Service Manual Section on Transmission System of RS8200 Road Roller

Service Manual of RS8200 Road Roller
SERVICE MANUAL
Version:0410
4 Transmission System
Service Manual for RS8200 Road Roller
CONTENTS
4 Transmission System ........................................................................................... 4-1
41 Clutch and Operating System .............................................................................. 4-2
411 Description................................................................................................... 4-2
412 Clutch........................................................................................................... 4-2
413 Clutch Booster ............................................................................................. 4-5
414 Clutch Master Cylinder ............................................................................... 4-6
415 Disassembly & Assembly of Clutch Booster .............................................. 4-8
416 Disassembly & Assembly of Clutch Master Cylinder ................................ 4-9
42 Transmission Box Assembly ............................................................................. 4-11
421 Description of Transmission...................................................................... 4-11
422 Description of Gear Shifting Hydraulic System ....................................... 4-16
423 Disassembly and Assembly of Transmission Box .................................... 4-19
424 Precautions for Transmission Box ............................................................ 4-24
425 Cleaning of Transmission Parts ................................................................. 4-25
426 Inspection of Transmission Parts .............................................................. 4-26
43 Transmission Shaft Assembly ........................................................................... 4-27
431 Description of Transmission Shaft ............................................................ 4-27
432 Disassembly and Assembly of Transmission Shaft .................................. 4-28
44 Drive Axle Assembly ........................................................................................ 4-30
441 Description of Drive Axle ......................................................................... 4-30
442 Disassembly and Assembly of Drive Axle................................................ 4-33
45 Common Faults in Transmission System and Troubleshooting ....................... 4-36
451 Common Faults in Transmission Box and Troubleshooting ..................... 4-36
452 Common Faults in Clutch and Troubleshooting ....................................... 4-38
453 Common Faults in Drive Axle and Troubleshooting ................................ 4-38
I
4 Transmission System
The transmission system of SDLG RS8200 road roller mainly consists of transmission assembly,
clutch operating assembly, drive axle assembly and operating mechanism, in which transmission
assembly consists of gear shifting handle 3, speed change valve 6 and cable. Clutch manipulation
assembly consists of clutch pump 1, clutch booster 5, clutch 7 and oil pipes. Transmission system of
RS8200 road roller is illustrated below.
Fig. 4-1 Transmission system of road roller

1 Clutch cylinder 2 Transmission box 3 Gear shifting handle 4 Oil cup
5 Clutch booster 6 Speed change valve 7 Clutch 8 Transmission shaft
9 Drive axle 10 Gasholder
4-1
41 Clutch and Operating System
411 Description
The vibratory RS8160 road roller is equipped with a single-plate dry spiral spring clutch. This clutch
is of a single-plate dry helical spring clutch with operating modes of hydraulic control and air boost.
The main components are clutch, booster and clutch master cylinder as shown in the figure below:
Fig.4-2 Clutch and operating system assembly

1 Clutch master cylinder 2 Clutch assembly 3 Booster assembly 4 Oil cup 5 Gasholder
Through friction effect on contact surface between flywheel and pressure plate and driven disc, the
torque from engine is transmitted to the driven disc; when the driver depresses the clutch pedal, under
the effect of oil, pressurized air from gasholder acts on clutch assembly by means of booster assembly;
at this moment, the driven part of clutch assembly is separated from driving part.
Power transmission line of clutch:
Pedal Master cylinder Hose Booster Clutch Road roller power cutoff
Gasholder
412 Clutch
In transmission system, clutch is a component that is directly connected to the engine, and mainly
responsible for connecting/disconnecting power and transmission system; the release travel is 10mm,
and the free stroke of pedal is 35mm~40mm.The functions of clutch are as follows:
1. Make engine start under no-load condition.
2. Temporarily power off for gear shift. Without clutch, gears would be subject to impact or even
4-2
get damaged during gear shift.

3. When the road roller starts to run in static conditions, it can combine engine system with running
system smoothly so as to avoid generating starting impact.
4. When the transmission system is subject to excessive load, the clutch can slip for a short time to
prevent transmission damage due to overload.
5. The method of releasing clutch can temporarily stop the road roller.
From the above, it is known that clutch can ensure a smooth start of road roller, make transmission
system gearshift smooth, limit the max. load subjected to transmission system, and protect
components of transmission system against damage, so the clutch is an essential component in
transmission system.
Fig. 4-3 Schematic diagram of clutch A Input B Output

1 Release sleeve 2 Shift fork 3 Release bearing 4 Clutch (cover) 5 Release lever
6 Pressure plate 7 Engine flywheel 8 Pressure spring 9 Driven disc
When clutch is engaged, there is a clearance between release bearing 3 and release lever 5, flywheel 7,
driven disc 9 and pressure plate 6 will be pressed under the effect of pressure spring 8, and engine
torque is transmitted to driven disc via friction plate which is located between flywheel and driven
disc.
When booster functions, release fork 2 is rotated and pushes release bearing 3 to move left along the
sleeve, release bearing 3 pushes the internal end of release lever 5 to move left, release lever 5
4-3
revolves around pin, the external end of release lever 5 swings rightward, pressure plate 6 overcomes
the force from pressure spring 8 and moves rightward, pressure plate 6 detaches from driven disc 9,
and torque transmission stops.
1 2 3 4 5 6
Fig. 4-4 Clutch

1 Transmission 2 Clutch shift fork assembly 3 Release bearing
4 Clutch pressure plate assembly 5 Clutch driven disc assembly 6 Engine
Pressure plate as the driving part of clutch is bolted to engine flywheel. Front end of annular pressure
plate, formed into a plane, can connect to driven disc through friction plate. The rear end face has a
spring seat with several cylindrical bosses for installing pressure springs. In addition, there is a
hook-shaped boss for mounting release lever mechanism.
The driven part of clutch is installed between flywheel and pressure plate, which mainly consists of
driven disc body, friction plate and rivet.
The following should be noted during the operation of clutch:
1. Driven disc assembly should be kept clean, and friction plate is required to be of dustproof,
antifouling and oil proofing lining.
2. When assembling clutch, alternately tighten bolts.
3. When assembling clutch, properly lubricate driven disc spline and transmission shaft spline with
temperature and pressure resistant grease.
4. Ensure that the release travel complies with relevant requirements. If the release travel is too long,
it has a risk of release lever contacting with driven disc; if the release travel is too short, clutch
will not be released completely.
5. When clutch is in engaging state, there should be a clearance of 3~5mm kept between release
bearing and release lever to ensure that pressure plate can be pressed against friction plate for
reliable transmission of engine torque even in the case that the friction plate is worn. New road
roller under normal operation should be adjusted after running 2,000-3,000km and every
4-4
6,000km thereafter.
6. When friction plate reaches its wear limit, it is required to replace the driven disc assembly timely
to prevent clutch from sliding and scratching pressure plate and flywheel. Do not keep depressing
the clutch pedal. In principle, it is required to release clutch quickly to prevent the occurrence of
prolonged semi-linkage state.
413 Clutch Booster
When clutch is released and engaged, this assembly, installed between clutch and clutch master
cylinder without additional mechanical transmission component, can help increase output force. Its
working principle is as follows:
When clutch pedal is depressed, master cylinder will pump and deliver oil to piston 2 of booster
working cylinder (slave cylinder). Some oil pushes piston 2 and push rod 1 to move forward and
drives the clutch release fork; a small amount of oil passes oil duct and pushes control piston 5 to
move forward and forces rubber valve open; then compressed air passes U-tube 6 and enters rear
chamber of booster body 4 to push piston 3 to move forward, and push rod is pressed against piston 2
and they move forward together, which increases the release force and largely reduces clutch pedal
force so that boosting function is realized.
Fig. 4-5 Clutch booster

1 Push rod 2 Piston 3 Piston 4 Booster 5 Piston 6 U-tube
Operation, maintenance and common faults
The clutch booster must be designed with excellent reliability. Once fault occurs, clutch will not be
4-5
released and engaged, and road roller cannot work normally. Therefore, it is essential to operate it
correctly and maintain it carefully. The following should be noted:
1. The oil to be used must be clean, and it is not allowed to mix oil of different grades. During 600h
maintenance, change oil. The air in oil duct must be eliminated (if any), otherwise, it will affect
the normal work of booster.
2. Light clutch booster pedal and slow release action may be caused by air in the line, and it is
required to eliminate the air completely. Check the line for air leakage.
3. The wear of control piston seal ring will lead to oil and air mixing. The compressed air going to
the piston leads to slave cylinder thrust to decrease which will cause incomplete clutch release.
4. After road roller has worked for 600km, clutch booster should be disassembled, cleaned,
inspected and its wear part should be replaced by a special operator.
414 Clutch Master Cylinder
Working principle
When the clutch pedal is depressed, brake fluid of master cylinder will be transmitted to clutch
booster via pipe to the push booster piston to move forward and drive the clutch release fork to move.
The release fork turns clutch release bearing seat to force clutch to be released and engaged.
Fig. 4-6
1 Clutch master cylinder 2 Clutch pedal
Operation and maintenance precautions:
1. The grade of brake fluid to be used must comply with relevant requirements, and it is required to
4-6
check and add fluid regularly (every 200h).It is not allowed to mix fluids of different grades for
using.
2. The air in the oil line must be eliminated thoroughly. If there is air in line, it will definitely affect
the normal work of clutch operating system. After air bleeding, the air bleed screw should be
tightened and covered with shield.
3. The oil must be clean. If oil is contaminated with sand grains or metal particles, it will scuff the
surfaces of master cylinder, slave cylinder and piston, which will leads to oil leakage.
4. Commonly used synthetic brake fluid has a corrosive effect on aluminum piston surface. If road
roller is parked for a long period of time (more than six months), it will lead to piston expanding
seizure. Check the working condition of operating system regularly (every month).
5. During 600h maintenance, disassemble master cylinder and slave cylinder, and check them for
wear.
ATTENTION
The air in clutch control system can affect the effective separation stroke of the clutch,
causing abnormal working of the clutch control system, therefore, the air in the pipe should
be discharged first. First add brake fluid HZY3(DOT3) to the oil cup, making the pipeline
full of brake fluid. Remove the dust cap of clutch booster, and there will be brake fluid
outflow when loosen air bleeding plug of booster, then tighten the plug. Step the clutch pedal
to the bottom, loosen the air bleeding plug, you will see bubble or foamy oil coming from the
hole, tighten the plug and release the clutch pedal. Repeat the bleeding process for several
times, until the overflowed oil is free of air or bubble. After the operation is complete, cover
with dust cap.
4-7
415 Disassembly & Assembly of

Clutch Booster
Disassembly of clutch booster

1. Remove the connecting hose between the left
lower joint of clutch booster and the clutch
master cylinder.
2. Remove the air intake pipe on the right side of
clutch booster connected to gasholder.
3. Remove the pin shaft connector of clutch
booster and clutch fork.
1 2
Fig. 4-7 4. Remove the mounting bolt of clutch booster,
1 Clutch booster 2 Intake pipe and remove the booster.
Assembly of clutch booster
1. Use nut and the attached bolt to fix clutch
booster assembly to clutch booster bracket; use
cotter pin and pin shaft to connect booster to
the plate of fork shaft.
2. Use bolt and copper gasket to connect air
intake pipe of clutch booster to the right side
of booster as shown in the figure; fix the other
end of air intake pipe to the rightmost joint of
1 2
gasholder.
Fig. 4-8
1 Lower joint 3. Connect the other end of hose which is
2 Booster bracket connected to clutch master cylinder to the
lower joint of booster, and fasten the hose at
appropriate position with tie wire.
ATTENTION
It is required to adjust the clearance between
push rod and piston and ensure a clearance of
1-2mm. After adjustment, mount the return
spring.
4-8
416 Disassembly & Assembly of

Clutch Master Cylinder
Disassembly of clutch master cylinder

1. Remove the bolt which fixes clutch bracket to
cab.
2. Remove the lower joint of clutch master
cylinder and the rubber hose, and remove the
clutch master cylinder.
12
Fig. 4-9
1 Rubber hose 2 Bolt
3. Remove the pin shaft connection of pedal

weldment and bracket weldment.
4. Remove the pin shaft connection of clutch
master cylinder and pedal, and remove torsion
spring.
5. Remove clutch master cylinder from the
bracket weldment.
1 2 3
Fig. 4-10
1 Pin shaft 2 Bolt 3 Torsion spring
4-9
Assembly of clutch master cylinder

1. Use two bolts, two nuts and four washers to fix
clutch master cylinder to the bracket
weldment.
2. Install bolts, nuts and washers to the upper
adjusting hole of welded bracket.
1 2
Fig. 4-11
1 Clutch master cylinder 2 Bolt
3. Use pin shaft, cotter pin, washer and torsion

spring to install pedal weldment to the bracket
weldment.
4. Use pin shaft, cotter pin and washer to connect
the pedal weldment to the joint of clutch
master cylinder.
1 2 3
Fig. 4-12 5. Use bolts, nuts and washers to fix the welded
1 Pin shaft 2 Bolt 3 Torsion spring bracket to frame.
6. Install the elbow of clutch master cylinder
hose to the lower joint of clutch master
cylinder, and use hose clamp to install rubber
hose to upper joint of clutch master cylinder.
ATTENTION
1. Ensure the clearance between piston push
rod of clutch master cylinder and piston is
0.5~1.0 mm.
12
Fig. 4-13 2. Adjust the height of pedal to make the
1 Rubber hose 2 Bolt distance between pedal and cab floor of
90~110mm, and adjust the bolt to limit the
position of pedal so that it cannot rise.
4-10
42 Transmission Box Assembly
421 Description of Transmission
The roller is equipped with a fixed shaft power shift transmission box, which mainly consists of
gear selector, transmission control valve and transmission box. The transmission constitutes 5 sets
of multi-plate wet friction clutch, when shifting, corresponding gear clutch friction plate is
compressed by the piston pushed by axial working oil cylinder, a return spring is designed to release
and reset the return spring. The transmission box has three forward gears and three reverse gears,
and the transmission housing adopts unitary structure. Main technical parameters are as follows:
Table 4-1
Hangzhou Advance YD13 power shift transmission box assembly
Rated input power 130kw

Maximum input
800Nm
torque
Rated input speed 2200r/min

Forward III and
Gears
Reverse III
Structure Fixed shaft
Speed
control Transmission oil pressure
M101
parameters measuring port
Transmission oil pressure
1.3~1.7
(MPa)
Forward gear I 8.936

Transmission box
Forward gear II 4.543
Forward gear III 1.900

Transmission
ratio
Reverse gear I 8.936
Reverse gear II 4.543
Reverse gear III 1.900
4-11
Introduction to transmission box external components
1 Transmission control valve

2 Reverse gear shaft
3 Oil drain plug
4 Clutch booster pump
5 Input shaft
6 Forward gear shaft
7 Intermediate shaft
8 Output shaft
Fig. 4-14
Introduction to transmission principle
Fig. 4-15 Transmission principle diagram Fig. 4-16 Spatial location map
A Input shaft B Forward gear shaft C Reverse gear shaft D Intermediate shaft
E Output shaft
KV: Forward clutch When forward clutch is engaged: Z2 and Z3 combine and rotate together
KR: Reverse clutch When reverse clutch is engaged: Z5 and Z6 combine and rotate together
4-12
K1: Gear I clutch When gear I clutch is engaged: Z3 and Z4 combine and rotate together
K2: Gear II clutch When gear II clutch is engaged: Z6 and Z8/Z7 combine and rotate
together
K3: Gear III clutch When gear III clutch is engaged: Z9 and Z10/Z11 combine and rotate
together
All gears of the electro-hydraulic controlled transmission box is controlled by four solenoid valves
in different combinations.
M1 M2 M3 M4 Clutch
Forward 1 KV K1
Forward 2 KV K2
Forward 3 KV K3
Reverse 1 KR K1
Reverse 2 KR K2
Reverse 3 KR K3
Table 4-2 Fig. 4-17
The four solenoid valves M1, M2, M3 and M4, in different combinations, can control five different
clutches, KV, KR, K1, K2 and K to achieve the selection of six gears respectively.
Introduction to power transmission line
Forward gear I (KV, K1 action)

Power inputGear Z1Z2, Z3, Z4 combined
togetherGear Z8Gear Z7Gear Z10Gear
Z11Gear Z12Power output
I=Z1/Z2*Z4/Z8*Z7/Z10*Z11/Z12
Four pairs of engaging gears used for transmission
Fig. 4-18 Forward gear I
4-13
Forward gear II (KV, K2 action)

Power inputGear Z1Z2, Z3 combined
togetherGear Z6, Z7 combined togetherGear
Z7Gear Z10Gear Z11Gear Z12Power
output
I=Z1/Z2*Z3/Z6*Z7/Z10*Z11/Z12
Fig. 4-19 Forward gear II
Forward gear III (KV, K3 action)

togetherGear Z6Gear Z9, Z10 combined
togetherGear Z12Power output
I=Z1/Z2*Z3/Z6*Z6/Z9*Z11/Z12
Fig. 4-20 Forward gear III
Reverse gear I (KR, K1 action)

togetherZ3, Z4 combined togetherGear
Z8Gear Z7Gear Z10Gear Z11Gear
Z12Power output
I=Z1/Z5*Z6/Z3*Z47/Z8*Z7/Z10*Z11/Z12
Five pairs of engaging gears used for transmission
Fig. 4-21 Reverse gear I
4-14
Reverse gear II (KR, K2 action)

Power inputGear Z1Z5, Z6, Z8 combined
togetherGear Z7Gear Z10Gear Z11Gear
Z12Power output
I=Z1/Z5 *Z7/Z10*Z11/Z12
Three pairs of engaging gears used for
transmission
Fig. 4-22 Reverse gear II
Reverse gear III (KR, K3 action)

Power inputZ5, Z6 combined togetherZ9, Z10
combined togetherGear Z11Gear Z12Power
output
I=Z1/Z5 *Z6/Z9*Z11/Z12
Three pairs of engaging gears use for transmission
Fig. 4-23 Reverse gear III
4-15
422 Description of Gear Shifting Hydraulic System
Functions of hydraulic system:

1. Provide suitable pressure and flow for hydraulic shift mechanism.
2. Take the heat generated during working away and cool down the working fluid. If the working
fluid is not being cooled, the temperature of transmission oil will rapidly increase and unable to
work, even result in damage.
Its working principle is illustrated in the figure below:
This system mainly consists of gear pump, transmission control valve, radiator, filter, oil sump and
pipes.
Fig. 4-24
1 Radiator 2 Gear pump 3 Filter 4 Transmission control valve 5 Transmission box
Gear oil route of walking hydraulic system
Transmission Transmission
box oil sump Gear pump Filter Transmission control valve Radiator box oil sump
Gear pump
Transmission oil supply pump applied by this
roller is Parker gear pump. This pump is driven
directly by the engine and absorbs oil from the
bottom of transmission box sump.
4-16
Technical parameters of the pump are as follows:

Table 4-3
Nominal displacement 16ml/r

Maximum continuous working
25MPa
pressure
Minimum speed 500 r/min
Maximum speed 3500 r/min
Direction of turning Right-hand
1
Fig. 4-26
1 Gear pump
Filter
Filter fineness of the applied filter is 10 um, which
is used to guarantee cleanliness of lubricating oil.
Transmission control valve
A pressure switch, which is installed on brake
pedal, it can separate transmission box clutch and
set the machine to neutral when engaging the brake,
in order to avoid impacting the transmission box.
Meanwhile, electronic shifter has a function of
self-locking to protect the transmission box, gear
shifting can be carried out only after the clutch is
free of engagement and the power to transmission
Fig. 4-26 box is cut-off.
1 Main control pressure Pressure oil from transmission control valve flows
2 K2 clutch pressure
into clutch directly, as shown in Fig. 4-27.
5 KR clutch pressure
6 KV clutch pressure
4-17
4-18
Fig. 4-27 Principle diagram

A Control pressure B Lubrication oil pressure C Oil return tank
1 Radiator 2 Safety valve 3 Filter 4 Pressure selection valve 5 Control pressure valve 6 Return valve 7 Gear valve
423 Disassembly and Assembly of

Transmission Box
Disassembly of transmission box

1. Refer to Section 281 in this manual for
disassembly of Engine. Lift engine and
transmission box assembly up and place them
on appropriate support.
1
Fig. 4-28
1 Engine and transmission box assembly
2. Remove the connecting bolts of transmission

and engine.
ATTENTION
Before removing transmission box, lift it with
lifting rope to prevent it from falling in case that
connecting bolts are removed.
3. After removing bolts, carefully shake the
transmission horizontally to separate the
1 2 3 4
Fig. 4-29 engine from it.
1 Engine 2 Connecting bolts
3 Transmission box 4 Lifting rope
4. Remove the connecting bolts of clutch

pressure plate and engine flywheel plate.
5. Remove driven disc and pressure plate of
clutch.
1 2
Fig. 4-30
1 Pressure plate 2 Bolt
4-19
Assembly of transmission
1. Place the engine on appropriate support. Fit
clutch pressure plate and driven disc to the
engine flywheel plate with pressure plate
outside and driven disc inside, and pre-tighten
the pressure plate to the flywheel plate with
bolts.
1 2
Fig. 4-31
1 Pressure plate 2 Bolt
2. Adjust the position of clutch driven disc to

make it be concentric with the inner race of
engine bushing, and then tighten the pressure
plate bolts.
ATTENTION
Apply proper amount of thread locking sealant
to the bolts.
527Nm
1 2
Fig. 4-32
1 Spline housing
2 Inner race of engine bearing
3. Lift transmission with lifting rope to the

position next to engine. Align the spline shaft
of transmission with clutch driven disc and
inner ring of engine bushing, and shake the
transmission horizontally to make clutch
housing connected to engine housing.
4. Tighten all bolts on clutch housing and remove
the lifting rope.
1 2 3 4
Fig. 4-33
1 Engine 2 Connecting bolts
3 Transmission box 4 Lifting rope
4-20
5. Install mounting bolts and push rod of clutch

booster.
ATTENTION
It is required to adjust the clearance between
push rod and piston and ensure a clearance of
1-2mm. After adjustment, mount the return
spring.
1 2 3
Fig. 4-34
1 Clutch booster 2 Spring
3 Push rod
6. Lift the engine and transmission assembly with

lifting rope to appropriate position of frame,
and assemble it. For details, please refer to
Section 282 for assembly of engine.
ATTENTION
Before installing engine and transmission box
assembly, check all related parts and assemblies
and ensure they are intact and firmly
1
assembled.
Fig. 4-35
1 Engine and transmission assembly
7. Install transmission shaft. For details, please

refer to Section 432 in this chapter, and
connect the absorption pipe of variable speed
pump.
1 2 3 4
Fig. 4-36
1 Transmission shaft 2 Bolt
3 Transmission box 4 Oil
absorption pipe
4-21
8. Tighten the absorption pipe 1 of transmission

box like lift picture.
1
Fig. 4-37
1 Absorption pipe
9. Install oil filler pipe of transmission box, and

tighten bolt.
1 2
Fig. 4-38
1 Oil filler pipe of transmission box
2 Bolt
10. Connect plug of oil temperature sensor of

transmission box and plug of pressure switch
of transmission box.
1 2 3
Fig. 4-39
1 Oil temperature sensor of
transmission box
2 Plug
3 Pressure switch of transmission box
4-22
11. Install transmission box oil inlet pipe 1 and oil

outlet pipe 3.
12. Connect harness of transmission control valve.
1 2 3
Fig. 4-40
1 Oil inlet pipe of transmission box
2 Transmission control valve harness
3 Oil outlet pipe of transmission box
13. Install intake pipe of clutch booster.

14. Add gear oil to transmission box through
transmission box filler pipe, and use the
dipstick to check oil level.
ATTENTION
Transmission oil level should between the
middle scale and lower scale on the dipstick
when the engine is running idly (800~1000r/min)
1
and oil temperature is about 40oC; When oil
Fig. 4-41
1 Air intake pipe temperature gets to 60oC, the oil level should
between the middle scale and upper scale on the
dipstick.
15. After checking and ensuring that there is no
mistake in transmission box assembly
connection, and in the statue of engine flameout,
try to operate and trample clutch, in order to
check clutch pedal stroke and booster pump
stroke.
16. After ensuring each work above is correct, try
to start engine, while slowly lift the clutch
transmission box, while carefully listening to
4-23
the sound operation, if no abnormal noise, put

the transmission operate 10 minutes in neutral,
then test the machine.
424 Precautions for Transmission Box
Precautions for disassembling:

1. Before removing transmission assembly from road roller, it is required to park the road roller at
a flat and safe place, shift transmission to Neutral, shut down engine and disconnect master
power switch, and wedge front and rear wheels for safety.
2. Before removing transmission, clean the transmission housing thoroughly. And the removal of
transmission shall be conducted at a clean place to prevent dust and foreign material from
entering the transmission; otherwise, it will lead to part wear and bearing burnt intensifying.
3. It is required to use special tools for bearing removal, and to pay special attention to the
removal sequence and method, and the removal of individual parts may need special tools
4. When using copper hammer or copper rod to remove parts, pay attention to the force applied on
shaft or housing, which shall be appropriate so as not to damage the parts.
5. After removal, carefully clean the residual sealant and broken paper gasket off the sealing
surface of transmission housing, bearing cover and side cap.
Precautions for assembling
1. When assembling transmission, strictly comply with the specified sequence.
2. Check the wear condition of the clutch friction plates when assembling, you need to replace
timely when more than 2/3 depth of the plate groove is worn off.
3. When assembling the transmission control valve, the paper gaskets must be replaced with new
ones.
4. When assemble bear, use special tools to press it vertically, not allowed to use hard instruments
and to apply impact load to put it in, and should guarantee bearings axial clearance (By selecting
adjusting washer with different thickness).
5. It is required to use special tools to press each bearing in vertically. It is not allowed to use hard
tools and apply impact force on bearings. And bearing axial clearance must meet the
requirements (By using adjusting washers with different thickness).
6. When assembling oil seal, it is required to press it in vertically, and pay attention to assembling
direction.
Precautions for operating:
4-24
1. In the process of road roller running, frequently check the stroke of clutch pedal, and check the
clutch for thorough release and engagement. Otherwise, the performance of gearshift and the
service life of synchronizer will be affected.
2. Select high gears whenever possible during road roller running to ensure the engine speed is
within the economic range, which will improve the dynamic performance and economic
efficiency of complete road roller.
3. Do not frequently apply sharp acceleration or emergency braking during road roller running.
4. For gearshift, depress the clutch pedal to the bottom and operate the gearshift lever to the
desired gear smoothly and correctly.
425 Cleaning of Transmission Parts
Due to the components of transmission are inclined to be contaminated by dirty oil and sludge, so
the part cleaning work is very important.
Common methods for cleaning transmission components:
Table 4-4
1 Vapor cleaning 2 Pressure cleaning 3 Light oil cleaning
4 Acid solution cleaning 5 Alkaline solution cleaning 6 Neutral medium cleaning
8 Ethylene trimerization solution
7 Magnetic cleaning 9 Magnus solution cleaning
vapor cleaning
Cleaning of metal parts:

Light oil: Different from other solutions, light oil does not have the ability of penetrating or
dissolving sludge. Therefore, wire brush or other tools shall be used to eliminate sludge on surfaces
expect for the polished surface, and brush surfaces for twice by the above method.
Alkaline solution: It is used to clean steel and cast iron parts efficiently. If components are made of
alloy, do not use alkaline solution for cleaning.
ATTENTION
If alkaline solution is used for cleaning, it is required to prepare neutralizing medium such as
boric acid solution. Once skin or eyes contact to alkaline solution, use the neutralizing
medium to clean the alkaline solution immediately.
Cleaning of rubber parts:
Generally, use alcohol or a clean cloth to eliminate oil and sludge, and do not use mineral oil for
cleaning.
WARNING
4-25
The damage of parts may occur due to exposure in the process of cleaning, so it is required to
pay special attention to the part being cleaned.
426 Inspection of Transmission Parts
After maintaining the transmission box, carefully check each part for damage, abnormal wear or
excessive wear, and prevent faulty parts from being installed in transmission; otherwise, it may lead
to unnecessary loss.
Bearing
1. Check steel ball, roller and ball track for pit or flaking;
2. Check axial clearance and aperture clearance of bearing, and replace the bearing which has
large clearance;
Gear
1. Check the tooth flank of gear for corrosive pitting, and if any, replace the gear.
2. Check all meshing gears for abnormal wear and impact damage during gearshift, and if any,
replace it.
3. Check axial clearance of gears, and if large clearance, check the retainer ring for excessive
wear.
Spline
Check splines of all shafts for abnormal wear. If the excessive wear of spline causes work piece
looseness, replace the worn parts.
Thrust washer
Check the surfaces of all thrust washers. Replace the washer which has scratches or is in excessive
wear.
Release components of clutch
1. Check the wear condition of release components of clutch. Replace the release fork and release
bearing which are in excessive wear.
2. Check the wear condition of release fork shaft.
4-26
43 Transmission Shaft Assembly
431 Description of Transmission Shaft
Structure and functions of universal driving device

The transmission shaft installed between transmission and drive axle is as a universal driving device.
Normally, it consists of universal joint assembly and transmission shaft (Customarily, universal
driving device is called transmission shaft assembly).Since road and working field is not flat, when
road roller is running, the axis of the output shaft of transmission and that of the input shaft of drive
axle are hard to coincide, and the relative position of the two shafts varies frequently. Therefore,
rigid connection between output shaft of transmission and input shaft of drive axle is not available,
and it is required to employ a universal driving device composed by two cardan universal joints and
one transmission shaft. The universal driving device is designed to address the nonaxiality of
transmission and drive axle so as to satisfy the angle variation between the transmission and the
drive axle and transmit power from transmission to drive axle.
1 Universal joint 2 Hexagon head bolt 3 Transmission shaft

Fig. 4-42 Transmission shaft assembly
Driving characteristics of cardan universal joint:
The cardan universal joint features Non-constant Speed transmission. The so called Non-constant
Speed Transmission indicates that the speed of driven shaft varies when the driving shaft rotates in
constant angular speed, i.e., the Non-constant Speed characteristic of single cardan universal joint
under angle transmission. It should be noted that, the Non-constant Speed Transmission refers to
the unequal angular speeds of the driven shaft in one rotation. When the driving shaft makes one
rotation, so does the driven shaft. Therefore, their mean rotating speeds are equal.
The non-constant speed transmission of common cardan universal joint will produce torsional
vibration of the driven shaft and the attached drive components and then generate additional
repeated load which will affect the service life of the components. For this reason, the Constant
Speed Transmission method emerges: Relating the non-constant speed transmission characteristic
4-27
of single cardan universal joint to that between two shafts (output shaft of transmission and input
shaft of drive axle).
Structure and characteristics of transmission shaft:
The transmission shaft, one of the most important components of the universal driving device, is
mainly used for connection of transmission and drive axle. The transmission shaft consists of pipe
sleeve fork assembly, universal joint fork and spline shaft assembly. During the operation of road
roller, the relative position of transmission and drive axle varies frequently; to avoid motion
interference, the transmission shaft is equipped with sliding spline connecting components
composed by sliding fork and spline shaft to achieve changes in the length of the transmission shaft.
To reduce wear, grease cup, oil seal and spline jacket are installed on the transmission shaft to
ensure good lubrication of spline shaft in the sleeve fork and to prevent water and dust from
entering the spline.

Transmission Shaft
ATTENTION
Before removing transmission shaft, wedge the
wheels of road roller.
Parking brake shall be applied.
Disassembly of transmission shaft assembly
1. Wedge the tires of road roller with wooden
wedge.
shaft and transmission.
shaft and drive axle.
ATTENTION
1 2 3 4 When removing bolts, lift transmission shaft to
Fig. 4-43 prevent it from falling suddenly.
1 Drive axle 2 Transmission shaft
3 Transmission box 4 Bolt
4-28
Assembly of transmission shaft assembly
ATTENTION
Normally, once transmission shaft is in failure,
it shall be replaced integrally. Never use the
transmission shaft assembly which has
deformation, cracks or is scrapped.
1. Install the connecting bolts of transmission
Bolts: 110~130Nm
1 2
Fig. 4-44
1 Drive axle 2 Transmission shaft
2. Install the connecting bolts of transmission

shaft and transmission.
Bolts: 180~210Nm
ATTENTION
Before installing transmission shaft, first check
the universal joint for normal condition, and
check the transmission shaft for cracks and the
capability of axial expansion. If fault occurs,
1 2
Fig. 4-45 replace the part.
1 Transmission shaft
2 Transmission box
4-29
44 Drive Axle Assembly
441 Description of Drive Axle
The drive axle of road roller mainly consists of axle housing assembly, gearset, axle shaft and wheel
reducer.
The drive axle, installed on frame, is subject to load from frame and transmits it to wheels. The axle
housing of drive axle assembly is a carrier for installation of final drive, axle shaft and wheel
reducer.
The main functions of drive axle are to transmit torque received from transmission shaft to tires,
reduce the rotating speed of transmission output shaft, increase torque and realize wheels on both
sides run at different speeds. In addition, drive axle housing has functions of load bearing and force
transmission.
Fig. 4-46
1 Caliper disc brake 2 Axle housing assembly 3 Gearset
4 Brake disc 5 Wheel reducer 6 Axle shaft
Power transmission line
Input flange Driving spiral bevel gear Driven spiral bevel gear Differential housing
assembly Universal joint Bevel gear Axle shaft gear Axle shaft Sun gear
Planetary gear Planetary gear carrier Wheel rim assembly Tire
4-30
Gearset
The gearset mainly consists of carrier assembly,
driving and driven spiral bevel gears and
differential assembly.
The functions of gearset are to reduce rotating
speed of transmission output shaft again, increase
torque, and change the rotating direction of input
shaft by 90 and then transmit torque to wheel
reducer via differential and axle shaft.
1 2 3 4
Fig. 4-47
1 Driving spiral bevel gear
2 Carrier assembly
3 Differential assembly
4 Driven spiral bevel gear
Differential assembly
The drive axle differential of road roller, a
symmetrical bevel gear differential, mainly
consists of left housing, right housing, axle shaft
gear, bevel gear and universal joint. The left
1 2 housing and right housing of differential are bolted
Fig. 4-48
1 Left housing of differential as a whole. The driven spiral bevel gear of gearset
2 Right housing of differential is bolted to the flange of right housing of
differential. The journal of universal joint is
engaged in the hole formed by two grooves
respectively on left housing and right housing
interfaces. Each journal is covered with a straight
bevel gear, and they are meshed with two axle
shaft gears. The journals of the two axle shaft gears
are held in the left and right seat holes of
differential housing correspondingly, and connect
1 2 3 to axle shaft via spline to transmit power.
Fig. 4-49
1 Axle shaft gear 2 Universal joint
3 Bevel gear
4-31
Axle shaft
The axle shaft, a solid shaft, transmits power
between differential and wheel reducer. Its internal
end is connected to axle shaft gear of differential
via spline, and its external end is connected to sun
gear of wheel reducer via spline and retainer ring.
1 The left and right axle shafts of drive axle are
Fig. 4-50 designed with a fully floating structure. Because of
1 Axle shaft
this structure, the two ends of axle shaft only bear
torque and are not subject to any counter force or
bending moment.
To prevent axial float of axle shaft under the effect
of lateral force, a strut (or steel ball) is installed at
the joint end of axle shaft and sun gear of wheel
reducer.
The torque and motion from gearset is transmitted
to axle shaft via differential, and then transmitted
from axle shaft to wheel reducer.
Wheel reducer
The wheel reducer adopts planetary driving
mechanism. The complete mechanism consists of
driving sun gear, stationary gear ring, and driven
planetary gear carrier and planetary gear.
Working principle:
The sun gear and axle shaft are connected as a
1 2 3
Fig. 4-51 whole by spline, and gear ring is fixed on the
1 Gear ring 2 Sun gear support axle at both ends of drive axle housing,
3 Planetary gear
which is stationary. The planetary gear, meshed
with sun gear and gear ring, is installed on
planetary gear carrier via needle roller planetary
gear shaft. Planetary gear carrier and wheel rim are
bolted together; therefore, wheel rim rotates
together with planetary gear carrier. The power
from gearset is transmitted to planetary gear via
4-32
axle shaft and sun gear, which will drive the

planetary gear to run along the stationary inner
gear ring and then drive planetary gear carrier and
wheel assembly to rotate.
Functions of wheel reducer:
The wheel reducer is the last mechanism which
increase torque and reduce speed in transmission
system. It can increase the gear ratio of
transmission system and then satisfy the
1 requirements of running and operation of road
Fig. 4-52
roller.
1 Planetary gear carrier
The wheel reducer adopts planetary driving
mechanism. The complete mechanism consists of
driving sun gear, stationary gear ring, and driven
planetary gear carrier and planetary gear.

Drive Axle
Disassembly of drive axle

1. Remove the two tires on rear axle. For details,
refer to Section 732 for disassembly of tires.
2. Remove axle brake pipe from tee union.
ATTENTION
During removal, place a container under it to
collect brake fluid. Provide necessary protection
to the removed joint, avoiding contamination.
1
Fig. 4-53
1 Axle brake oil pipe
4-33

1 2
Fig. 4-54
1 Drive axle 2 Bolt
4. Lift rim bolts on both ends of axle with lifting
equipment.
5. Remove the connecting bolts and nuts of axle
and frame.
6. Slowly lower down lifting rope till axle is
placed on a trolley; remove the lifting rope,
and push out the trolley with axle.
1
Fig. 4-55
1 Bolt
Assembly of drive axle

1. Lift the assembled axle on a trolley, and push
the trolley under frame.
2. Lift drive axle assembly to the bottom of
frame, and use bolts, nuts and washers to fix
the drive axle on rear frame.
Bolt: 660~800Nm
ATTENTION
1 1. Check if the lifting rope is in complete
Fig. 4-56 conditions.
1 Bolt
2. Pay attention to lifting position,
avoiding object falling.
3. During lifting, no person is allowed to
stand underneath.
4-34
3. Install the connecting bolts of rear

transmission shaft and rear drive axle.
Bolts: 660~130Nm
4. Install rear axle brake pipe to the tee union.
5. Install rear tires. For detail, refer to Section
733 in this manual.
1 2
Fig. 4-57
1 Drive axle 2 Bolt
4-35
45 Common Faults in Transmission System and Troubleshooting
451 Common Faults in Transmission Box and Troubleshooting
Basic procedures for fault diagnosis

1. Preliminary inspection:
Visual inspection: Check the road roller with faulty transmission, carefully search for damage signs,
and pay attention to the condition of some key parts and components, such as the connecting
position of clutch housing with engine and gearshift mechanism and the connecting condition of
transmission shaft.
Inquiry: Ask the owner or driver about the working condition and operating condition of the faulty
road roller, occurring process of the fault, and faults occurred before.
2. Overhaul transmission
Store oil sample for checking the content of impurities (if necessary);
During transmission disassembly, check if each part is correctly installed and if there is omitted or
wrong installation;
According to the operation requirements of part cleaning, carefully clean each part, and at the same
time check the wear condition of them.
3. Determination of fault types and causes and troubleshooting
Common causes of faults and solutions
Table 4-5 Faults of transmission box
Fault phenomenon Probable causes Solutions
Check electric circuit of gear

No gear is engaged, the gear selector
selector and engaging
fails to return
accuracy of gears
Engine works
normally, but the The oil level is too low Add oil
roller couldnt
travel Pump is damaged or leaking oil, which
Replace oil seal or pump
result in inadequate oil supplying
Coupling or main clutch failure Overhaul
Main pressure is low Check main pressure

Insufficient driving
Slipping clutch Check clutch
force
Engine failure Overhaul
4-36
Valve is jammed Cleaning or replace

Check oil level, and pipeline
Pumping cavitation
with blockage or not
Low oil pressure
Pump failure Replace
Clutch leaking oil Overhaul
Oil level is too high or too low Add oil
Vent cap is clogged Replace
Oil cooler is broken Overhaul
Lubricating oil Brake is locked or towed heavily Adjust or replace

temperature is high
Bear is burnt, the oil path is impeded Replace
Suspension, restart work after

Work overload
the temperature drops down
Check other components: rear
Overheating of other components
axle, engine
Bad contact or burnt out of fuse, bad
Check
contact of connectors.
Gear selector does
not work, gear Gear selector is broken Repair or replace
engaging accuracy Malfunction of electrical system or
is poor Check, measurement
voltage is low
This phenomenon may also be caused by valve element seizure
Table 4-6 Main faults of control part and elimination methods

Fault phenomenon Probable causes Solutions
Check whether power source and fuses in
electrical control box are normal, and
Check the gear selector circuit
check whether connectors between
and gear engaging accuracy
Transmission box electrical control box and gear selector
has no gear are in good condition.
Adjust the oil pressure of
Check oil pressure of transmission
transmission control valve, to
control valve
meet the requirements
Connect a pressure gauge to the pressure
If there is no pressure or the
measuring port of transmission control
pressure is low, disassemble
valve, and check whether the pressure is
Driving force is the valve element and clear it
within 1.3~1.7MPa
insufficient
Connect a pressure gauge to the pressure
If oil pressure is normal, check
measuring port of the shaft end cover,
transmission box
check the oil pressure of clutch
4-37
452 Common Faults in Clutch and Troubleshooting
Table 4-7
Road roller shaking; Replace pressure
Spring fragile and weak
clutch sliding plate.
Sliding Oil dirt sticking Clean it off.

Shaking and sliding Clutch overheat and friction plate burning damage Replace it.
Abnormal wear Improper clearance adjustment beyond 3~5 mm 3-5mm
Driven disc or friction plate warped Replace it.
Adjusting position changed; pressure plate inclined Adjust it.
Driven disc having difficulty in axial movement Adjust it.

Incomplete release
Friction plate damped Replace it.
Large stroke of pedal Adjust it.

Adjust it and bleed
Clutch operating line lack of oil
air.
Fixing bolts of clutch cover and flywheel in loose

condition; Fixing bolts of transmission and flywheel
Other causes housing in loose condition; newly changed oil seal of Tighten them.
transmission shaft too tight; foot brake or hand brake
dragging
453 Common Faults in Drive Axle and Troubleshooting
1. Abnormal noise
The noise of drive axle is complicated. If the quality of parts is non-conformed, and final drive is
installed and adjusted improperly or excessive wear is produced during operation, the road roller
will make noise during running and work. Normally, noise becomes louder as the speed of road
roller increases. The specific conditions are as follows:
(1) Noise caused by improper backlash between driving and driven gears
Causes and symptoms: The backlash is too large, causing mutual impact between gear teeth, and the
noise presents irregular clip-clop sounds; the backlash is too small, causing mutual squeeze between
gear teeth, the noise presents continuous whiz sounds, and drive axle overheats; when the backlash
is not uniform, the noise presents regular choking sounds, and even drive axle will swing when it is
serious.
Solution: Remove final drive, and readjust the backlash between driving and driven gears.
4-38
(2) Noise caused by improper bearing clearance

Causes and symptoms: When bearing clearance is too small, the noise presents continuous buzzing
sounds; when bearing clearance is too large, the noise presents irregular halahala sounds.
Solution: Remove final drive and add adjusting washer to readjust bearing clearance; if bearing is
damaged, replace it with a new one and adjust the clearance.
(3) Noise from differential
Causes and symptoms: Planetary gear gets stuck with universal joint pin, producing snap sounds
which usually occur at turning; poor meshing of planetary gear will produce complicated noise:
When road roller is in straight running, the noise presents um" sounds and becomes louder as
the speed of road roller increases; when road roller makes a turning, the noise presents clip-clop
sounds.
Solution: Remove final drive and replace universal joint pin or planetary gear as well corresponding
washer.
2. Overheating
Causes and symptoms: After road roller runs or works for a period of time, touch axle housing, and
if it feels hot beyond the limit, this is drive axle overheat. Drive axle overheat is mainly caused by
small adjusted bearing clearance, small backlash between driving and driven gears and lack of
lubricating oil.
Solution: First check the amount of lubricating oil. If it is sufficient, remove final drive, and check
and adjust bearing clearance or backlash between driving and driven gears.
3. Oil leakage
Causes and symptoms: When road roller is working or parked, gear oil leaks from joint of final
drive and axle housing, internal side of wheel reducer, and the position between input flange and oil
seal cap. Oil leakage from final drive and axle housing is mainly caused by loose bolts or
interrupted sealant line; oil leakage from the internal side of wheel reducer is mainly caused by
double-lip framework oil seal; oil leakage between input flange and oil seal cap is caused by input
oil seal failure.
Solution: Replace corresponding seal components.
During operation, if drive axle produces abnormal, overheats or leaks, it is required to stop the road
roller immediately, identify causes and do troubleshooting; otherwise, it may cause serious damage
to internal components of drive axle or wheel reducer, and once gear oil escapes to brake disc, it
will lead to brake failure which may cause a major accident.
4-39

Service Manual Section on Transmission System of RS8200 Road Roller

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Service Manual Section on Transmission System of RS8200 Road Roller

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Service Manual of RS8200 Road Roller

Fig. 4-1 Transmission system of road roller

41 Clutch and Operating System

Fig.4-2 Clutch and operating system assembly

get damaged during gear shift.

Fig. 4-3 Schematic diagram of clutch A Input B Output

Fig. 4-4 Clutch

413 Clutch Booster

Fig. 4-5 Clutch booster

414 Clutch Master Cylinder

415 Disassembly & Assembly of

Disassembly of clutch booster

416 Disassembly & Assembly of

Disassembly of clutch master cylinder

3. Remove the pin shaft connection of pedal

Assembly of clutch master cylinder

3. Use pin shaft, cotter pin, washer and torsion

42 Transmission Box Assembly

421 Description of Transmission

Rated input power 130kw

Rated input speed 2200r/min

Forward gear I 8.936

Forward gear III 1.900

Reverse gear II 4.543

Reverse gear III 1.900

Introduction to transmission box external components

1 Transmission control valve

Table 4-2 Fig. 4-17

Introduction to power transmission line

Forward gear I (KV, K1 action)

Fig. 4-18 Forward gear I

Forward gear II (KV, K2 action)

Fig. 4-19 Forward gear II

Forward gear III (KV, K3 action)

Fig. 4-20 Forward gear III

Reverse gear I (KR, K1 action)

Fig. 4-21 Reverse gear I

Reverse gear II (KR, K2 action)

Fig. 4-22 Reverse gear II

Reverse gear III (KR, K3 action)

Fig. 4-23 Reverse gear III

422 Description of Gear Shifting Hydraulic System

Functions of hydraulic system:

Technical parameters of the pump are as follows:

Nominal displacement 16ml/r

Fig. 4-27 Principle diagram

423 Disassembly and Assembly of

Disassembly of transmission box

2. Remove the connecting bolts of transmission

4. Remove the connecting bolts of clutch

2. Adjust the position of clutch driven disc to

3. Lift transmission with lifting rope to the

5. Install mounting bolts and push rod of clutch

6. Lift the engine and transmission assembly with

7. Install transmission shaft. For details, please

8. Tighten the absorption pipe 1 of transmission

9. Install oil filler pipe of transmission box, and

10. Connect plug of oil temperature sensor of

11. Install transmission box oil inlet pipe 1 and oil

13. Install intake pipe of clutch booster.

the sound operation, if no abnormal noise, put

424 Precautions for Transmission Box

Precautions for disassembling: