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ANDVANCE WG180 Transmission Service Manual

Preface The Service Manual introduces the transmission removal and assembling process and offers the transmission service process technology and standard requirements, which can help the service personnel understand the transmission removal and assembling methods more profoundly as well as lay a solid technical foundation for the service personnel to correctly judge the malfunction and do troubleshooting. The Service Manual mainly includes following content: Chapter I. Introduction The chapter mainly introduces the transmission service precautions as well as symbol meanings and common thread tightening torque value in the text. Chapter II. Transmission System The chapter mainly introduces the mechanical principles of different gears of the transmission as well as Gearbox control system 、Transmission Function Testing and maintenance. Chapter III. Transmission Removal The chapter introduces the correct parts removal steps as well as precautions during removal. Chapter IV. Transmission Assembling The chapter introduces the correct parts assembling steps as well as precautions during assembling. Chapter V. Malfunction Diagnosis and Troubleshooting The chapter introduces the malfunction diagnosis and troubleshooting of the EST Semi-Automatic Gear Controller and transmission.

Attention Due to product improvements, relevant parts in the Service Manual will be subject to change without further notice. For the newest data and information, please consult with or get them from Shandong Lingong Construction Machinery Co., Ltd.

ADVANCE WG180 Transmission Service Manual 880×1230 mm

16#

1st Edition in 2014. 5

18pieces 1st Print

SHANDONG LINGONG CONSTRUCTION MACHINERY CO.，LTD Address: Linyi Economic Development Zone Tel: 86-0539-8785688 Fax: 86-0539-8785698 Postal code：276023 Website：www.sdlg.cn Services Tel：8008607999 4006587999 0539-8785800 Services Fax：86-0539-8785671

ANDVANCE WG180 Transmission Service Manual

Contents 1 Introduction ....................................................................................................................................................... 1 1.1 Safety Precautions ........................................................................................................................................ 1 1.2 Instructions of Marks and Symbols .............................................................................................................. 3 1.3 Common Bolt Tightening Torque Table ....................................................................................................... 3 2 Transmission System ......................................................................................................................................... 5 2.1 Transmission................................................................................................................................................. 5 2.1.1 Transmission Introduction ................................................................................................................... 5 2.1.2 Basic Parameters of the Transmission-torque Converter Assembly .................................................... 6 2.1.3 Mechanical Principles of the Gears of the Transmission..................................................................... 7 2.1.4 Gearbox control system ..................................................................................................................... 10 2.1.5 Transmission Function Testing .......................................................................................................... 20 2.1.6 Operation and Maintenance of WG200 Power Gearshift Transmission............................................ 22 3 Transmission Removal .................................................................................................................................... 27 3.1 Transmission Assembly Removal .............................................................................................................. 27 3.1.1 Torque Converter Removal ............................................................................................................... 27 3.1.2 Transmission Control Valve Removal ............................................................................................... 28 3.1.3 Oil Filter Removal ............................................................................................................................. 29 3.1.4 Removal of the Auxiliary PTO Wheel Hub ....................................................................................... 29 3.1.5 Input Device Removal ....................................................................................................................... 30 3.1.6 Removal of the Lubricating Oil Pipe Component and Auxiliary PTO .............................................. 31 3.1.7 Dismantle the three Sets of the clutch Assembly .............................................................................. 32 3.1.8 Removal of the Parking Brake and the Output Device ..................................................................... 33 3.1.9Intermediate Shaft Assembly Removal .............................................................................................. 37 3.1.10 Removal of the Torque Converter Pressure Regulating Valve ........................................................ 38 3.2 Transmission Assembly Component Removal ........................................................................................... 39 3.2.1 Main PTO Removal ........................................................................................................................... 39 3.2.2 Input Component Removal ............................................................................................................... 40 3.2.3Three Sets of the Clutch Removal ...................................................................................................... 45 I

ANDVANCE WG180 Transmission Service Manual 4 Transmission Assembly ................................................................................................................................... 53 4.1 Assembling of the Transmission Assembly................................................................................................ 53 4.1.1 Three Sets of the Clutch Assembly ................................................................................................... 53 4.1.2 Main PTO Assembly ......................................................................................................................... 63 4.1.3 Input Part Assembly .......................................................................................................................... 65 4.2 Transmission Assembly.............................................................................................................................. 70 4.2.1 Output Part Assembly ....................................................................................................................... 70 4.2.2 Intermediate Shaft Component Assembly ......................................................................................... 73 4.2.3 Torque Converter Pressure Control Valve Assembly ........................................................................ 74 4.2.4 Assembling of the K3K4 Clutch Assembly....................................................................................... 74 4.2.5 KRK2 、KVK1Clutch Assembly..................................................................................................... 76 4.2.6 Auxiliary PTO Assembly .................................................................................................................. 76 4.2.7 Input Component Assembly .............................................................................................................. 78 4.2.8 Main PTO Component Assembly ..................................................................................................... 79 4.2.9 Oil Filter Assembly ........................................................................................................................... 79 4.2.10 Transmission Control Valve Assembly............................................................................................ 80 4.2.11 Torque Converter Assembly ............................................................................................................ 81 5 Malfunction Diagnosis and Troubleshooting ................................................................................................ 82 5.1Malfunction Diagnosis and Troubleshooting of the EST Semi-Automatic Gear Controller....................... 82 5.2Malfunction Diagnosis and Troubleshooting of the Transmission .............................................................. 84

II

ANDVANCE WG180 Transmission Service Manual

1 Introduction 1.1 Safety Precautions Important Safety Precautions The maintenance and repair is very important for a safe vehicle operation. The Manual mainly describes the correct removal and assembling technology of the transmission assembly. To avoid personal injuries, will be made as the safety mark in the Manual. The precautions with shall be paid high attention to. In case of potential dangers, it is recommended to consider the own safety first of all, and then consider taking necessary safety measures. Safety Tips During assembling and removal, wrong operation method will lead to parts damages, service life shortening, service performance deterioration, and other unsafe factors. Accordingly, when assembling and removing the parts, it is recommended to carefully read the Manual. 1. All parameters, figures and relevant content in the Manual are applicable for the standard equipped product. For derivative product, please consult with us or refer to relevant materials. 2. In the repair workshop, the places special for assembling and removal operation and storing removed parts shall be prepared, and the corresponding tools and parts shall be placed in a proper site. In addition, the working area shall be kept clean, which shall be free from oil dirt and pollutants. Smoking is only allowed in the specified place; smoking is not allowed during operation, and corresponding fire extinguishers shall be prepared. 3. The welding operation can only be conducted by the trained personnel with welding experience. During welding, welding gloves, retainer, goggles, work cap and other work clothes applicable for welding operation. 4. Before removing the transmission-torque converter assembly, it is necessary to clean pollutants on the surface of the transmission-torque converter assembly, so as to avoid polluting the parts during removal. 5. During operation, it is necessary to wear safety boots and safety helmet. It is not allowed to wear unqualified work clothes; it is necessary to fasten buttons of the work clothes. When knocking the parts with the copper rod, it is necessary to wear goggles. 6. The gasoline, kerosene and water-based oil stain cleaning agent can be used to clean the removed parts. 7. When applying the traveling crane or other hoisting equipment, check relevant spreader for damages first of all, and such hoisting equipment with sufficient hoisting capacity shall be used. During hoisting, the appointed hoisting position shall be used for slow hoisting, so as to avoid parts collision. It is not allowed to work in the area under the hoisted parts.

1

ANDVANCE WG180 Transmission Service Manual Attention As the torque converter has no axial positioning, it is necessary to prevent its slipping in case of removal and assembling of the transmission, as shown in Figure 1-1

Figure 1-1 8. In case of simultaneous operation with two or more persons, they shall reach an agreement in the operation procedures before operation, so as to avoid accidents due to incompatible pace. 9. It is necessary to properly keep all tools and be familiar with their application methods. 10. In case of alignment of two holes, it is forbidden to insert hands and fingers. For parts to be directly assembled by hand, it is necessary to pay attention that the gripping position is free from squeezing danger. 11. It is necessary to test the removed parts; the parts whose application performance is affected shall be replaced with a new one. 12. After assembling, the parts shall be free from interference. 13. When assembling the oil seal and seal ring through the keyway, screw hole and step, it is necessary to apply relevant protection measures to avoid damages. 14. When assembling the parts, the applied tools shall match with the thread fastener, so as to avoid damages. 15. When screwing down the connector body and screw plug, it is not allowed to use pneumatic wrench and other similar tightening tools. It is necessary to screw them down by hand and then with the torque wrench with corresponding capacity, so as to reach the corresponding torque value. 16. When draining out fluid in the transmission, it is necessary to slowly screw off the oil drain plug, so as to avoid fluid spraying.

2

ANDVANCE WG180 Transmission Service Manual

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

Item

Remarks Special attention shall be given to the safety in case of operation.

Safety

Special attention shall be given to the safety in case of operation as there is pressure inside. Special attention shall be given to the technical requirements in case of operation to ensure that the operation is qualified.

Attention

Part or device weight or removal and assembling method. Weight

Attention shall be given to selection of the spreader and its operation posture.

Tightening torque

Special attention shall be given to the tightening torque of the component in case of assembling.

Coating

The place which needs adhesive and lubricating grease coating.

Oil and water

Fill the engine oil, water and fuel with certain capacity.

Draining

The place needing oil or water draining and draining capacity.

1.3 Common Bolt Tightening Torque Table Table 1-2 Nominal diameter of bolt mm

Yield strength N/mm2

6

4.6

240

4~5

10~12

5.6

300

5~7

6.8

480

8.8

Bolt strength grade

8

10

12

14

20~25

36~45

55~70

12~15

25~32

45~55

70~90

7~9

17~23

33~45

58~78

93~124

640

9~12

22~30

45~59

78~104

124~165

10.9

900

13~16

30~36

65~78

110~130

180~210

12.9

1080

16~21

38~51

75~100

131~175

209~278

Bolt strength grade

Yield strength N/mm2

Tightening torque N.m

Nominal diameter of bolt mm 16

18

20 Tightening torque N.m

3

22

24

ANDVANCE WG180 Transmission Service Manual 4.6

240

90~110

120~150

170~210

230~290

300~377

5.6

300

110~140

150~190

210~270

290~350

370~450

6.8

480

145~193

199~264

282~376

384~512

488~650

8.8

640

193~257

264~354

376~502

521~683

651~868

10.9

900

280~330

380~450

540~650

740~880

940~1120

12.9

1080

326~434

448~597

635~847

864~1152

1098~1464

Bolt strength grade

Yield strength N/mm2

27

4.6

240

450~530

540~680

5.6

300

550~700

6.8

480

8.8

Nominal diameter of bolt mm 30

33

36

39

670~880

900~1100

928~1237

680~850

825~1100

1120~1400

1160~1546

714~952

969~1293

1319~1759

1694~2259

1559~2079

640

952~1269

1293~1723

1759~2345

2259~3012

2923~3898

10.9

900

1400~1650

1700~2000

2473~3298

2800~3350

4111~5481

12.9

1080

1606~2142

2181~2908

2968~3958

3812~5082

4933~6577

Tightening torque N.m

4

ANDVANCE WG180 Transmission Service Manual

2 Transmission System 2.1 Transmission 2.1.1 Transmission Introduction The type WG180 (max. transmission power of 180KW) power gearshift transmission is composed of the hydraulic torque converter and rear-mounted countershaft transmission with multi-sheet friction clutch. The SDLG 958、959 wheel loader adopts the 4WG180 gearbox assembly which can realize speed switching between 4 forward gears and 3 reverse gears. The SDLG G9190 grader adopts the 6WG180 gearbox assembly which can realize speed switching between 6 forward gears and 3 reverse gears

1 2 3 4 5 6 7

1. Transmission control valve 2. Oil filter 3. Torque converter oil temperature measuring port 4. Transmission oil outlet 5. Oil suction pipe 6. Transmission housing 7. Rotation speed sensor

Figure 2-1

8. Torque converter 9. Variable-speed pump 10. Auxiliary PTO 11. Clutch (3 groups in total) 12. Output shaft assembly 13. Parking brake

8 9 10 11 12 13

Figure 2-2 5

ANDVANCE WG180 Transmission Service Manual

2.1.2 Basic Parameters of the Transmission-torque Converter Assembly Table 2-1 4WG180

Item

Single-stage and single-turbine hydraulic torque converter with three elements

Type Torque ratio Torque converter

2.55

2.14

Oil cooling method

Circulating water cooling

Torque converter inlet oil pressure (bar)

8.5

Torque converter outlet oil pressure (bar)

5

Type

Countershaft electro-hydraulic gear shift Four forward gears and three reverse gears

Six forward gears and three reverse gears

First forward gear

4.278

5.991

Second forward gear

2.368

3.447

Third forward gear

1.126

2.596

Fourth forward gear

0.648

1.494

Fifth forward gear

—

1.179

Sixth forward gear

—

0.678

First reverse gear

4.278

5.991

Second reverse gear

2.368

2.596

Third reverse gear

1.126

1.179

Transmission gear

Transmission

6WG180

Transmission ratio

Variable speed pump type

In-built gear pump

Transmission working pressure (bar)

13~17

6

ANDVANCE WG180 Transmission Service Manual

2.1.3 Mechanical Principles of the Gears of the Transmission 1. Construction Principle of Transmission

The actuating mechanism in the gearbox consists of 6 clutches, which are K1, K2, K3, K4, KV and KR respectively and the KR is reverse clutch. Different gears can be realized through the combinations, and there are must two clutches working simultaneously at each gear, see figure 4-4 for the working principles of the gearbox.

Figure2-3 2. Hydraulic oil system of transmission

A gear pump as the oil supply of the torque converter and pilot valve is installed within the transmission and driven directly by engine through power taking-off shaft. With a flow rate of Q= 35L/1000r/min, the oil pump pumps the hydraulic oil, filtered by a suction filter (pre-filtration) in the oil circuit , into a screw-in filter (secondary filtration) at the housing top or any other location of the vehicle, which is away from the transmission and is connected to it by oil pipes. The filter accuracy is 0.025mm and filter area 5100cm2 . Oil from the filter flows into the pilot valve ; through a pressure-control valve after its working pressure being limited by a control pressure valve (main pressure regulating valve). The role of pressure control valve is to regulate the boost characteristics of clutch cylinder at the moment of shifting, which means, oil pressure will be reduced instantaneously when shifting and increased back to 14-18bar (pressure limited by control pressure valve) after shifting (clutch engaged). This can reduce shift shock to improve shift quality. Hydraulic oil through pilot valve enters into clutch directly. The shifting valve is fixed by steel balls, springs and recesses. Control pressure valve sends those spilled oil into torque converter and lubrication piping while limiting the maximum working pressure.

7

ANDVANCE WG180 Transmission Service Manual A pressure limiting valve (with a response pressure of 8.5-10bar) is equipped at the inlet of torque converter oil circuit to prevent components damage due to high internal pressure in it. According to the working principle of hydraulic transmission, oil is the medium for conveying energy within the torque converter. So, in order to avoid cavitation erosion of oil, the converter cabinet should be always full of oil, which may be realized by the pressure control valve (backpressure valve with a response pressure of 2.5bar) at the outlet of torque converter oil circuit. Oil spilled from the converter enters directly into the oil cooler (oil-water or oil- air heat exchanger). When a water-cooled engine is applied, the cooler shall be installed in the engine’s cooling water pipe line. An oil-air cooler is applicable when a blower cooled engine is applied, and the cooler is to be installed at the blasting end of the cooling fan. Cooler assembly and connecting oil pipe assembly dose not to be supplied by our factory. A bypass valve shall be equipped for the oil cooler to protect it at low temperature or when blocked. Oil from the cooler enters directly into the lubrication circuit to supply adequate lubrication cooling oil to each lubricating point. A pressure shut-off valve can be mounted if required. The operation of the pressure cut-off valve can be easily controlled by regulating pneumatic pressure or oil pressure through a second brake pedal. Hydraulic pressure should be not less than 40bar, and pneumatic pressure not less than 2.5 bar. The role of a pressure cut-off valve is to cut off the oil pressure of clutch oil circuit, and to disengage the clutch while the shifting (reversal) valve doesn’t operate. By doing so, all of the engine power can be provided to the external pump and the shifting valve dose not need to be positioned at neutral position while operating pressure shut-off valve.

8

Fig 2-4 Hydraulic principle of electro-hydraulic control

ANDVANCE WG180 Transmission Service Manual

9

ANDVANCE WG180 Transmission Service Manual

2.1.4 Gearbox control system The shift control of gearbox is electro-hydraulic control, in our machine: 4WG180 transmission is equipped with EST Semi-Automatic Gear Controller (as shown in figure 2-5), 6WG180 transmission is equipped with SG-6S gear selector (as shown in figure 2-6), the hydraulic slide valves are controlled by the shift selector and the solenoid valves are connected with the shift selector to realize shift control in sequence. Do not control the gears in a manner of skipping some gear. The gear pump used for supplying oil for the torque converter and control valve is installed in the gearbox and is directly driven by the engine through the PTO shaft, and the flow is Q=35L/min. The hydrodynamic drive oil enters the variable-speed control valve after the suction oil filter and pressure control valve in the oil line, and the control pressure of gearbox is 13~18bar. The function of the pressure control valve is to adjust the pressure rising characteristic of clutch cylinder during shifting to reduce the shifting impact and improve the shifting quality.

Figure2-5

Figure2-6

1. EST Semi-Automatic Gear Controller (1) Principle EST-series gear controller is a electric control system based on EST-4 (four valves) or EST-5 (five valves) electric control unit, as shown in Fig (2-5), having semi-automatic controlling function of reversing and speed changing. The system consists of following five sub-assemblies, as shown in Fig. 13-7 and 13-9: a) Control handle DW-4 (Four-gear selector), installed under the wheel, operated by left hand b) Electric control unit EST-4 (or -5) c) Special wire harness and connectors d) Solenoid valves on control valve e) Speed sensor (without in current four-solenoid controller) The four subassemblies a) to d) must be used together, with the diagram as shown in Fig. (2-10) and Fig. (2-12). The control system is currently used to control transmission model WG180 that matches loader. Both signals from DW-4 selector and other from vehicle electric circuit are input to EST-4 electric control unit, which analyses and determines signals comprehensively and then as per control request to the transmission, outputs corresponding voltage to solenoid valves on 10

ANDVANCE WG180 Transmission Service Manual transmission control valve. The solenoids combination control related oil circuit, then hydraulic oil pushes related clutch, thus realizing operation on direction and gear. In addition, the EST-4 electric control unit outputs four signals to vehicle circuit, including neutral signal AS (for starting interlock), reverse signal RF (for reversal indication), forced gear-down indication (H1) and alarming indication (H2). Refer to “Function Sheet of EST-4 Output Signals” for details. All of them are plus output, i.e. +24V. EST-4 electric control unit possesses functions of measurement and protection. Before using, connect plugs of all leading-out cables. As for those to vehicle circuit, except for positive and negative wire of power supply, that of starting interlock signal AS must also connected and others may depend on. If any solenoid valve did not connect, or short circuit occurred, or power supply was abnormal, the unit would lock all outputs except alarming signal (light H2 flashing and ticking inside). At the time, cut off the power supply and eliminate faults. About operation of this control system, gears and direction can be changed by moving the handle of selector DW-4, additionally, brake signal BR and emergent brake BR2 in vehicle circuit can also affect controller output. At first and second gears in forward or backward, if any of the two signals is connected to +24V, outputs of EST-4 are identical to neutral of corresponding gear of DW-4. Technical Dada:

Table2-2

Rated voltage

DC 24V

Working voltage range

DC 20～32V

Input current

Max.5A

Output signal current

Max. 0.5A for each

Working temperature

-20～+70℃

Storage temperature

-40～+80℃

(2) Operation Before starting vehicle engine, put the handle of gear selector DW-4 at neutral ‘N’ position, or the engine cannot be started. If it is the first time to operate the selector DW-4 after being electrified, the handle should also be put at neutral position first and then moved to required gear, or not, the EST-4 will have no signal output. a) Push or pull handle horizontally to change moving direction, including F (forward), N (neutral) and R (reversal); rotate the handle to change gears, anti-clockwise for gearing-up and clockwise for gearing down. The operation force needs not too big. Numbers 1, 2, 3 and 4 on the handle indicate positions for four gears, among which gear 1 is slowest and 4 fastest. b) This controller has the function of forced gear-down (KD): when DW-r selector is at gear 2 in forward or backward, press the handle forward once, the gear will be change to 1, at the same time light H1 will flash. The function is invalid in other gears other than 2. It can be relieved by taking any of following measures: (1) press the handle again; (2) turn the handle to change gear; (3) take reversal operation; (4) change to neutral. c) During the vehicle running at gear 1 or 2, in case of foot braking and emergent braking, signals output from ECU are identical to that of corresponding neutral position. Releasing the braking switch, original gear will be back to immediately. However, if in gear 3 or 4, braking is invalid.

11

ANDVANCE WG180 Transmission Service Manual d) When the vehicle parking, put the handle of gear selector DW-4 at neutral ‘N’ position. e) If alarm occurs during vehicle running (the vehicle does not run; light H2 flashes and ECU ticks), shift the handle to neutral (N), if the alarm is eliminated, continue to normal operate; if not, it means there are troubles in wiring. Cut off power supply and check thoroughly. Reconnect power after removing the troubles.

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

Table2-3 Gear Output

Forward 1

2

3

M1 M2

●

M3

●

●

M4

●

●

Reverse

Neutral

4

1

2

3

4

●

●

●

●

●

● ●

01

02

03

04

●

●

●

●

●

●

●

AS

12

●

● ●

●

●

●

ANDVANCE WG180 Transmission Service Manual RF H1

●

●

●

●

Light in KD condition Flash when having alarm or light when the sensor is disconnected for

H2 types with speed sensor. “●”：Indicates having signal output, lamp lights

2. SG-series Gear Selector (1) Principle Shown as the outside view Fig (2-6), the selector works on the principle as follows: the handle moves the slotted cylinder turning, thus selecting expected gear. Up- or down-ward (or left- or right-ward) movement of the handle can determine running direction: Forward, Backward and Neutral. First, an optical sensor detects position of the handle; the signal is amplified and combined as a code demanded by this expected gear, and then output to a hydraulic control valve inside the transmission, thus pushing corresponding clutch and making output speed of the transmission meeting the selected gear. Power for the selector is supplied by vehicle electrical system, with working voltage being stable DC 24V. Generally, the storage cell on the vehicle and the DC generator can satisfy the power demand. Connection between selector and external circuit is realized by a 20-core cable with two plugs, one with suspension fuse connects to vehicle electrical system and the other to control valve of the transmission. Electrical diagrams for various selector models are shown as Fig. (2-7) and (2-8).

Technical Data

Table2-4

Rated voltage

DC 24V

Working voltage range

DC 20～32V

Input current

Max. 5A

Output signal current

Max. 0.5A for each

Working temperature

-20～+70℃

Storage temperature

-40～+80℃

13

F 编码

F-code

Fig.2-7（SG-6S）Wiring diagram “F”

ANDVANCE WG180 Transmission Service Manual

14

Fig.2-8

Wiring diagram of（SG-6S with locking

ANDVANCE WG180 Transmission Service Manual

15

Fig2-9

ANDVANCE WG180 Transmission Service Manual

16

Fig.2-10

ANDVANCE WG180 Transmission Service Manual

17

F i g . 2 - 11

ANDVANCE WG180 Transmission Service Manual

18

Fig.2-12

ANDVANCE WG180 Transmission Service Manual

19

ANDVANCE WG180 Transmission Service Manual

2.1.5 Transmission Function Testing 1. Test of electro-hydraulic controlled transmission Attention The test shall not be done until the transmission temperature reaches 80～95℃ and the engine is at the maximum speed.

2/13 KV K1 G 1

KR

3/14

K2

4

K4

5

K3

Figure2-13

6 7

12

8

11

9

10

Figure2-14 (1) Testing points for oil pressure: 1= torque converter inlet port pressure pressure of clutch K1

6= steering pressure

10=pressure of clutch KV

8=pressure of clutch K2

(2) Testing points for temperature:

9=pressure of clutch K3

3=torque converter outlet port

20

3= torque converter outlet port

11=pressure of clutch KR 12=pressure of clutch K4

7=pressure

ANDVANCE WG180 Transmission Service Manual Electrical measuring points: G=coil pick-up

Steering valve (24V)

(3) Testing points for flow rate：2=filter inlet port； 13=filter outlet port (minimum flow rate is 50L/min)； 4= cooler inlet port；6=cooler outlet port (minimum flow rate is 40L/min)； Connection thread of each testing points: 1、6、10、7、8、9、12·· ··· ·M10×1；14···· ··M14×1.5； · · · · ·M26×1.5；4、5· · · · · ·M30×1.5. 2、13·

Table2-5

Figure2-15

21

ANDVANCE WG180 Transmission Service Manual

2.1.6 Operation and Maintenance of WG200 Power Gearshift Transmission 1. Application precautions (1) When checking the transmission oil level, the engine shall run at idle speed (about 1000 rpm) and the oil temperature shall be kept at the normal working temperature; (2) When the oil temperature is 40℃, the oil level shall be between the middle and lower scale lines of the oil dipstick. When the oil temperature is 80℃, the oil level shall be between the middle and upper scale lines of the oil dipstick. (3) Strictly follow the maintenance requirements and periodically replace the transmission oil and the filter. (4) Before starting the vehicle engine, ensure that the control handle is at the neutral gear. (5) Before every traveling, loosen the parking brake (release the brake). (6) In case of engaging or separating the engine and the transmission and lifting the transmission, try to avoid torque converter detachment. (7) During parking, the gearshift handle shall be turned to the neutral gear. (8) The normal working oil temperature shall be kept between 80—110℃; when bearing the heavy load, it can rise to 120℃ in a short time. It is necessary to pay special attention to the control oil pressure of the transmission. If transmission is discovered to be abnormal during use, it is necessary to stop the vehicle for check. (9) When the vehicle has malfunction and needs electric welding maintenance, it is necessary to remove the cable plug on EST—computer controller (cut off the circuit leading to the computer controller); or else, the computer controller may be burnt due to impact current during electric welding. 2. Operation (1) Preparations and maintenance before traveling Before transmission operation, it is recommended to properly fill the lubricating oil with specified specification. In case of initial oil filling of the transmission, it is necessary to consider that the oil radiator, filter and connecting pipe shall be filled with oil. Accordingly, the lubricating oil in the first filling shall be much more than that for the subsequent normal maintenance. As the torque converter oil on the vehicle will flow to the transmission via the oil radiator and oil pipe under a stationary state, the oil level shall be correctly controlled under the thermal equilibrium temperature in case of neutral gear engagement upon parking, idle engine running and normal transmission operation. The oil level can be tested when the control handle is turned to the neutral gear. When checking the oil level, it is necessary to insert the oil dipstick to the lower limit of the oil pipe. When cleaning the main oil circuit filter, pay attention that no dirt and sediment can enter into the oil circuit. In addition, it is necessary to place a cover plate to prevent the parking brake from oil immersion. 22

ANDVANCE WG180 Transmission Service Manual When installing the filter, it shall not be screwed down too tightly. (2) Traveling and gear shift In case of engine start, it is necessary to confirm that the gearshift handle is turned to the neutral gear. For the sake of safety, before engine start, the parking brake shall be in a brake state, so as to ensure that the vehicle will not be started due to engine start. After engine start, release the parking brake; properly select the traveling direction and gear; slowly throttle up the vehicle for start. In case of vehicle traveling, the torque converter will replace the function of the main clutch. When the road conditions are good, the vehicle can be driven with a high gear. If the vehicle is stopped but the engine still runs and the transmission gear is engaged, the engine will not be stopped. For some traction force may be produced when the engine passes the torque converter at idle speed, the vehicle may crawl on a straight pavement. The rational method is to turn the parking brake to a brake state upon each parking. To park the vehicle for a long time, the control handle shall be turned to the neutral gear. During traveling, it is recommended to loosen the parking brake of the vehicle. From experience, we draw a conclusion that the operator is hard to immediately find out that: When the torque converter speed changes, due to large output torque ratio of the torque converter, the vehicle can overcome the brake torque and forcedly travel even under the normal operation conditions. The consequence is that the torque converter oil temperature will rise and the brake will become too hot. Due to impact of the torque converter, when shifting to low speed gear from the high speed gear, the engine rotation speed will increase, specially the gear shift with skipping a grade. Accordingly, if conditions permit, when shifting to low speed gear from the high speed gear, firstly step down the foot brake; perform deceleration slowly and then shift gear. When the vehicle travels at high speed and the traveling direction is changed, it is necessary to reduce the engine rotation speed. (3) Suspension and parking As there is no rigid connection between the engine and the torque converter output shaft, when the vehicle is parked on the slope (upslope or downslope) while the driver wants to leave the vehicle, to avoid vehicle sliding, we recommend to apply the parking brake and place stop blocks under wheels. (4) Dragging The max. dragging speed is 10km/h and the max. dragging distance is 10km. When the distance is longer, the vehicle with malfunction shall be placed on other vehicle for transportation. (5) Oil temperature The transmission oil temperature shall be monitored with the temperature sensor. The max. oil temperature of the torque converter outlet shall not be higher than 120℃; the normal control component and the transmission with sufficient traveling mileage will not have higher temperature. If the oil temperature is higher than 120℃, the vehicle shall be stopped for oil leakage check. And, the transmission shall be turned to the neutral gear and the engine shall run at 1200~1500rpm. In 23

ANDVANCE WG180 Transmission Service Manual such case, the oil temperature will quickly reduce to the normal value (within about 2~3 min.). If the oil temperature doesn’t fall down, it means that the system has malfunction, and operation can be continued after troubleshooting. Normal gear shift oil pressure range: 1.6~1.8MPa (16~18bar). To monitor the control pressure, it is necessary to install a pressure gauge or pressure monitoring meter. In case of engaging some gear and applying the clutch but the pressure drops to the min. pressure lower than the specified pressure (the pressure will quickly drop temporarily in case of gear shift), it is necessary to do troubleshooting. If the control pressure is too low, the clutch will be damaged, for the clutch without sufficient contact pressure will make the friction lining continuously slip and become too hot. 3. Maintenance (1) Oil level check —— Park the vehicle in a flat place —— Turn the transmission gearshift handle to the neutral gear (“N”) and the parking brake to the brake position. —— Idly run the engine with about 1000rpm —— Counterclockwise loosen the oil dipstick and then take it out and wipe it off —— Insert the oil dipstick in the oil level pipe and screw it down; keep it for about 3s after reaching the target position, and then take it out (twice measurement at the least) —— At 40℃, the oil level shall be between the lower scale “cold” and the middle scale —— At 80℃, the oil level shall be between the upper scale “hot” and the middle scale The cold vehicle oil level check is only to ensure that the transmission and the torque converter have sufficient circulating flow. The final standard to determine the oil level is to meet the hot vehicle oil level requirements.

Figure2-16

Attention If the oil level is lower than the min. scale, it is necessary to fill the recommended lubricating oil till the oil level rises to the correct scale range of the corresponding temperature (see Figure 2-16). (2) Oil replacement When the vehicle reaches the first 100 working hours, the first oil replacement shall be done. After that, the oil replacement shall be done once every 1000 working hours or every year. During oil replacement, it is recommended to stop the vehicle in a flat place; keep the 24

ANDVANCE WG180 Transmission Service Manual transmission at the working temperature; take out the oil drain plug and seal ring, and drain out residual oil. ——Start the engine and run it at idle speed ——Turn the transmission control handle to the neutral gear (“N”) ——Fill oil till reaching the upper scale in the “cold” oil area ——Turn the parking brake to the safe position ——Select all gears once ——Check the oil level again ——If necessary, fill oil again —— At 40℃, the oil level shall be between the lower scale “cold” and the middle scale ——At 80℃, the oil level shall be between the upper scale “hot” and the middle scale Oil Replacement Period Table: Part name

First oil replacement

Table 2-6 Normal oil replacement

Upon every 1000 Upon 100 working hours, working hours, not longer than Transmission(WG180) the filter shall one year, and the also be filter shall also be replaced replaced Other optional oil product:

Oil product standard

Oil level check

ADVANCE HC-WG01 private oil

Before daily use

Table 2-7

Specification and Standard of Permissible Oil Grade（in case there is no HC-WG01 private oil available） American petroleum institute API CF-4/CG-4/CH-4 SAE（15W-40）；European automobile manufacturer association ACEA E2-96（15W-40）；ZF TE-ML03 SAE（15W-40）；American automobile engineer association SAE 306 SAE（15W-40）；Caterpillar T0-4 SAE（15W-40）； Fuchs CF-4/ SAE（15W-40）； Mobil 1300 CF-4/ SAE（15W-40）。

25

ANDVANCE WG180 Transmission Service Manual (3) Oil filter replacement In case of each oil replacement, ZF coarse filter shall also be replaced. The replacement requirements are as follows: ——Coat the seal ring with a thin layer of oil ——Press down the filter till it contacts with the sealing surface of the transmission; after that, screw it down for 1/3 to 1/2 circles by hand ——Fill oil ——Start the engine ——When the engine idly runs (about 1000rpm) and the transmission oil has a working temperature, check the transmission oil level. ——When the oil temperature is 40℃, it shall be within the “cold” oil level range. ——When the oil temperature is 80℃, it shall be within the “hot” oil level range. ——Check if it is screwed down. If necessary, screw it down by hand again.

26

ANDVANCE WG180 Transmission Service Manual

3 Transmission Removal 3.1 Transmission Assembly Removal 3.1.1 Torque Converter Removal 1. Pull out the intermediate ring and the torque converter from the transmission; completely drain out residual oil in the torque converter and place it aside. about 20kg

1

2

Figure 3-1 1 Torque converter 2 Intermediate ring 2. Remove the bolt connecting with the shell and the transmission.

1

2

Figure 3-2 1 Hexagon screw ×14 2 Tension pin

27

ANDVANCE WG180 Transmission Service Manual

3.1.2 Transmission Control Valve Removal 1. Remove socket heat bolts 10-M8×45 、 6-M8×75from the pilot valve with a M8 socket head wrench. Attention Strictly follow the sequence of “From outside to inside and diagonal removal” to remove bolts. Pay attention to keep the valve spacer intact while taking off the pilot valve. 1

Figure 3-3 1 pilot valve 2. Remove the six oil pipe on the oil delivery plate one by one. They are K2, K1, K3, K4, KR, KV, from the top down, among which pipe KV and KR change according to the rotation of back axles from different machine factories. In addition, remove the oil passage connector on the clutch shafts and take down six oil pipes. Attention 1

2

Figure 3-4 1 Oil pipe connector of the oil passage plate 2 Oil passage connector of the clutch shaft

Do well in oil pipe connector protection, and mark the oil pipe number with the marker. After removing the connectors, do well in their cleaning and protection. 3. Take off socket head bolts 3-M8×45 and 6-M8×35 connecting the plate and the housing, then remove the oil delivery plate and the baffle plate and put them aside. Attention Strictly follow the sequence of “From outside to inside and diagonal removal” to remove bolts. After removing the oil passage plate, do well in its cleaning and protection.

1

Figure 3-5 1 Oil passage plate

28

ANDVANCE WG180 Transmission Service Manual

3.1.3 Oil Filter Removal 1. Rotate the oil filter with the belt spanner for removal.

1 Figure 3-6 1 Belt spanner

3.1.4 Removal of the Auxiliary PTO Wheel Hub 1. Take down the bolt between the auxiliary PTO wheel hub and the transmission body.

1

2

Figure 3-7 1 Hexagon head screw 2 Auxiliary PTO wheel hub 2. After pushing out the wheel hub with the crowbar and taking down the PTO wheel hub and its seal ring, the removal is completed.

1

2

Figure 3-8 1 Auxiliary PTO wheel hub 2 Crowbar

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ANDVANCE WG180 Transmission Service Manual

3.1.5 Input Device Removal 1. Remove the hexagon bolts between the pump impeller bearing seat and the oil feed flange.

1 2

3

Figure 3-9 1 Oil feed flange 2 Pump impeller bearing seat 3 Hexagon head screw (M8*28)×8 2. Slightly knock the bearing seat with the copper rod for loosening. Take down the bearing seat and the packing.

1

2

Figure 3-10 1 Pump impeller bearing seat 2 Packing 3. Take down the bolt between the main PTO wheel hub and the transmission body.

1

2

Figure 3-11 1

Hexagon head screw ×10

2

Main PTO wheel hub 30

ANDVANCE WG180 Transmission Service Manual 4. Hold one about φ30*400mm copper rod by left hand to jack up the variable speed pump end cover, and hold another copper rod by right hand to knock out the oil feed flange and the variable speed pump component and place them aside. Attention The copper rod shall be used to slightly knock the oil feed flange and the variable speed pump component, so as to avoid component slipping. 1 Figure 3-12 1 The bar copper with stands the spot

3.1.6 Removal of the Lubricating Oil Pipe Component and Auxiliary PTO 1. Respectively screw off hollow bolts (M18) at both ends of the transmission lubricating oil pipe and then take out the oil pipe.

1 Figure 3-13 1 Lubricating oil pipe component 2. Take down the snap ring from the PTO shaft with the snap ring pliers.

1 2 Figure 3-14 1 Snap ring 2 Snap ring pliers

31

ANDVANCE WG180 Transmission Service Manual 3. Knock out the PTO shaft with the copper rod and take down the PTO driving gear.

1

2

3

Figure 3-15 1 Driving gear

2 PTO shaft

3 Retainer ring 4. The auxiliary PTO removal is completed.

1 Figure 3-16

3.1.7 Dismantle the three Sets of the clutch Assembly

1 Ball bearing

1. Remove the three bolts connecting each clutch shaft with the housing.

1

2

3

Figure 3-17 1 Clutch shaft K3+K4

2 Clutch shaft K2+KR

3 Clutch shaft K1+KV 32

ANDVANCE WG180 Transmission Service Manual 2.Pull out the K1、K2、K3 clutch shaft with tooling Attention Put the clutch adjusting plate under the shaft end after pulling out each set of clutch for general assembly. When taking out the clutch assembly, place the transmission in a proper position, and the operation shall be slow to avoid slipping. 1

2

Figure 3-18 1 Clutch shaft removal tooling （2938001828）（2938001829）

3.1.8 Removal of the Parking Brake and the Output Device 1. Take the safety plates 2-M10×30 off the output shaft on the hand brake end, screw off the two bolts and remove the hand brake and the hand brake flange assembly together with a bob crowbar. Attention 1 Figure 3-19

When removing, the force shall be slow and sufficient, and protection measures shall be taken to avoid spring detachment.

1 Parking Brake 2. Take out the oil seal from the output device. Attention When taking out the oil seal, the force shall be uniform and sufficient to avoid damages. And, the special removal tooling can also be used.

1 Figure 3-20 1 Oil seal

33

ANDVANCE WG180 Transmission Service Manual 3. Take down the lock washer and remove the bolt between the pressure plate and the output flange.

1

2

Figure 3-21 1 Lock washer 2 Hexagon head screw×2 4. Take down the pressure plate, distance washer and O-ring in turn.

1

2

3

Figure 3-22 1 Pressure plate

2 Distance washer

3 O-ring 5. Take down the output flange.

1 Figure 3-23 1 Output flange

34

ANDVANCE WG180 Transmission Service Manual 6. Take down the oil seal. Attention When taking out the oil seal, the force shall be uniform and sufficient to avoid damages. And, the special removal tooling can also be used.

1 Figure 3-24 1 Oil seal 7. Remove the front end bearing snap ring and compensation washer of the output shaft with the snap ring pliers.

1

2

Figure 3-25 1 Snap ring 2 Compensation washer 8. Knock the rear end of the output shaft with the copper rod.

1

2

Figure 3-26 1 Rear end of the output shaft 2 Copper rod

35

ANDVANCE WG180 Transmission Service Manual 9. Take down the output shaft, bearing and shaft sleeve.

1

2

3

Figure 3-27 1 Bearing

2 Output shaft

3 Shaft sleeve 10. Take out the output gear and remove the bolt between the retainer, oil shield and transmission body.

1

2

3

Figure 3-28 1 Output gear

2 Connecting retainer

3 Hexagon head screw×2 11. Take out the oil shield and the retainer.

1

2

3

Figure 3-29 1 Output gear

2 Oil shield

3 Retainer 36

ANDVANCE WG180 Transmission Service Manual

3.1.9Intermediate Shaft Assembly Removal 1. Remove the sealing washer.

1 Figure 3-30 1 Sealing washer 2. Remove the bolt between the intermediate shaft and the transmission body.

1 Figure 3-31 1 Head cap screw 3. Take out the intermediate shaft and the O-ring.

1

2

Figure 3-32 1 Intermediate shaft 2 O-ring 37

ANDVANCE WG180 Transmission Service Manual 4. After taking out the intermediate shaft and the bearing component, the removal is completed.

1

2

Figure 3-33 1 Intermediate shaft gear 2 Roller bearing

3.1.10 Removal of the Torque Converter Pressure Regulating Valve 1. Remove the screw plug fixing the valve sleeve component.

1

2

3

Figure 3-34 1 Valve sleeve component 2 Screw plug (CM30*1.5)

3 O-ring 2. After taking out the valve sleeve components (valve sleeve, valve stem, pressure spring and gasket) from the torque converter pressure valve hole of the transmission body, the removal is completed.

1

2

3

Figure 3-35 1 Pressure spring

2 Valve stem

3 Valve sleeve 38

ANDVANCE WG180 Transmission Service Manual

3.2 Transmission Assembly Component Removal 3.2.1 Main PTO Removal 1. Remove the retainer ring fixing the driving gear on the PTO shaft with the snap ring pliers.

1 Figure 3-36 1 Retainer ring 2. Remove the snap ring fixing the inner ring of the ball bearing on the PTO shaft.

1

2

Figure 3-37 1 Snap ring 2 Ball bearing 3. Expand and fix the ball bearing elastic retainer ring with the screwdriver and knock the PTO shaft from another side.

1 Figure 3-38 1 Elastic retainer ring ×2

39

ANDVANCE WG180 Transmission Service Manual 4. Take down the driving gear, PTO shaft and ball bearing.

1

2

3

Figure 3-39 1 Driving gear

2 PTO shaft

3 Ball bearing 5. After taking down two retainer rings fixing the needle bearing on the PTO wheel hub and removing two elastic retainer rings fixing the ball bearing, the removal is completed.

1 2 Figure 3-40 1 Retainer ring 2 Needle bearing

3.2.2 Input Component Removal 1. Remove 4 bolts between the variable speed pump and the oil feed flange.

1 Figure 3-41 1 Hexagon head screw (M8*85)×4 40

ANDVANCE WG180 Transmission Service Manual 2. Remove 4 bolts between the variable speed pump and the oil feed flange.

1 Figure 3-42 1 Hexagon head screw (M8*115)×4 3. Knock the output shaft with the copper rod to knock out the variable speed pump.

12 Figure 3-43 1 Copper rod 2 Output shaft 4. Take down the variable speed pump, packing and output shaft and remove the bolt between the variable speed pump cover and the variable speed pump shell.

1

2

Figure 3-44 1 Hexagon head screw×4 2 Output shaft

41

ANDVANCE WG180 Transmission Service Manual 5. Take down the bearing snap ring from the output shaft with the snap ring pliers and remove the ball bearing, piston ring and compensation washer.

1

234

Figure 3-45 1 Ball bearing 2 Piston ring (30×2) 3 Snap ring

4 Compensation washer 6. Knock the output shaft with the copper rod and take down the variable speed pump cover, internal gear and other component.

1

2

Figure 3-46 1 Variable speed pump shell 2 Variable speed pump cover 7. Remove the internal gear of the variable speed pump, output shaft, variable speed pump cover and ball bearing.

1

2

Figure 3-47 1 Internal gear of the variable speed pump 2 Variable speed pump cover 42

ANDVANCE WG180 Transmission Service Manual 8. Take out the external ring gear of the variable speed pump.

1

2

Figure 3-48 1 Variable speed pump shell 2 External ring gear 9. Take down the safety valve of the oil inlet of the torque converter on the oil feed flange, steel ball and pressure spring.

1

2

Figure 3-49 1 Steel ball 2 Pressure spring 10. Take down the snap ring fixing the ball bearing on the drive shaft with the snap ring pliers.

1 Figure 3-50 1 Snap ring 43

ANDVANCE WG180 Transmission Service Manual 11. Knock the drive shaft with the copper rod for removal.

1

2

Figure 3-51 1 Drive shaft 2 Copper rod 12. Take down the driving gear, ball bearing and roller bearing.

1

2

3

Figure 3-52 1 Roller bearing

2 Driving gear

3 Ball bearing 13. Remove the plunger ring from the drive shaft.

1

2

Figure 3-53 1 Drive shaft 2 Plunger ring 44

ANDVANCE WG180 Transmission Service Manual

3.2.3Three Sets of the Clutch Removal Attention The KVK1 and KRK2 clutch disassembling process can follow the K3K4 clutch assembling process, which is omitted here. 1. Take down the K4 clutch gear bearing. Place the bearing aside. 1 Figure 3-54 1 Needle bearing

1

2. Take down the lining seal ring component and roller of the needle bearing of the K3 clutch gear.

2

Figure 3-55 1 Roller×12 2 K3 clutch gear 3. Take down the gear, washer and thrust washer of the K3 clutch.

1

2

Figure 3-56 1 Washer 2 Thrust washer

45

ANDVANCE WG180 Transmission Service Manual 4. Take down the gear and thrust washer of the K4 clutch.

1

2

3

Figure 3-57 1 Thrust washer

2 K4 clutch gear

3 Thrust washer 5. Take down the elastic retainer ring of the K4 clutch.

1 Figure 3-58 1 Elastic retainer ring 6. Take out the bearing plate of the K4 clutch.

1 Figure 3-59 1 Bearing plate 46

ANDVANCE WG180 Transmission Service Manual 7. Take out the external and internal friction linings of the K4 clutch.

1

2

Figure 3-60 1 Internal friction lining 2 External friction lining 8. Install the clutch tooling onto the clutch.

1 Figure 3-61 1 Clutch spring removal tooling （2938001826）（2938001827）

1

9. Screw down the tooling nut and press down the clutch spring.

2

Figure 3-62 1 Clutch spring removal tooling 2 Pressure spring 47

ANDVANCE WG180 Transmission Service Manual 10. Take down the retainer ring fixing the pressure spring with the snap ring pliers.

1 Figure 3-63 1 Retainer ring 11. Take out the retainer ring and the guide ring of the K4 clutch in turn.

1

2

Figure 3-64 1 Retainer ring 2 Guide ring 12. Take out the upper guide ring, pressure spring and lower guide ring on the K4 clutch in turn.

1 2 Figure 3-65 1 Guide ring 2 Pressure spring

48

ANDVANCE WG180 Transmission Service Manual 13. Take out the piston and seal ring of the K4 clutch.

1

2

3

Figure 3-66 1 Seal ring

2 K3 clutch piston

3 Seal ring 14. The removal of the K4 clutch is completed.

Figure 3-67 15. Take out the elastic retainer ring of the K3 clutch bearing plate.

1 Figure 3-68 1 Elastic retainer ring

49

ANDVANCE WG180 Transmission Service Manual 16. Take out the K3 clutch bearing plate.

1 Figure 3-69 1 Bearing plate 17. Take out the external and internal friction linings of the K3 clutch.

1 2 Figure 3-70 1 Internal friction lining 2 External friction lining 18. Press down the K3 clutch pressure spring with the clutch spring removal tooling.

1

2

Figure 3-71 1 Clutch spring removal tooling 2 Pressure spring

50

ANDVANCE WG180 Transmission Service Manual 19. Take down the retainer ring fixing the pressure spring with the snap ring pliers.

1 Figure 3-72 1 Retainer ring 20. Take out the retainer ring and guide ring of the K3 clutch in turn.

1

2

Figure 3-73 1 Retainer ring 2 Guide ring 21. Take out the upper guide ring, pressure spring and lower guide ring of the K3 clutch in turn.

1

2

Figure 3-74 1 Guide ring 2 Pressure spring

51

ANDVANCE WG180 Transmission Service Manual 22. Take out the piston and seal ring of the K3 clutch.

1 2

3

Figure 3-75 1 Seal ring

2 K4 clutch piston

3 Seal ring 23. Remove the needle bearing and check valve of the K3K4 clutch.

1

2

Figure 3-76 1 Check valve 2 Needle bearing 24. The K4 clutch removal is completed.

Figure 3-77

52

ANDVANCE WG180 Transmission Service Manual

4 Transmission Assembly 4.1 Assembling of the Transmission Assembly 4.1.1 Three Sets of the Clutch Assembly Attention The KVK1 and KRK2 clutch assembling process can follow the K3K4 clutch assembling process,

1

2

which is omitted here.

Figure 4-1

1. Knock the needle bearing into the clutch bearing hole and install the retainer ring.

1 Retainer ring

Attention

2 Needle bearing

Before assembling, clean all parts. 2. Install the seal ring into the piston groove and install the piston component into the clutch cylinder. Attention When installing the seal ring, the sealing surface of the seal ring shall face towards the pressure oil surface. 1

2

Figure 4-2 1 Seal ring 2 Seal ring

1

2

Figure 4-3 1 Pressure oil surface 2 Friction lining

53

ANDVANCE WG180 Transmission Service Manual 3. Place the guide ring and the pressure spring into the clutch cylinder.

1

2

3

Figure 4-4 1 Guide ring

2 Pressure spring

3 Guide ring

4. Place the guide ring and the retainer ring into the clutch cylinder.

1

2

Figure 4-5 1 Guide ring 2 Retainer ring 5. Install the spring removal and assembling tooling onto the clutch.

1 Figure 4-6 1 Clutch spring removal and assembly tooling (2938001826) (2938001827)

54

ANDVANCE WG180 Transmission Service Manual 6. Screw down the nuts on the tooling and press down the clutch spring.

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

1

2

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

1 Figure 4-9 1 External friction lining

55

ANDVANCE WG180 Transmission Service Manual 9. Place the internal friction lining into the K3 clutch. Attention Firstly, place the external friction lining into the K3 clutch and then place the external and internal friction linings in turn.

1 Figure 4-10 1 Internal friction lining 10. Place the bearing plate into the K3 clutch.

1 Figure 4-11 1 Bearing plate 11. Install the elastic retainer ring into the K3 clutch.

1 Figure 4-12 1 Elastic retainer ring 56

ANDVANCE WG180 Transmission Service Manual 12. Slightly push the K3 clutch friction lining upwards to the upper limit position with the screwdriver; record the clutch piston stroke which is measured by the dial indicator, and the K3 clutch assembling is completed. Attention Press the dial indicator contact onto the bearing plate and select different positions for three measurements at the least. The dial indicator reading is the K3 clutch piston stroke. Select the internal friction lining with different thickness to ensure that ：

1 Figure 4-13

the piston stroke （Three Sets of the Clutch are same）is 1.9mm~2.2mm.

1 Dial indicator

13. Knock the K4 clutch needle bearing into the clutch bearing hole and install the retainer ring.

1

2

Figure 4-14 1 Retainer ring 2 Needle bearing 14. Install the seal ring into the K4 clutch piston groove. Attention When installing the seal ring, the sealing surface of the seal ring shall face towards the pressure oil surface. (Refer to Figure 4-3)

1 Figure 4-15 1 Seal ring 57

ANDVANCE WG180 Transmission Service Manual 15. Install the K4 clutch piston into the clutch.

Figure 4-16 16. Install the guide ring and the pressure spring into the clutch cylinder.

1

2

3

Figure 4-17 1 Guide ring

2 Pressure spring

3 Guide ring 17. Install the guide ring and the retainer ring.

1

2

Figure 4-18 1 Guide ring 2 Retainer ring

58

ANDVANCE WG180 Transmission Service Manual 18. Install the clutch spring removal and assembling tooling onto the clutch. Screw down the nuts on the clutch removal tooling and press down the clutch spring.

1 Figure 4-19 1 Clutch spring removal and assembling tooling (2938001826) (2938001827) 19. Install the retainer ring into the cylinder clip groove of K4 clutch with the snap ring pliers. Take down the clutch spring removal and assembling tooling.

1

2

Figure 4-20 1 Retainer ring 2 Snap ring pliers 20. Firstly, place the external friction lining into the K4 clutch. Attention During use, if the external friction lining of the clutch is worn out and more than 2/3 parts of the pattern groove of the friction lining are worn out, timely replacement shall be done. 1 Figure 4-21 1 External friction lining

59

ANDVANCE WG180 Transmission Service Manual 21. Install the internal friction lining into the K4 clutch.

1 Figure 4-22 1 Internal friction lining 22. Place the bearing plate into the K4 clutch.

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

1 Figure 4-24 1 Elastic retainer ring

60

ANDVANCE WG180 Transmission Service Manual 24. Slightly push the K4 clutch friction lining upwards with the screwdriver and record the clutch piston stroke which is measured by the dial indicator. Attention Press the dial indicator contact onto the bearing plate and select different positions for three measurements at the least. The dial indicator reading is the K4 clutch piston stroke. Select the internal friction lining with different thickness to ensure that the piston stroke is stroke: 1.9mm~2.2mm.

1 Figure 4-25 1 Dial indicator

25. Install the thrust washer into the K3 clutch gear. Attention The thrust washer shall be coated with grease.

1

2

Figure 4-26 1 K3 clutch gear 2 Thrust washer 26. Install the gasket and the thrust washer into the K3 clutch.

1

2

Figure 4-27 1 Thrust washer 2 Washer

61

ANDVANCE WG180 Transmission Service Manual 27. Install the K3 clutch gear. Attention Before installing the gear, it is necessary to perform alignment to the internal friction lining splines of the clutch.

1 Figure 4-28 1 K3 clutch gear 28. Install the lining seal ring component and roller of the internal needle bearing of the K3 clutch gear. Attention The roller shall be coated with grease to prevent the clutch assembly dropping when being installed into the transmission body.

1 Figure 4-29 1 Roller×12 29. Install the thrust washer into the K4 clutch cylinder clip and gear. Attention The thrust washer shall be coated with grease.

1

2

Figure 4-30 1 Thrust washer 2 Thrust washer 62

ANDVANCE WG180 Transmission Service Manual 30. Install the needle bearing into the K4 clutch gear.

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

1 Figure 4-32 1 K4 clutch gear

4.1.2 Main PTO Assembly 1. Install the needle bearing into the wheel hub of the output transmission body and then install the retainer ring.

1

2

Figure 4-33 1 Retainer ring×2 2 Needle bearing 63

ANDVANCE WG180 Transmission Service Manual 2. Install the retainer ring into the transmission gear hole and then install the gear into the wheel hub of the output transmission body.

1

2

Figure 4-34 1 Transmission gear 2 Retainer ring 3. Insert the PTO shaft into the gear hole; knock in the ball bearing, and insert 2 elastic retainer rings and 1 retainer ring.

1

2

Figure 4-35 1 Ball bearing 2 Elastic retainer ring×2 4. The PTO assembling is completed.

1 Figure 4-36 1 Retainer ring

64

ANDVANCE WG180 Transmission Service Manual

4.1.3 Input Part Assembly 1. Knock the ball bearing onto the auxiliary driving shaft.

1

2

Figure 4-37 1 Ball bearing 2 Auxiliary driving shaft 2. Install the flat key of the internal gear of the gear pump on the shaft and cover it with the oil pump.

1 Figure 4-38 1 Internal gear of the gear pump 3. Knock another ball bearing into the oil pump bearing hole. Attention Ensure that the auxiliary driving shaft can flexibly rotate.

1 Figure 4-39 1 Ball bearing 65

ANDVANCE WG180 Transmission Service Manual 4. Install the clip for shaft and buckle seal ring.

12 Figure 4-40 1 Clip 2 Seal ring 5. Knock the needle bearing into the bearing hole of the pump impeller bearing seat and then install the oil seal. Attention Replace the old oil seal with a new one.

1

2

Figure 4-41 1 Oil seal Φ75 2 Needle bearing 6. Install the roller bearing into the bearing hole of the oil feed flange. Attention Before assembling, it is necessary to clean the oil feed flange.

1

2

Figure 4-42 1 Roller bearing 2 Oil feed flange 66

ANDVANCE WG180 Transmission Service Manual 7. Install the input gear into the oil feed flange and adjust the gear clearance.

1 Figure 4-43 1 Input gear 8. Install the seal ring onto the drive shaft.

1

2

Figure 4-44 1 Drive shaft 2 Seal ring 9. Insert the drive shaft and install the ball bearing.

1

2

Figure 4-45 1 Drive shaft 2 Ball bearing

67

ANDVANCE WG180 Transmission Service Manual 10. Use the depth gauge to measure : two ends’ distance and write down: h

1

2

Figure 4-46 1 Oil feed flange end 2 Bearing end 11. Use the depth gauge to measure : two ends’ distance and write down: H Attention the output shaft bearing is：D=H-h Install the adjustable washer into the gear pump hole. Ensure that the axial run-out clearance of the output shaft bearing is: 0.2mm~0.4mm. 1

2

Figure 4-47 1 Oil pump bearing hole end

2Oil pump joint end 12. Install the steel ball and the pressure spring into the safety valve hole of the torque converter on the oil feed flange.

1

2

Figure 4-48 1 Steel ball Φ20mm 2 Pressure spring 68

ANDVANCE WG180 Transmission Service Manual 13. Place the oil pump packing on the oil feed flange oil pump surface; coat it with grease, and insert the oil pump component into the oil feed flange component hole.

1 Figure 4-49 1 Oil pump packing 14. Screw down the bolt between the oil pump component and the oil feed flange component. 23N.m

1

2

Figure 4-50 1 Hexagon head screw (M8*115)×4 1 Hexagon head screw (M8*85)×4 15. Place the packing of the pump impeller bearing seat on the oil feed flange surface.

1 Figure 4-51 1 Packing 69

ANDVANCE WG180 Transmission Service Manual 16. After knocking in the pump impeller bearing seat and screwing down the bolt between the pump impeller bearing seat and the oil feed flange, the assembling is completed. 23N.m

1 Figure 4-52

4.2 Transmission Assembly

1 Hexagon head screw (M8*28)×8

4.2.1 Output Part Assembly 1. Place the output shaft gear; install the baffle plate and the oil shield into the transmission body, and then fix them with two bolts (M8*16) and the washer.

1

2

3

Figure 4-53 1 Output shaft gear

2 Baffle plate

3 Oil shield 2. Knock out the roller bearing and place it at the output gear shaft end, and then place it into the oil shield; install the spacer sleeve and insert the output shaft.

Figure 4-54

70

ANDVANCE WG180 Transmission Service Manual 3. Adjust the washer in turn. Attention Select the adjustable washer with different thickness, so as to ensure that the axial clearance of the bearing is 0.1mm~0.3mm.

1 Figure 4-55 1 Output shaft 4. Install the snap ring.

1

2

Figure 4-56 1 Adjustable gasket 2 Snap ring 5. Install the oil seal into the transmission body with the tooling. Attention Replace the removed oil seal with a new one.

1

2

Figure 4-57 1 Oil seal 2 Oil seal assembling tooling (2938001833) 71

ANDVANCE WG180 Transmission Service Manual 6. Install the output flange and pressure plate, and screw tight the bolts 2-M10×30. 46N.m

1 Figure 4-58 1 Output flange 7. Install the output flange, O-ring, distance washer and pressure plate in turn.

1 Figure 4-59 1 Lock washer assembling tooling (2938001838) 8. Install the parking brake flange.

1 Figure 4-60 1 Parking brake flange

72

ANDVANCE WG180 Transmission Service Manual 9. Lock the locking plate after amounting the brake assembly, the brake drum wheel, the pressure plate and screwing tight the bolts.

1 Figure 4-61 1 Parking Brake

4.2.2 Intermediate Assembly

Shaft

Component

1. Install the roller bearing into the bearing hole of the intermediate shaft gear and fix it with grease for standby.

1 2

3

4

Figure 4-62 1 O-ring 2 Intermediate shaft 3 Roller bearing 4 Intermediate shaft gear 2. Place the intermediate shaft gear component into the gear groove of the transmission body; insert the intermediate shaft and install the gasket.

1

2

Figure 4-63 1 Intermediate shaft gear 2 Gasket

73

ANDVANCE WG180 Transmission Service Manual 3. Install the screw and then install the sealing washer. 80N.m

1 Figure 4-64 1 Head cap screw×1

4.2.3 Torque Converter Pressure Control Valve Assembly 1. Install the pressure spring and the valve core into the valve sleeve hole.

1

Install the O-ring onto the screw plug, and then install the valve sleeve component into the pressure maintaining valve hole of the torque converter of the transmission body and screw down the screw plug; after that, the assembling is completed.

2

Figure 4-65 1 O-ring 2 Screw plug

4.2.4 Assembling of the K3K4 Clutch Assembly 1. Install the O-ring and piston ring on the K3K4 clutch shaft.

1

2

Figure 4-66 1 Piston ring×3 2 O-ring

74

ANDVANCE WG180 Transmission Service Manual 2. Place the clutch transmission body.

assembly

into

the

about 15kg Attention When placing the clutch, use the tooling and jack up the bottom of the clutch to avoid its falling.

1 Figure 4-67 1 Clutch assembling tooling 2938001832 3. Overturn the transmission to make it be in a horizontal position, and then install the clutch assembling tooling.

Figure 4-68

4.

Use the depth gauge to measure : a、The bearing step Of clutch shaft and write down : height h。 b、The housing surface to the Roller of the needle bearing of the K3 clutch and write down: height H. Attention

The axial clearance of the clutch assembly: 1

2

Figure 4-69 1 K3K4 clutch shaft 2 Roller of the needle bearing of the K3 clutch

A=H-h Select the adjustable washer with different thickness, so as to ensure that the axial clearance of the clutch assembly is: 0.1mm~0.3mm.

75

ANDVANCE WG180 Transmission Service Manual 5. Take out the tooling; install the K4K3 clutch shaft and screw down the nut fixing the clutch assembly. Attention The K3K4 clutch gear can flexibly rotate. 23N.m

Figure 4-70

4.2.5 KRK2 、KVK1Clutch Assembly 1. Amount the clutch assemblies K2+KR and K1+KV onto their separate hole on the housing and adjust the bearing clearance to be between 0.1-0.3mm. Then insert shafts K2 and K1and fix them with bolts 3-M8×18. Attention

1

2

Figure 4-71

Select the adjustable washer with different thickness, so as to ensure that the axial clearance of the clutch assembly is: 0.1mm~0.3mm.

1 KVK1 clutch assembly 2 KRK2 clutch assembly

4.2.6 Auxiliary PTO Assembly 1. Place the transfer gear into the transmission body.

1 Figure 4-72 1 Transfer gear

76

ANDVANCE WG180 Transmission Service Manual 2. Knock in the PTO shaft to make the retainer ring on the shaft fits with the gear.

1

2

Figure 4-73 1 PTO shaft 2 Retainer ring 3. Install the bearing snap ring on the PTO shaft with the snap ring pliers.

1 Figure 4-74 1 Snap ring 4. Assemble the PTO end cover and install the additional packing. Screwing down the bolt between the PTO end cover and the transmission body. Attention Replace the removed packing with a new one. 16N.m

1 Figure 4-75 1 PTO end cover 77

ANDVANCE WG180 Transmission Service Manual

4.2.7 Input Component Assembly 1. Install the input device onto the transmission body; install the additional packing and knock it in with the copper rod. Attention Upon installation, screw in two bolt positioning thread holes. Replace the removed packing with a new one. 1 Figure 4-76 1 Input component 2. Assemble the lubricating oil pipe component and screw down the hollow screw between the oil pipe and the transmission body. 34±5N.m

1 Figure 4-77 1 PTO lubricating oil pipe component 3. Assemble the connecting shell and knock it in with the copper rod. Attention Upon assembling, align it at the positioning pin hole. Upon knock in, ensure that the force which is applied on the connecting shell is uniform.

1 Figure 4-78 1 Torque converter connecting shell

78

ANDVANCE WG180 Transmission Service Manual 4. After screwing down the bolt between the transmission body, flange and connecting shell, the assembling is completed. Attention Align at the pin position, and repeatedly screw down the bolt in accordance with the diagonal sequence. 68N.m 1

2

Figure 4-79 1 Tension pin×2 2 Hexagon head screw×14

4.2.8 Main PTO Component Assembly 1. After installing the main PTO component and screwing down the bolt and nut between the PTO and the transmission body, the assembling is completed. Attention Repeatedly screw down the bolt in accordance with the diagonal sequence. 1

23N.m

2

Figure 4-80 1 Hexagon head screw×10 2 Hexagonal nut (M8)×1

4.2.9 Oil Filter Assembly 1. Screw down the oil filter.

Figure 4-81

79

ANDVANCE WG180 Transmission Service Manual

4.2.10 Transmission Assembly

Control

Valve

1. Place a paper gasket, a lower baffle, a paper gasket and a oil delivery plate onto the surface of the valve plate on the housing and fix them with the bolt 3-M8×30 and socket screws 3-M8×45 and 6-M8×35. Attention Replace the removed paper pad with a new one. 1

2

Figure 4-82

Before assembling, clean the valve plate, oil passage plate and baffle plate of the transmission body. 20N.m

1 Oil passage plate 2 Paper pad

2. Place a paper gasket, a upper baffle, a paper gasket and a pilot valve onto the oil delivery plate, and fix them with the bolt 3-M8×30 and socket screws 3-M8×45 and 6-M8×35. Attention Replace the removed paper pad with a new one. Figure 4-83

Repeatedly screw down the bolt in accordance with the diagonal sequence. 20N.m 3. The six oil-holes on the oil delivery plate, from the top down, are K2,K1, K3, K4, KR,KV.( Pipe KR and KV is determined by the rotation direction of the differential gear on the back axle of each engine.) Connect them respectively with oil-line holes on shaft K1, K2 and K3. Attention

Figure 4-84

After adjusting the hose position, screw down the bolt again. 55±5.5N.m

80

ANDVANCE WG180 Transmission Service Manual

4.2.11 Torque Converter Assembly 1. After installing the intermediate ring and the torque converter into the connecting shell, the assembling is completed. About 20kg Attention

1

2

As there is no axial positioning after installing the torque converter, fixing measures shall be adopted to avoid its falling.

Figure 4-85 1 Torque converter 2 Intermediate ring

81

ANDVANCE WG180 Transmission Service Manual

5 Malfunction Diagnosis and Troubleshooting 5.1Malfunction Diagnosis and Semi-Automatic Gear Controller

Troubleshooting

of

the

EST

Table 5-1 No.

Troubles

Causes

Remedies

1

Engine cannot be started

1) Abnormal power voltage

1) Check the voltage, if battery

2) Troubles in starting relay or other related apparatuses

losses too much power, charge firstly;

3) DW-4 handle is not at neutral

2) Check starting circuit of the

4) Bad contact of EST plugs or

engine, to see any bad connection

EST troubles

or damaged elements 3) Put selector handle to neutral, when the starting relay on the engine should be engaged 4) If AS has no signal (voltage on line 0 is not +24V), it shows output

of

EST

is

failure.

Reconnect the plugs once, making sure right contact. If it still does not work, replace EST. 2

Vehicle cannot run at any

1) Open or short circuit

gear

2) Damaged solenoid valves; In

1)

Disconnect the plugs, resistance of solenoid valves

these two cases, ECU will

within 60~70ohm. Replace

output alarming, lamp H2

solenoid valves if necessary;

flash and tick and tock can be

2)

heard inside the box

4) Damaged EST-4 or bad contact of connectors 5) Troubles in oil circuit or other

worn-out

in

necessary 3)

Check if contact of leading

-out plugs of DW-4 and EST correct, if loosened, press tightly. 4)

mechanical failures

Replace DW-4 selector or EST ECU

5)

Replace hydraulic control valve

82

any

connection cables. Replace if

3) Damaged DW-4 selector handle or bad contact of plugs

Check

ANDVANCE WG180 Transmission Service Manual 3

Vehicle cannot run at gears

1)

one and two but can run at gears three and four

Choked brake switch BR or emergent brake switch BR2;

2)

3)

1) Check if two switch work freely; if not, do some treatment;

Wire between BR and +24V

2) Disconnect lines to BR or

has short circuit;

BR2, if gear normal, check wiring

Damaged solenoid valve M4

and remove troubles 3) Replace M4

4.

No

high-speed

gears.

1) It normally happens in types

Speed at gear 3 or 4 is

with speed sensor. The cause is

identical to that at gear 1 or

unconnected or bad contacted or

2

damaged sensor.

1)

mentioned above. Replace if it damaged 2)

2) Bad contact of DW-4 plugs or damaged selector 5.

No forward gears 1, 2 and 3

1) Damaged internal elements of selector DW-4

Inspect the sensor as

Check

wiring

to

sensor.

Repair if damaged. 3)

Replace selector DW-4

1) Replace selector 2) Replace solenoid valve M3

2) Damaged solenoid valve M3 6.

7.

No reverse

1) Damaged solenoid valve M1

1) Replace solenoid valve M1

2) Damaged selector

2) Replace selector

Vehicle is sometimes in

1) Unstable power supply

1) Check vehicle power supply

gear and sometime out

2) Bad contact somewhere

and remove voltage fault

in connection plugs

2) Check all plugs, tidy and

3) Unstable solenoid valves or electric control unit

83

press all connectors 3) Replace electric control unit

ANDVANCE WG180 Transmission Service Manual

5.2Malfunction Diagnosis and Troubleshooting of the Transmission Table 5-1 No.

1

2

Symptom

The engine doesn’t work.

Low pressure at all the speeds.

Cause 1、 Fail to start the circuit. （such as power supply, electric lock, relay or engine.） 2、 The lever is not placed at the neutral position. 3、 Fuse on the engine to the controlling circuit burnt. 4、 Loose contact of the lever plug or lever fault. 5、 Loose contact of the connection-peg in the electric-control box or electro-control box fault. 1、 Pressure gauge failure. 2、Insufficient tight torque of the shift controlling valve bolt. 3、 Broken spring of main pressure valve. 4、 Worn shifting pump. 5、 Chips fall in to the transmission control valve or the valve blocked.

3

Low display pressure at ahead speed1,2, 3 while the rest is normal.

1、Internal releasing in ahead gear of the clutch.

4

Low display pressure at astern speed1, 2, 3 while the rest is normal.

1、Internal releasing in astern gear of the clutch.

5

Low pressure at the first speed of both ahead and astern while the others are normal.

1、Internal releasing at the first speed of the clutch.

84

Troubleshooting 1、 Check the engine circuit and refer to the “starting of engine circuit” on the instruction. 2、 Place the lever at the neutral position. 3、 Renew the fuse. 4、 Settle the connection-peg or check the lever circuitry for connection. 5、 Settle the connection-peg or handle it as the way for electro-control box failure.

1、Replace the pressure gauge. 2、Increase the tight torque of the bolt to M8 class 20Nm. 3、Replace. 4、Replace the shifting pump. 5、Replace the filter and clean the control valve.

1、Block the oil circuit to KV clutch after stalling the engine, then restart the engine, and shift to the ahead speed 1, 2, 3. If the shifting pressure rise to normal value, we can draw the conclusion that internal releasing happens to the clutch of this speed. Carry out mechanical maintenance to the transmission. 1、 Block the oil circuit to KR clutch after stalling the engine, then restart the engine, and shift to the astern speed 1, 2, 3. If the shifting pressure rise to normal value, we can draw the conclusion that internal releasing happens to the clutch of this speed. Carry out mechanical maintenance to the transmission. 1、 Block the oil circuit to K1 clutch after stalling the engine, then restart the engine, and shift to the astern and ahead speed 1. If the shifting pressure rise to normal value, we can draw the conclusion that internal releasing happens to the clutch of this speed. Carry out mechanical maintenance to the transmission.

ANDVANCE WG180 Transmission Service Manual

6

Short shifting time for all the speeds。

7

Long shifting time for all the speeds.

8

High oil temperature of the torque converter.

1、Broken O-shape ring on the throttle plug screw. 2、The tight torque of the bolt on pressure control valve is not in the specified range. 1、Choked throttle plug screw. 2、Stuck pressure control valve.

1、Failed oil sensor. 2、Failed temperature gauge. 3、Insufficient oil level. 4、There are air in oil radiator. 5、Oil circuit from the torque converter to radiate or is not smooth. 6、Insufficient rejecting ability of the radiator. 7、Choked back pressure valve of the torque converter.

1、Insufficient oil level. 2、Elastic board between the engine and the torque converter teared, or power connection failure from the torque converter to the transmission input gear. （rarely） 。 3 、 Circuit failure of the machine. 4、Too low pressure of the transmission. 5、Broken solenoid valve. 6、Broken shifting lever. 7、Failed electro-control box.

9

The vehicle does not move at any speed.

10

The vehicle does not move at speed 1 and 2.

1、 Broken switch of emergency brake pressure or parking brake pressure. 2 、 Invalid solenoid valve. （M4）

11

The vehicle moves at the speed of 2nd gear under 3nd or forth gear.

1、Damaged speed sensor.

85

1、Replace the O-shape ring. 2、M8 class tight torque of the bolt is 20Nm.

1、Clean and dredge it. 2、Clean and check it。

1、Replace. 2、Replace. 3、Check the oil level and fill in oil in correct way. 4、Exhaust air through the exhausting hole on the radiator.(for engines with exhausting holes.) 5、Check if the oil circuit from the radiator to the transmission and the radiator are choked. 6、Check if the radiator is capable of rejecting heat. For example, check the engine fan belt for tightness, and check the radiate appearance for feculence. 7、Check the hose joint from the transmission to the radiator. If it is inserted into the housing by an excessive length, it will stick to the core of backpressure valve, thus choking the valve and resulting in difficulty of the oil circuit. 1、Check the oil level and fill in oil in the correct way. 2、Replace the elastic board or corresponding broken pieces. 3、Check if the voltage of the power supply is normal, if the cable is teared and if the cable plug is loosened. 4、Correct it by the above-mentioned.way 5、Check the resistance value of the solenoid valve, which is to be 65±5ohms. If the resistance value is zero or ∝, the solenoid valve is broken. Replace it. 6、Check and replace it as the service method of lever fault. 7、Check according to the troubleshooting of electro-control box or through PR68 detector. 1、Disconnect the emergency brake pressure switch or the parking brake pressure switch and the circuit. If the first and second speed works under this condition, the switch is broken. Replace it. 2、Replace the solenoid valve. 1、Measure the resistance value of the speed sensor which is to be 1020±100ohms. If it is measured to be 0 or ∝，it is damaged and need replacing.

ANDVANCE WG180 Transmission Service Manual

12

13

14

15

16

The vehicle has no ahead speeds1, 2, 3.

Astern speed does not work.

Unsteady speed

Abnormal sound of the transmission

The vehicle moves back at neutral speed, keeps still at ahead speed 1, 2, 3 and moves normally at astern speed.

1、Internal releasing at ahead clutch. 2、Burnt contact points in the internal circuit of the shifting lever and loose circuit contact. 3、Invalid solenoid.（M3） 。 4、Choked control valve of the transmission. 1、Internal releasing of the astern speed clutch. 2、Burnt contact points in the circuit of the shifting lever and the circuit is out of charge. 3 、 Invalid solenoid valve. （M1） 4、Choked valve. 1、Unsteady power supply to electric control system. 2、Loose contact of the supply circuit for electric control system. 3、Unsteady work of the shifting lever of loose contact of its connection -peg. 4、Insufficient oil level of the transmission。 5、Unsteady work of the solenoid valve or electro -control box or loose Contact of its connection-peg. 6、Choked valve. 1、Loosened Connecting bold. 2、Insufficient transmission oil level. 3、Transmission shaft failure that connects the transmission. 4、Elastic board between he engine and the torque converter teared. 5、Internal mechanical failure of the transmission.

1、Fritted astern clutch. 2、Choked valve. 3、Invalid solenoid valve （M1）. 4、Lever fault.

86

1、Follow the method of dealing with internal releasing in clutch. 2、Sort the lever line or replace the lever. 3、Check the resistance value of the solenoid valve, which is to be100±10 ohms. If the resistance value is zero or ∝, the solenoid valve is broken. Replace it. 4、Clear the shifting control valve. 1、Handle it as internal releasing of the clutch. 2、Sort the lever line or replace the lever. 3、Check the resistance value of the solenoid valve, which is to be 65±4、 ohms. If the resistance value is zero or ∝, the solenoid valve is broken. Replace it. 1、 Clear the shifting control valve.

1、Check the supply system of the machine. 2、Search in accordance the engine circuit. 3、Sort the connection-peg of the shifting lever or replace it. 4、Add oil by the correct method. 5、Sort the connection-peg. 6、Clear.

1、Check and fix it. 2、Add oil to normal oil level. 3、Check the transmission oil. 4、Replace the elastic board. 5、Dismantle the transmission shaft and check for abnormal sound after dismantlement. If so, check the transmission for mechanical failure.

1、Block the oil circuit of KR clutch after stalling the engine, then restart it. If the vehicle moves at astern speed, we know that the astern clutch is fritted and needs mechanical maintenance. 2、Clear. 3、Replace the solenoid valve. 4、Replace the lever.

ANDVANCE WG180 Transmission Service Manual

17

The vehicle moves head at neutral speed, remains still at astern speed and moves normally at speed 1, 2, 3.

1、Fritted ahead clutch. 2、Choked valve. 3 、 Invalid solenoid valve. （M3） 4、Lever fault.

18

The vehicle only moves at ahead speed 1 and astern speed 1. It remain still at other speeds.

1、Fritted K1 clutch. 2、Choked valve。 3、Invalid solenoid valve. 4、Lever fault.

87

1、Block the oil circuit of KV clutch after stalling the engine, then restart it. If the vehicle moves at ahead speed 1, 2, 3, we know that the ahead clutch 1 is fritted and needs mechanical maintenance. 2、Clear. 3、Replace the solenoid valve. 4、Replace the lever. 1、Block the oil circuit of K1 clutch after stalling the engine, then restart it. If the vehicle moves at astern speed1 and amend speed 1, we know that the clutch of speed 1 is fritted and needs mechanical maintenance 2、Clear. 3、Replace the solenoid valve. 4、Replace the lever.