
7
Service transmission.

1
Insufficient oil level.
2
Flexible plate that connected the engine
and torque converter is torn off.
3

Connection between torque converter to


transmission input gear faults.
4
Machine electric circuit faults.
5
Shift pressure is too low.
6
Solenoid valve is damaged.
7
Shift control lever is damaged.
8
Controller is damaged.

1
Check the oil level as correct procedures
and replenish the oil.
2
Replace flexible plate or replace the
corresponding damaged parts.
3
Check if the supply voltage is normal, cable
is damaged.
4
Check the solenoid valve for normal power
supply.
5
Follow the above troubleshooting.
6 830mA
Check if the rated current of solenoid valve
is 830mA.
7
Follow lever troubleshooting. Replace it.
8
Follow controller troubleshooting. Replace
it.

266
Troubleshooting
Troubleshooting

No

Feature

Machine gears are


not always effective.

Possible Reason
1
Voltage supplies to electrical control
system is not stable.
2

Power supply circuit of electrical control


system contacts poorly.
3

Shift control lever works not well or its


connector contacts poorly.
4
Insufficient transmission oil level.
5

Solenoid valve or controller works not


well or its connectors contact poorly.
6
Valve blockage.

Solutions

1
Check the machine power supply system.
2
Find faults according to machine circuit.
3
Check or replace shift control lever plug.
4
Replenish oil as correct method.
5
Check plugs.
6
Clean

267
Appendix
Transmission Route Chart

Appendix

2. F2)

Transmission
Route Chart
1. F1)

2
1

1. Input
2. Output

CV C2
Clutch engagement: CV, C2
2
1. Input
2. Output

CV C1
Clutch engagement: CV, C1
Z2 Z3 Z7 Z6 Z10 Z12
Z13
Route: Z2 Z3 Z7 Z5 Z9 Z12 Z13

Z2 Z3 Z7 Z11 Z12 Z13


Route: Z2 Z3 Z7 Z11 Z12 Z13

268
Appendix
Transmission Route Chart

4. F4)

3. F3)

2
1. Input
2. Output

CV C3
Clutch engagement: CV, C3
Z2 Z3 Z7 Z4 Z8 Z12
Z13
Route: Z2 Z3 Z7 Z4 Z8 Z12 Z13

1. Input
2. Output

CV C4
Clutch engagement: CV, C4
Z2 Z3 Z7 Z5 Z9 Z12
Z13
Route: Z2 Z3 Z7 Z5 Z9 Z12 Z13

269
Appendix
Transmission Route Chart

6. R2)

5. R1)

2
1. Input
2. Output

CR C1
Clutch engagement: CR, C1
Z1 Z5 Z6 Z10 Z12 Z13
Route: Z1 Z5 Z7 Z11 Z12 Z13

1. Input
2. Output

CR C2
Clutch engagement: CR, C2
Z1 Z5 Z7 Z11 Z12 Z13
Route: Z1 Z5 Z7 Z11 Z12 Z13

270
Appendix
Transmission Route Chart

7. R3)

8. R4)

2
1. Input
2. Output

CR C3

2
1. Input
2. Output

CR C4

Clutch engagement: CR, C3

Clutch engagement: CR, C4

Z1 Z5 Z4 Z8 Z12 Z13

Z1 Z5 Z9 Z12 Z13

Route: Z1 Z5 Z4 Z8 Z12 Z13

Route: Z1 Z5 Z9 Z12 Z13

271
Appendix
Electrical Control Circuit

Electrical Control Circuit

272
Appendix
Electrical Control Circuit

Gear Control Logic Table

Gear

Clutch Engagement

Solenoid Valve

Shift Control Lever Input Controller Output

F1

CVC1

MF M1

271 572 573

541 542

F2

CVC2

MF M2

271 572 574

541 543

F3

CVC3

MF M3

271 572 575

541 544

F4

CVC4

MF M4

271 572 576

541 545

N1

No

M1

271 573 574

542

N2

No

M2

271 574

543

N3

No

M3

271 575

544

N4

No

M4

271 576

545

R1

CRC1

MR M1

271 572 573 574

540 542

R2

CRC2

MR M2

271 572 574

540 543

R3

CRC3

MR M3

271 572 575

540 544

R4

CRC4

MR M4

271 572 576

540 545

273
Appendix
PT300 Hydraulic Schematic for PT300 Transmission

PT300 Hydraulic Schematic for PT300


Transmission

274
Appendix
PT300 PT300 Transmission Measuring Points Layout

PT300 PT300 Transmission Measuring Points


Layout

5
2

1. KV=
KV= Forward gear pressure measuring port (M101,
1.8~2.0MPa)

2. KR=
KR= Reverse gear pressure measuring port (M101,
1.8~2.0MPa
3. Pg=
4. K4=
Pg= System pressure measuring port (M101, 2.5MPa)
K4= Gear 4 & Gear 2 pressure measuring port (M101,
1.8~2.0MPa
5. K3=
6. K2=
K3= Gear 3 & Gear 2 pressure measuring port (M101,
K2= Gear 2 pressure measuring port (M101,
1.8~2.0MPa)
1.8~2.0MPa
7. K1=
K1= Gear 1 pressure measuring port (M101,
1.8~2.0MPa)

275
Appendix
PT300 PT300 Transmission Oil Inlet

PT300 PT300 Transmission Oil Inlet

2
3

8
6
9

10
11
1. CR oil inlet
3. C3 oil inlet

2. -
CV & CR assembly oil inlet
4. C1 oil inlet

5. C4 oil inlet

6. - C2 & C4 assembly oil inlet

7. CV oil inlet

8. Transmission oil inlet

9. - C1 & C3 assembly oil inlet 10. C2 oil inlet


11. Oil suction port

276
Appendix
PT300 PT300 Transmission Oil Inlet

275
Index

Index

Safety Information...............................3

Flexible Plate, Housing


and Shaft ......................................................... 35
Stator Seat Group................. 46, 237
Electrical Control Circuit ...... 269
Shift Control Valve............... 208
Shift
Control Valve, End Cap Group and Clutch
Assembly ......................................................... 67
Shift
Control Valve, End Cap Group and Clutch
Assembly ....................................................... 189
Shift Control Valve................. 69
End Cap Group and Idler Shaft
....................................................................... 193
End Cap Group and Idler
Shaft ............................................................. 71

Torque Converter Housing............45


Torque Converter Housing
Group .......................................................40, 221
Torque Converter..............................39
Torque Converter Group ....... 33, 240
Charging Pump, Flange,
Outlet Valve .............................................42, 234
Check the Machine
after Repairing ...............................................252
General Torque
Specifications ...................................................16
Parts Disassembly ............................29
Lifting The Parts ............................10
Cleaning and Inspection ........ 27
Parts Reassembly...........................122

CV&CR Assembly ................... 122


CV&CR Assembly ..................... 81
Crushing and Cutting Prevention
........................................................................... 7
Burn Prevention.................................. 8
Attachment ............................................ 265
Attachment Cautions ............... 9

Symbols
- C1-C3 Assembly.....................92
- C1-C3 Assembly...................141
.............................................. 142
- C2-C4 Assembly...................159
- C2-C4 Assembly...................103
C2 Assembly........................ 160
C3 Assembly........................ 151
C4 Assembly........................ 170

G
Transimission oil Filter--Replace 255
Operating Principle........................... 12
Troubleshooting .......................... 256
General Hazard
Information......................................................... 3

C
H
Troubleshooting.......................262
Store Accessories Safely..................10

D
Conversion Table ..........................17

Welding Operation............................ 10
CR Assembly ................... 132
Transmission Oil--Replace .................... 254

276
Index

Denomination of Standard
Dimensions ......................................................17
Technical Specifications ...................15
.................................................................. 27
Connectors and Hose
Assembly .................................................59, 210
Inlet Valve, P.T.O
Gear, P.T.O Shaft ............................................49

Output Shaft Group .................... 180


Output Shaft Group..................... 115
Transmission and Torque
Converter Accessories ............................ 29, 248
No Power Output for All
Gears............................................................. 258
Shifting Intervals for All
Gears Are Too Short ..................................... 258
Oil Pressure in All Gears
is Low ............................................................ 256

L
Clutch Assembly ...................78, 190

M
Fire Extinguishers and First-aid
Kit .......................................................................8

P
PT300 PT300 Transmission
Measurement Points Arrangement ................272
PT300PT300 Transmission Oil Inlet
.......................................................................273
PT300 Hydraulic Schematic of
PT300 Transmission ......................................271

Q
CV Assembly....................123
Preface.......................................................1
Cleaning................................................... 27
P.T.O Gear, P.T.O
Shaft, Inlet Valve ............................................223

R
Lubrication .............................................254

Y
Oil Brand................................................ 254
Transmission Oil Level--Check ...... 254
Oil Temperature is Too High .......... 260

Z
Oil Pressure in
Certain Gears is Too Low .............................. 257
Support the Machine Correctly
......................................................................... 10
Brake ........................................... 55, 217
Transmission Route Chart .......... 265
Steering Frame Lock ........... 9
Tool Table ........................................ 18