CAGF5-90 Transmission Service Manual

I
CAGF5-90 Transmission Service Manual
FOREWORD
This manual briefly introduces working principle and service manual of the CAGF5-90
transmission(CA5-50GF05 transmission also refer it), and provides maintenance technics and
standard requirements of the transmission, which can help the serviceman profoundly understand
how to disassemble and assemble the transmission, and also help to lay a solid technical foundation
for the serviceman to diagnosis and solve the faults.
ATTENTION
The parts and components that mentioned in this manual may change along with
product improvements, but we do not promise to inform the changes of products
that have been sold, please consult or ask Shandong Lingong Construction
Machinery Co. Ltd for the updated details.
I
880×1230 mm 16# 18pieces
1st Edition in 2014. 12 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
CONTENT
1 GENERAL .................................................................................................................. 1
1.1Safety Precautions .................................................................................................. 1
1.2Marks ...................................................................................................................... 2
1.3Tightening Torque of Main Bolts of Transmission ................................................ 3
1.4Special tool for service ........................................................................................... 4
2 TRANSMISSION SYSTEM ...................................................................................... 5
2.1Main Technical Parameters of Transmission ......................................................... 5
2.2Summary of Transmission ...................................................................................... 5
2.3Structure Description of Transmission ................................................................... 6
2.4Shifting Principle of Transmission ......................................................................... 8
2.4.1Structure of Transmission.............................................................................. 8
2.4.2Transmission Line of Each Gear ................................................................... 8
3 Lubrication and Maintenance of Transmission ........................................................ 10
3.1Lubrication of Transmission................................................................................. 10
3.2Maintenance of Transmission............................................................................... 10
3.3Precautions of Transmission Use ......................................................................... 11
4 Fault Diagnosis of Transmission and Analysis Causes ............................................ 12
4.1Base Program of Fault Diagnosis ......................................................................... 12
4.2Analysis of Common Failure Cause and Elimination Methods ........................... 13
5 Disassembly of Transmission ................................................................................... 15
5.1Announcement of Disassembly and Dismantlement of Transmission Assembly 15
5.2Disassembly of Transmission ............................................................................... 15
5.3Disassembly of assembly ..................................................................................... 16
5.3.1Disassembly of Rear Transmission Assembly ............................................ 16
5.3.2Disassembly of Clutch Separation Structure ............................................... 18
5.3.3Disassembly of Top Cap Assembly ............................................................ 19
5.3.4Disassembly of Upper Cover Assembly ..................................................... 19
I
5.3.5Disassembly of Primary Shaft Assembly .................................................... 19

5.3.6Disassembly of Rear bearing cap, Reverse Idler Gear and The Second Shaft
Assembly ...................................................................................................... 21
5.3.7Disassembly of Intermediate Shaft Assembly ............................................. 24
5.4Disassembly of Assembly Parts ........................................................................... 24
5.4.1Disassembly of Rear Transmission Assembly ............................................ 24
5.4.2Disassembly of Top Cap Assembly............................................................. 29
5.4.3Disassembly of Upper Cover Assembly...................................................... 33
6 Assembly of Transmission ....................................................................................... 34
6.1Announcement of Assembly of Transmission ..................................................... 34
6.2Disassembly of assembly ...................................................................................... 34
6.2.1Assembly of Rear Transmission Assembly ................................................. 34
6.2.2Assembly of Rear Transmission Assembly ................................................. 37
6.2.3Assembly of intermediate shaft Assembly .................................................. 42
6.2.4Assembly of Upper Cover Assembly .......................................................... 43
6.2.5Assembly of Top cap Assembly .................................................................. 45
6.3Assembly of assembly .......................................................................................... 49
6.4Assembly of Transmission ................................................................................... 58
7 Cleanout and Inspection of Parts .............................................................................. 60
7.1Cleanout of parts ................................................................................................... 60
7.2Parts Inspection ..................................................................................................... 60
II
1 GENERAL
1.1 Safety Precautions
Important Safety Notes

Maintenance and repair is vitally important for safety operation of the machine. This
manual mainly expounds techniques about how to correctly disassemble and assemble the
transmission assembly.
To protect related personnel against injury, this manual uses as safety label, for
precautions marked with this label, please be careful during the operation and must never
on any account be negligent. For operations that possible dangers are involved, firstly pay
attention to your own safety and necessary security measures shall be taken.
Safety Tips
In the process of assembly and disassembly, wrong operation method may damage the parts or
components, shorten the service life and deteriorate the performance of the machine, even brings
potential safety hazard. Therefore, before assembling and disassembling each component, please
read related content in this manual carefully.
1. The parameters, graphs and related contents in this manual are applicable to products of standard
configuration. As for the updated products, please consult our company or refer to related
materials.
2. In repair workshop, special placing area should be should be designated for the removed parts,
components and tools, where the corresponding tools and components should be placed orderly.
Meanwhile, be sure to keep the operation area clean and make sure there is no oil dirt or
pollutant. Smoking is strictly forbidden during the operation and fire extinguishing devices
should be in preparation.
3. Welding operation should be performed by well trained and experienced personnel. Be sure to
wear gloves, baffles, goggles, hats and work clothes during welding operation.
4. Before disassembling the torque converter-transmission assembly, the external surface of which
must been cleared up to avoid polluting the parts in the process of disassembling.
5. Always wear safety shoes and safety helmet during the operation. Never wear unqualified work
clothes, and be sure to button the clothes neatly. When knocking parts/components with copper
1
rod, be sure to wear goggles.

6. The disassembled parts/components could be cleaned with petrol, gasoline and water-based oil
cleaner.
7. When use the travelling crane or other lifting appliance, firstly check whether the lifting tools
are broken. Make sure the lifting appliance has enough lift range. During lifting operation, be
sure to use specified lifting positions and operate carefully to prevent bumping against other
parts/components. Nobody is allowed to operate or stand under lifting parts/components.
8. For operation requires two or more people, be sure to come up an operating procedure before
the operation to avoid accidents caused by out of step.
9. All tools must be kept properly, and be familiar with their using methods.
10. When aligning two mounting holes, do not put your hands and fingers into the holes. Pay
attention to crushing danger when assembling parts by hand directly.
11. The disassembled parts/components must be inspected. The part with defects that may affect its
service performance must be replaced.
12. Make sure there is no interference after assembling each part/component.
13. When assembling the oil seal and the seal ring, if key grooves, screw holes or shoulder are exist
in the fitting area, be sure to take protective measures to avoid damaging the seal or seal ring.
14. When assembling the parts/components, all tools you use must be matched with threaded
fastener to avoid damaging the screw fasteners.
15. It is not allowed to use pneumatic impact wrench to tighten the joint bodies or screw plugs.
Pre-tighten them by hand first, and then tighten them with specified torque wrench to meet
related torque requirements.
16. When draining the oil in the transmission, loose the oil drain plug slowly to avoid spurting of
oil.
1.2 Marks
In order to emphasize the significance of safety and quality visually, and help the user make best
use of this manual, we design the signs in table 1-1 as marks.
2
Table 1-1
Marks Items Notes
Be careful for the safety during the operation.

Safety
Be quite careful for the safety if there is pressure inside
during the operation.
Emphasize the technical requirements to ensure that the
Attention operation can meet the requirements of standard during
operation.
Weight and installation way of parts or device.
Weight
Carefully select hanging tools and the operation gesture.
Tightening Pay more attention to the tightening torque of assembly
torque parts.
Carefully note the parts need to be coated with grease or
Coating
adhesion agent.
Oil, water Fill a certain amount of water, oil and fuel.
Be careful for the parts where water and oil need to be

Draining
drained, and judge their volume.
1.3 Tightening Torque of Main Bolts of Transmission

Table 1-2
Number Section Specification Tightening Quantity

Torque
1 Bolt of bearing cap of primary shaft and output M12 70-80Nm 8
shaft
2 Bolt of rear bearing cap of transmission and front M12 70-80Nm 12
cover of output shaft
3 Cover plate bolt of reversing idler M10 35-45Nm 12
4 Locking plate bolt of reverse gear shaft M8 30-40Nm 1
5 Locknut of rear-end of the second shaft M42×1.5 330-500Nm 1
6 Fixing bolt of output end of rear transfer-box M42×1.5 330-500Nm 1
7 Fixing bolt of upper cover of transmission M10 50-60Nm 19
8 Fixing bolt of cap of transmission M10 30-40Nm 4
9 Connecting bolt of transmission and clutch housing M18 229-298Nm 8
10 Oil filler plug M30×1.5 130-150Nm 1
11 Oil drain plug M22×1.5 69-100Nm 1
12 Locknut-Intermediate shaft M14×1.5 20-29Nm 1
13 Breather plug M16×1.5 15-20Nm 1
3
1.4 Special tool for service

Table 1-3
Number Designation Diagrammatic sketch Application
Pull device for rear

Disassembly of bearing of
1 bearing of second
output end
shaft
Pull device for rear
Disassembly of rear bearing of
2 bearing of
intermediate shaft
intermediate shaft
Installation of bearing of
3 Setting tool
second shaft
Installation of rear bearing of

4 Setting tool
intermediate shaft
Chest-developer of
5 Disassembly of odometer
odometer
Disassembly of oil seal of

6 Oil seal erector
output end
Disassembly of oil seal of input

7 Oil seal erector
end
4
2 TRANSMISSION SYSTEM
2.1 Main Technical Parameters of Transmission

Table 2-1
Items Parameters/contents
Centre distance Centre distance of main tank160 mm
Max input torque 800Kgm
Weight 400Kg(containing clutch housing but not lubricating oil)
Maneuver form Parallels remote manipulation
Gear stage Three forward gears, two reverse gear
Shifting way The synchronizer gear shift lock ring synchronizer
I II III IV RI RII
Speed ratio
9.22 4.72 2.23 1(Reservation-function) 9.318 4.708
Oil number Gear oil of medium load vehicle80W/90 或 85W/90(GL-4)
Lubricant Main tank9.0-9.5 L Auxiliary tank5.5-6.0 L
Adaptable automobile
RS8160/RS8180/RS8200/RS8220/RT8180
modes
2.2 Summary of Transmission

CAGF5-90 is mainly composed of main tank and
auxiliary tank. Main tank is triaxial synchronous
mechanical transmission, and it has three forward
gears and two reverse gears. All gears all have lock
ring flywheel synchronizer. Transmission housing
is unitary. Transmission cover is divided into two
parts, namely upper cover and top cap. The left of
top cap has breather plug. Auxiliary tank also have
breather plug.
Fig. 2-1
5
2.3 Structure Description of Transmission
1/2gear Shift fork- Reverse1/2gear

Shifting synchronizer Shifting Shifting- Gear Gear Gear - synchronizer
fork shaft assembly fork-3/4gear head cover (gear I)(reverse I)(reverse I) assembly Gear
Shifting (reverse II)
fork-3/4gear 192315K
Gear (gear II) Drive gear
assembly
II shaft
NUP315ENR assembly
Oil-seal assembly
front shell
69022
NUP311ENR
I shaft
Idle gear
3/4gear synchronizer assembly
assembly Idle gear shaft
Gear III gear assembly
Intermediate Output shaft
shaft assembly
NJ310E
Intermediate Intermediate Intermediate Reverse shaft
gear shaft gear shaft assembly assembly
( gear III)
Fig2-2 schematic diagram of structure of transmission

Transmission assembly aligns location through primary shaft bearing cap outer cylindrical surface
and clutch housing seam allowance. Fix transmission and clutch housing by 8 bolts.
Primary shaft front end hold up in engine crankshaft flange bearing hole. Rear end hold up in
transmission housing bearing hole by cylindrical roller bearing whose outer ring have snap groove.
There has locating snap ring inside groove to limit axial movement of primary shaft. Primary shaft
bearing cap has oil seal to avoid oil leak.
Primary shaft gear meshes with intermediate shaft reduction gear by interference fit. Transmit
engine power to intermediate shaft. Ⅲ/Ⅳ gear of intermediate shaft is installed onto intermediate
shaft by interference fit. OtherⅠ, Ⅱand reverse gears are made entire with intermediate shaft.
Intermediate shaft front end bears on cylindrical roller bearing. Rear end bears on cylindrical roller
bearing. Rear end bearing limit it axial float by locknut and bearing cap. Front bearing can have
axial movement adapting to the heat-expansion and cold-contraction. Intermediate shaft front end
has sealed cap.
Second shaft hasⅠ,Ⅱ,Ⅲ,Ⅳ and Ⅰ,Ⅱ reverse gears. These gears support on the second shaft
6
journal by different specification needle bearings with different specification holders. All needle
roller bearing of gear are entirety form and rolling needle is cydariform so that shaft can have line
contact at workload condition to reduce second shaft indentation. Needle bearing of Ⅲ andⅡ
reverse gear bear in second shaft by bush. All bushes have small clearance with second shaft.
Second shaft also is equipped with reverse stationary toothholder, Ⅰ , Ⅱ gear stationary
toothholder and ,Ⅲ,Ⅳstationary toothholder. They connect second shaft with involute splines.
Second shaft front end supports in gear hole of primary shaft by needle bearing with no holder. It
consists of 19 rollers. It is limited by 2 distance ring and a snap ring. Second shaft rear end is
equipped with cylindrical roller bearing. They support in rear end holes of transmission housing.
Limit axial float by retainer ring and front housing.
Back of second shaft bearing is equipped with driving gear and connects with second shaft with
involute spline. And it is locked by locknuts with large gaskets.
Second shaft rear end is equipped with oil seal to avoid oil in main tank floating into auxiliary tank.
Reverse idler supports on rear of left transmission housing by mean of needle bearing and reverse
gear shaft. Limit axial and circumferential movement by locking plate and bolts (C0500816). Rear
end of reverse gear shaft has circular groove. It is equipped with O ring to avoid oil leak.
Transmission is equipped with 3 Shifting fork shafts. Shifting fork and guide block of every shaft
fixed by spring pins.
Transmission is also equipped with self-lock device and interlocking device. Self-lock device
consists of steel balls and spring. Interlocking device consists of interlocking block and interlocking
pin. So it can ensure one gear once.
Top cap of transmission is equipped with selector shaft, selector arm assembly and driving lever
assembly. It is also equipped with shifting block mashing with selector shaft by involute spline.
Realize selecting gear operation by rotation of selector shaft and shifting gear operation by turning
shifting block.
Rear transmission case adopts front/rear split-type. Position is fixed by connection of front housing
of rear transmission and rear end of transmission main housing. Then fix rear housing of rear
transmission together. Connect driving gear of rear transmission with second shaft with internal
spline. Output power is through meshing idle gear, meshing idle gear with output gear and
connecting front flange with output shaft by internal splines.
7
2.4 Shifting Principle of Transmission
2.4.1 Structure of Transmission
Input
Output
Fig2-3 Schematic diagram of structure of transmission

1 Shifting fork-the third speed 2 Shifting fork-the first/second speed
3 Shifting fork-the first/second reversing speed ⅠPrimary shaft
ⅡIntermediate shaft ⅢThe second shaft ⅣReversing shaft
ⅤIdler shaft ⅥOutput shaft
2.4.2 Transmission Line of Each Gear

1. KF gear I transmission line 2 KF gear II transmission line
Input
Input
Output
Output
Output
Fig2-4 Fig2-5
Z1→Z11→Z14→Z4→Z9→Z27→Z19→Z20 Z1→Z11→Z13→Z3→Z9→Z7→Z19→Z20
8
3. KF gear III transmission line 4 KR gear I transmission line
Fig2-6 Fig2-7
Z1→Z11→Z12→Z2→Z8→Z7→Z19→Z20 Z1→Z11→Z16→Z18→Z5→Z10→Z7→Z19→Z20
5 KR gear II transmission line
Input
Output
Output
Fig2-8
Z1→Z11→Z16→Z18→Z6→Z10→Z7→Z19→Z20
9
3 Lubrication and Maintenance of Transmission
3.1 Lubrication of Transmission

Lubrication form: It adopts splash system lubrication.
Oil number: Gear oil of Medium load vehicle80W/90W or 85W/90W (GL-4).It is prohibited to use
inferior oil and different number oil. And different oil cannot be used together.
Oil mass of main tank is 9.0-9.5t, auxiliary tank5.5-6.0t.When filling lubricating oil, the vehicle
should be placed on level road and oil should be up to lower edge of oil filler hole. If transmission
has power takeoff, fill oil until overflowing oil filler hole.
3.2 Maintenance of Transmission

Transmission should be cleaned and changed new lubrication oil, if operating range reaches
4000-6000Km. And check fastener of transmission assembly, junction surface and oil seal.
Transmission should be overhaul and changed new lubrication oil, if operating range reaches
25000-30000Km. Check fuel head regularly when vehicle is placed on horizontal position and oil
temperature is stable. If fuel head is lower than lower edge of oil filler hole, fill oil until
overflowing oil filler hole. Change lubricating oil every 20000Km
Maintenance of breather plug: oil temperature will increase when driving, draught head of
transmission is eliminated by breather plug to keep the balance of air pressure between inside and
outside. Avoid oil leak because of damage of sealing element in high pressure. So it is important to
keep breather plug clean and smooth. Check if there is dirt in breather plug regularly.
Fill lubricating grease onto lubrication hose of release bearing and straight-through tire mouth of
clutch regularly.
10
3.3 Precautions of Transmission Use

1. Check clutch pedal travel regularly and whether clutch is complete separation and total
conjugation when driving. Otherwise it will affect shift performance of transmission and
synchronizer life.
2. When driving, please be at higher gear stage to guarantee engine working at economic rotate
speed zone. So it can improve dynamic property and economical efficiency.
3. Don’t speed up rapidly and have emergency braking frequently when driving.
4. Guarantee transmission at neutral position and clutch total conjugation when starting the vehicle.
And work at idle speed for 3-5 minutes to make gear, synchronizer and bearing sufficient
lubrication through splash of gear oil. Otherwise it will affect shift performance and life of
transmission.
5. When vehicle sliding, transmission shouldn’t work at neutral position. Especially travel
downhill, we should change high gear. At this time, rear-wheel drives transmission shaft
rotating fast. So make the second shaft of transmission rotate at high speed. If at neutral position,
speed of intermediate shaft will drop and splash quantity of gear oil will decrease. It will cause
burning loss of synchronizer and bearing.
6. Clutch pedal should be treaded to the end. And move gear shift lever to right gear position in
short time.
7. When changing into reverse gear, we should stop the vehicle first and then put into gear.
Otherwise it will destroy reverse gear, gear sleeve and relevant element.
11
4 Fault Diagnosis of Transmission and Analysis
Causes
4.1 Base Program of Fault Diagnosis

a) Preliminary review
1. Observation: examine vehicle of fault of transmission to find indication of damage,
specially some key components such as the joint part of clutch housing and engine, he joint
part of gearshift and coupled condition of transmission shaft etc.
2. Inquiry: inquire condition of fault vehicle from driver, such as working condition, service
condition, malfunction appearance process and previous malfunction.
3. Record: do the file record including the record of lubrication, fault, maintenance andthe use
of mileage and time.
b) Disassembly of transmission
1. Keep oil sample in case that checking the impurity if necessary.
2. Check if parts are installed correctly in the process of disassembly. Make sure whether
there is neglected loading, misleading or counterfeit part.
3. According to the requirements of parts cleaning operation requirement, clean each part
carefully and check wear pattern.
c) Confirm the type of fault
d) Find reason for fault and eliminate it
12
4.2 Analysis of Common Failure Cause and Elimination Methods

Table 4-1
Fault
Analysis of possible causes Elimination methods
phenomenon
Bearing failure or crack; Replace the bearing
Tooth surface damage of bearing , oversize Repair or replace the bearing
Excessive backlash because of excessive abrasion;
noise or Part scrape in transmission; Check, repair, adjust
abnormal Abrasion or damage of synchronizer; Replace damaged parts
sound Short of lubricating oil or insufficient Full specified lubricating oil
lubrication;
Low viscosity of lubricating oil Replace certain level
lubricating oil
Part damage phenomenon in synchronizer; Check, repair, adjust
Abrasion or damage of bearing; Replace the bearing
Misalignment of synchronizer , not thorough Adjust
Difficulty in enough separation;
gear Misalignment of controls; Check, adjust
Synchronizer slide block out; Repair
Severe abrasion of synchronizer gear ring Replace simultaneous
close to failure; observation loop
High viscosity of lubricating oil; Replace certain level
lubricating oil
Transformation or damage of shifting fork; Adjust or replace
Severe wear between combining tooth Replace related parts
inverted cone and sliding gear sleeve;
Automatic Improper installation or damage of controls; Check, adjust
trip stop or Drop or damage of self-locking steel ball; Repair
out Severe transformation or damage of self- Replace
locking soring;
Severe transformation or wear of Shifting Replace
fork;
Axial float because of severe wear of bearing Replace
Looseness of locknut; Screw down as required
Random Miss or wear of self-locking steel ball or Overhaul ,replace, complement

block interlocking plunger
Oil leakage Too more lubricating oil; Drop some
Wear or damage of oil seal Replace
Damage of junction surface gasket or Replace or gelatinize
disproportionation of sealant;
Junction surface bump, failure to fix; Repair
Failure or block of breather plug; Unblocked, replace
Looseness of locknut of junction surface; Screw down as required
Miss brushing of bolt sealant; Paint sealant, assemble
13
Abnormal Lubricating oil is too dirty; Replace

damage of Insufficient lubrication or lubricating oil Check, replace
bearing doesn’t meet quality requirements;
Bad cleanliness of tank and each part; Attention to clean
Bearing id low quality; Replace
14
5 Disassembly of Transmission
5.1 Announcement of Disassembly and Dismantlement of

Transmission Assembly
1. Definition of direction: Define the end of transmission output shaft as rear. Define right and left
of transmission from the direction of output shaft end.
2. Place the vehicle on plain ground, make transmission be in neutral position and flameout before
disassembling transmission assembly. Put wedge in front of front and rear wheels to ensure
safety.
3. Provide a clean work-yard and equip necessary special tools to avoid damage of parts causing
unnecessary loss.
4. Clean oil and dirty on external transmission all-round before disassembling transmission
assembly.
5. Let all lubricating oil out from transmission and observe oily.
6. As far as possible put parts together as assembly to avoid mixing when disassembling.
7. Disassembly and examine at the same time. Mark unfamiliar parts and assembly direction of
marked parts.
8. Parts must be cleaned. Make sure there is no rust, magnetism, fragmentary and circulation of
gasket, oil duct and breather plug.
9. Put all parts on clean worktable in the order of disassembly. Avoid missing parts.
10. Use circlip pliers to disassemble circlip. It is easy to disassemble circlip and avoid damaging
circlip.
11. Take care of force exerting on shaft and housing when disassembling parts. Don’t damage parts.
And some parts are forbidden to disassemble. It is absolutely forbidden to applying force on
working follower. Be sure to use soft hammer, copper rod when disassembling parts.
5.2 Disassembly of Transmission

1. Place the vehicle on plain ground, make transmission be in neutral position and flameout before
disassembling transmission. Pull parking braking, shut down and turn off the power. Put wedge
in front of front and rear wheels to ensure safety.
2. Disassemble magnetic purge cock and let oil out (easy oil drainage when hot).
15
ATTENTION
Check quantity and quality of gear oil and if there are metal fragments or other things.
Because of magnetic purge cock, it will be stained with metal fragments. Remove metal
fragments before installing.
3. Disassemble transmission shaft
ATTENTION
Mark output flange and transmission shaft before disassembling transmission shaft.
4. Disassemble flexible shaft of gear shifting. Separate wiring harness of protection switch of
reverse/neutral gear and odometer wiring harness from transmission.
5. Disassemble return spring of clutch booster, shifting fork pins and high-pressure tracheal of
pump pushrod, and then screw out connecting bolts. Disassemble clutch booster.
ATTENTION
Pay attention whether there is oil leak at the joint of clutch pump oil pipe.
6. Place lifting platform under transmission and put block above to support transmission.
7. Screw out clamp nut of transmission housing and bell housing. Disassemble anode bond strap.
8. Move transmission horizontally until separation of release bearing. And put down transmission
carefully.
9. Lower lifting device and pull out transmission.
5.3 Disassembly of assembly
5.3.1 Disassembly of Rear

1. Screw out castle nuts of transmission and bolts

of rear housing and rear cover.
Fig. 5-1
16
2. Disassemble rear cover, castle nuts and

braking flange of transmission.
Fig. 5-2
3. Remove rear housing of rear transmission.
Fig. 5-3
4. Remove all bearings and front housing of rear

transmission.
Fig. 5-4
17
5.3.2 Disassembly of Clutch

Separation Structure
1. Screw out oil filling pipe of release bearing by

spanner.
Fig. 5-5
2. Remove fixed bolts of release fork.
Fig. 5-6
1 3. Take release bearing down from primary shaft
directly and remove separation fork shaft and
release fork.
2 3
Fig. 5-7
1 Separation fork shaft 2 Release fork
3 Release bearing
4. Screw out bolts of clutch housing. And knock

clutch housing by copper rod until there is
crack. Then pry clutch housing down directly.
5. Screw out bolts and remove upper and lower
cover plate.
1
Fig. 5-8
1 Clutch housing
18
5.3.3 Disassembly of Top Cap

Assembly
1 1. Screw out connecting bolts of top cap and

remove top cap assembly.
Fig. 5-9
1 Top cap assembly
1 5.3.4 Disassembly of Upper Cover
Assembly
1. Screw out connecting bolts of upper cover and

remove upper cover assembly.
Fig. 5-10
1 Upper cover assembly
5.3.5 Disassembly of Primary Shaft

Assembly
1. Screw out connecting bolts of front bearing

cap and remove front bearing cap and gasket.
1
Fig. 5-11 19
1 Bearing cap
2. Knock journal of primary shaft by copper rod

out of transmission directly.
1
Fig. 5-12
1 Primary Shaft Assembly
3. Take snap ring of primary shaft bearing down.
Fig. 5-13
4. Take clamp ring of roller down from primary
shaft. And take out two spacer rings and
rollers.
1 2
Fig. 5-14
1 Spacer ring 2 Ball
20
5.3.6 Disassembly of Rear bearing

cap, Reverse Idler Gear and The
Second Shaft Assembly
1. Knock locking plate of locknut. And screw out

locknuts.
1
Fig. 5-15
1 Locknut
2. If there is flange special tool, use it to pull

flange out; otherwise knock flange down
lightly by copper rod.
1
Fig. 5-16
1 Output flange
3. Screw out bolts of rear cover, and then knock

rear cover by copper rod. When there is crack,
use screw driver to pry it.
1
Fig. 5-17
1 Rear cover
21
4. Take spacer bush down, and disassemble

closing ring of bearing.
Fig. 5-18
5. Pull rear steady bearing out by bearing puller.
Fig. 5-19
6. Screw out 6 bolts of window cover plate of

reverse idler gear, and then take cover plate
down.
1
Fig. 5-20
1 Cover plate
22
7. Screw out bolts of reverse idler gear, and then

take locking plate down. Pull out reverse idler
gear from inside to outside in transmission
housing.
Fig. 5-21
8. Take off reverse idler gear and then needle

bearing.
1
Fig. 5-22
1 Reverse idler gear
9. Lift out the second shaft assembly; because

clearance between the second shaft assembly
and housing, ring easily has axial displacement
when lifting out backward gear and the sixth
gear cone.
Fig. 5-23
23
5.3.7 Disassembly of Intermediate

Shaft Assembly
1. Remove front end cover of intermediate shaft.

2. Remove snap ring of rear bearing of
intermediate shaft, and then pull rear bearing
out by bearing puller.
3. Take out intermediate shaft assembly from
housing.
Fig. 5-24
4. Knock out front bearing outer ring of

intermediate shaft.
Fig. 5-25
5.4 Disassembly of Assembly Parts
5.4.1 Disassembly of Rear

1. Hold up the second shaft to make the end

upwards.
2. Take down thrust washer and gear of the
second reverse gear.
3. Take down needle bearing of the second
reverse gear.
Fig. 5-26
24
4. Take down gear bushing of the second reverse

gear.
Fig. 5-27
5. Take down synchronizer assembly of the

first/second reverse gear.
Fig. 5-28
6. Remove gear of the first reverse gear.
1
Fig. 5-29
1 Gear of the first reverse gear
25
7. Take down needle bearing of the first reverse

gear.
Fig. 5-30
8. Hold up the second shaft to make fore-end

upwards.
9. Take down circlip by circlip plier.
Fig. 5-31
10. Remove synchronizer assembly of the

third/fourth gear.
1
Fig. 5-32
1 Synchronizer assembly of
third/fourth gear 26
11. Remove gear and cone of third gear.
1
Fig. 5-33
1 Bear of third gear
12. Take down needle bearing of third gear of

second shaft (pay attention to fission
structure).
Fig. 5-34
13. Take down circlip by circlip plier.
Fig. 5-35
27
14. Remove gear and cone of second gear.
1
Fig. 5-36
1 Bear of second gear
15. Take down needle bearing of second gear of

second shaft
Fig. 5-37
16. Remove synchronizer of second/third gear and

synchronizer ring.
1
Fig. 5-38
1 Synchronizer of second/third gear 28
17. Take out gear of first gear and bushing.
Fig. 5-39
Fig. 5-40
5.4.2 Disassembly of Top Cap

Assembly
1. Screw out arm of gear and breather plug.
Fig. 5-41 29
2. Remove shift shaft assembly.
Fig. 5-42
3. Remove attachment screw of shift shaft.
Fig. 5-43
4. Remove shifting block of shift shaft and shift

shaft assembly.
Fig. 5-43
30
5. Remove 2 plug screws.
Fig. 5-45
6. Take out 2 plug screws.
Fig. 5-46
7. Take down 2attachment stocks.
Fig. 5-47
31
8. Take out 2small bolts.
Fig. 5-48
9. Take out 2small springs.
Fig. 5-49
10. Remove two side oil seals
Fig. 5-50
32
5.4.3 Disassembly of Upper Cover

Assembly
1. Remove blanking cap of each axle hole.

2. Remove spring pins and resilient pins of each
hole.
3. Remove shifting fork of first/second reverse
gear.
1 2 3
Fig. 5-51
1Shifting fork of first/second reverse gear
2 Shifting fork of first/second gear
3 Shifting fork of third/fourth gear
4. Remove shifting fork of first/second reverse

gear and shifting guide block
Fig. 5-52
5. Remove shifting fork shaft of first/second gear

and shifting fork of first/second gear.
Fig. 5-53
33
6. Remove shifting fork shaft of third/fourth gear

and shifting fork of third/fourth gear.
7. Turn over upper cover and remove cotter.
Screw out hexagon slotted flat nuts. Remove
shifting fork shaft of first/second gear.
Fig. 5-54
6 Assembly of Transmission
6.1 Announcement of Assembly of Transmission

Before assembling, all parts need cleaning to prevent dirt and sundries entering transmission
causing unnecessary damage. Please observe the following announcements in assembly process:
1. To avoid oil leak and looseness, all fastening bolts must be screwed down according to
rules .Gaskets don’t need gluing.
2. It has directivity for the assembly of all parts including gaskets. So each part should be checked
its directivity.
3. Use special tools as possible when assembling. Because it influence assembly speed and quality.
If it is unconditional, common tools can be used, but can’t damage parts.
4. Check quality and assembly data of parts at any time. As assembly of second shaft, we should
check if axial clearance is qualified; after assembly, check operating and manipulating
condition of transmission. If they can’t reach requirement, disassemble them and adjust them.
5. If gear is damaged, change in pairs to increase working life because new gear and old gear will
have different degree wear. So do synchronizing ring and synchronizing ring cone.
6.2 Disassembly of assembly
6.2.1 Assembly of Rear Transmission

Assembly
1. Install distance ring into internal hole of

primary shaft.
1
Fig. 6-1
1 Distance ring
34
2. Coat lithium grease on internal hole of primary

shaft and then put 19 rollers in order.
Fig. 6-2
3. Install distance ring above the rollers.
Fig. 6-3
4. Install snap ring to fix roller bearing and coat

lithium grease.
Fig. 6-4
35
5. Put roller bearing onto press fitting base

(bearing with snap ring faces downward, upper
end with flat gasket). Insert spindle nose of
primary shaft into bearing press fitting base,
and press primary shaft into bearing hole by
press machine.
Fig. 6-5
6. Install snap ring.
1
Fig. 6-6
1 Snap ring
7. Finish assembling primary shaft assembly.
Fig. 6-7
36
6.2.2 Assembly of Rear Transmission

Assembly
ATTENTION
Assembly of second shaft: it’s one of key
points of assembly. If there is no condition
to heat some parts, use simple way to heat
them such as firing between two bricks.
When assembling part which is tighter, use
empty barrel auxiliary to press as far as
possible. So it can avoids damage parts.
1. Hold up second shaft and make rear end face
upwards.
2. Install needle bearing of second shaft the first
reverse gear of second shaft and coat lithium
grease.
Fig. 6-8
3. Match first reverse gear.
1
Fig. 6-9
1 First reverse gear
37
4. Install fixing bearing base and sliding gear

sleeve of first/second reverse gear.
Fig. 6-10
5. Install gear bush which has been heated of

first/second reverse gear (80~100℃), and coat
lubricating oil.
Fig. 6-11
6. Install needle bearing of second reverse gear

and coat lubricating oil.
Fig. 6-12
38
7. Install second reverse gear and anti-thrust

gasket.
1
Fig. 6-13
1 Second reverse gear
8. Hold up second shaft and make front end face

upwards.
9. Install needle bearing of first gear of second
shaft, spacer bush and needle bearing. Coat
lubricating oil.
Fig. 6-14
10. Match gears of first gear and install

synchronized cone with gear of first gear onto
second shaft.
Fig. 6-15
39
11. Install synchronizer assembly of first/second

gear and simultaneous loop.
Fig. 6-16
12. Install anti-rotating pin into the bottom of

second gear of second shaft.
13. Install bush of second gear. Be careful to align
anti-rotating pin of second shaft and check if
anti-rotating pin is out.
14. Install 2 needle bearings of second gear of
second shaft. Coat lubricating oil.
Fig. 6-17
15. Match gear of second gear and synchronized

cone of second gear.
Fig. 6-18
40
16. Install snap ring of fixing bush of second gear.
Fig. 6-19
17. Install needle bearings of third gear (be careful

about fission structure), and cat lubricating oil.
Fig. 6-19
18. Install synchronizer assembly of third/fourth

gear.
1
Fig. 6-21
1 Synchronizer assembly of third/fourth
gear
41
19. Install circlip by circlip plier. So far assembly

of second shaft is completed.
Fig. 6-22
6.2.3 Assembly of intermediate shaft

Assembly
ATTENTION
If intermediate shaft is damaged, we must
change it. But for the convenience of the
user, here lists order and method of
assembly of intermediate shaft assembly.
1. Hold up intermediate shaft and make frond
end face upward.
2. Heat gear of second gear (180-200℃). And
install gear which plane end face downward
onto intermediate shaft.
3. Heat constant mesh gear (180-200℃). And
install gear which plane end face downward
onto intermediate shaft.
ATTENTION
Make sure there is no clearance between
gear face of each gear.
4. Install bearing cone of intermediate shaft.
Assembly is completed.
42
6.2.4 Assembly of Upper Cover

Assembly
1. Press self-locking spring and steel balls into

speed shifting fork shaft by wedge-shape shaft.
And install speed shifting fork of first/second
reverse gear and guide block of first/second
reverse gear in order. Push fork shaft with
interlocking plunger into neutral position.
Then install self-locking block.
Fig. 6-23
1
Fig. 6-24
1 Speed shifting fork of first/second
reverse gear
2. Install self-locking spring, steel balls and

speed shifting fork shaft with interlocking
plunger and penetrate into corresponding holes
of upper cover. Install speed shifting fork of
first/second gear and push it into neutral
position. In the end install self-locking block
in self-locking hole.
1
Fig. 6-25
1 Speed shifting fork of first/second
gear
43
3. Install self-locking spring and steel balls into

speed shifting fork shaft of third/fourth gear
into corresponding holes of upper cover. And
install speed shifting guide block of
third/fourth gear.
Fig. 6-26
4. Rivet into speed shifting fork of each gear and

guide block respectively by wave mouth
spring pin and resilient pin. Then fix them.
Fig. 6-27
5. Install blanking caps of each fork shaft hole.
Fig. 6-28
44
6. Install reverse signaling switch with glue onto

cap.
Fig. 6-29
6.2.5 Assembly of Top cap Assembly
1. Coat oil in oil seal assembly and knock it into

corresponding holes of top cap by hammer and
special tools.
Fig. 6-30
2. Install grease baffle.
Fig. 6-31
3. Install two sides column and large spring.
Fig. 6-32
45
4. Screw two sides plug screws.
Fig. 6-33
5. Turn over upper cap and install two small steel

balls.
Fig. 6-34
6. Turn over upper cap and install two small steel

balls.
Fig. 6-35
46
7. Screw two small plug screws.
Fig. 6-36
8. Turn over upper cap and install selector shaft.

Put on shifting block.
Fig. 6-37
9. Screw attachment screw which is applied by

selector shaft.
Fig. 6-38
10. Knock into blanking cap.
Fig. 6-39
47
11. Install selector shaft and g selector deflector

rod.
Fig. 6-40
12. Install selector arm.
Fig. 6-41
13. Screw hexagon head plug screws.
Fig. 6-42
48
14. Screw breather plug.
Fig. 6-43
15. Assembly of top cap assembly is completed.
Fig. 6-44
6.3 Assembly of assembly
1. Clean front and back and upper end of

transmission by tools. Wipe off deflashing.
2. Assembly of intermediate shaft: install
NJK309V1bearing inner loop onto front end of
intermediate shaft. And install
NJK309V1bearing outer loop into bearing hole.
Coat lithium base grease on rollers and lower
housing. Press bearing into housing aligning
Fig. 6-45
the location holes. Then install snap ring onto
rear end of intermediate shaft. Lastly install
sealed cap into front bearing hole of
intermediate shaft.
49
3. Lift second shaft assembly. Shake second shaft

to make each gear engagement when hoisting
in place.
ATTENTION
Prevent simultaneous observation loop and
corn hub falling when hoisting.
Fig. 6-46
Fig. 6-47
4. Press bearing of second shaft into housing

aligning the location holes until there is no
space between closing ring and end face.
Fig. 6-48
50
5. Install reverse idler with needle bearing into

housing and penetrate reverse idler shaft.
Install locking plate outside housing and fix it
by bolts.
Fig. 6-49
6. Coat 618-glue on idler cover plate. Fix idler

cover plate by 8 M8 bolts onto housing.
Fig. 6-50
7. Knock primary shaft into transmission lightly.
Fig. 6-51
8. Install oil seal of primary shaft and fill
lubricating grease. Press fitting of oil seal must
be no deviation, no damage and no roll rim
(using special tools).
Fig. 6-52
51
9. Install primary shaft assembly. It’s best to put

protecting jacket on shaft. Then install front
bearing cap with gasket onto primary shaft and
fix it onto housing (be careful to make return
chute of primary shaft cap align spill port of
housing.
Fig. 6-53
10. Install spacer bush of second shaft on rear end

of second shaft to make end face fit rear end
bearing.
Fig. 6-54
11. Install rear cover of transmission. Install
gaskets and rear nearing cap in order.
ATTENTION
Fix bolts in specified torque according to
diagonal tighten torque (coat threaded
fastening adhesive firstly).
Fig. 6-55
12. Install flange, O ring and locknuts on second
shaft.
13. Check if each gear works well and neutral
position can disengage.
14. Install locating ring into locating ring hole and
coat 618-glue (junction surface is continuous
uninterrupted).
Fig. 6-56
52
15. Install gear sleeve and upper cover. Switch

Shifting fork into neutral position. Put Shifting
fork of upper cover on junction surface. Install
upper cover assembly.
Fig. 6-57
16. Fix bolts in specified torque according to

diagonal tighten torque
Fig. 6-58
17. Align shifting block to install it into guide

block of transmission. Be careful original
direction of shifting arm.
Fig. 6-59
18. Tighten top cap by bolts.
Fig. 6-60
53
19. Install bush into clutch bushing hole and

flange hole in turn. And install flange into
right side of clutch. Fix it onto clutch housing
with 2 bolts and spring washer. Fix inspection
openings cover plate onto clutch housing with
2 bolts and spring washer.
20. Make seam allowance of clutch housing align
Fig. 6-61
shell threaded hole. Then screw it with bolts.
21. Insert separation fork shaft and separation arm

assembly into clutch housing (coat lithium
base grease in the hole).
Fig. 6-62
22. Install flat key and separation fork on fork

shaft and insert it into the other fork shaft hole
of clutch.
Fig. 6-63
23. Install oil filling pipe which is filled with

lithium base grease on release bearing and
clutch housing. Whirl grease cup onto oil
filling pipe layup and screw it.
Fig. 6-64
54
24. Fix separation fork on fork shaft with bolts.
Fig. 6-65
25. Hold up transmission and make input end face

downward. Install front housing of
transmission case.
Fig. 6-66
26. Fasten front housing of rear transmission case.
Fig. 6-67
27. Install driving gear, idler, output gear and

related bearings.
Fig. 6-68
55
28. Fix locknuts on driving gear.
Fig. 6-69
29. Install rear housing of rear transmission case.
Fig. 6-70
30. Install bearing of driving gear.
Fig. 6-71
31. Screw castle nuts of idler shaft.
Fig. 6-72
56
32. Install gasket of rear bearing cover.
Fig. 6-73
33. Install rear bearing cover and fasten it.
Fig. 6-74
34. Screw fixing bolts of rear housing.
Fig. 6-75
35. Install rear cover of output end.
Fig. 6-76
57
36. Install front flange of rear transmission and

brake flange.
Fig. 6-77
6.4 Assembly of Transmission

Check all related parts and assembly and make sure well assembly, good condition and fastness
before installing transmission onto vehicle.
1. Auxiliary support and hanging bracket can be installed firstly onto transmission assembly.
2. Use jack or steel wire rope to install transmission and hanging bracket assembly onto vehicle.
And when aligning spline of clutch driven plate, we can select a gear. And then as turn primary
shaft slowly and move second shaft, as be installed onto clutch. It can ensure aligning spline of
clutch driven plate with spline of primary shaft.
3. Fasten all bolts of clutch housing. Fix ancillary shoring.
4. Install clutch booster, return spring and rod jaw pin; adjust push rod banking of clutch.
Push rod banking of clutch:2~3mm
5. Install control operating rod of transmission. Adjust rod appropriately to make sure gear
position exactly.
6. Install transmission shaft and intermediate support.
Tightening torque of transmission shaft bolts: 215~245Nm.
7. Connect all circuit: neutral gear switch, reverse gear switch, power takeoff switch and sensor of
speed.
8. Connect well pipeline and oil pump of power takeoff with transmission with power takeoff.
9. Screw transmission drain plug. Fill gear oil into transmission until oil surface is as tall as oiling.
Be careful about slow speed. Ensure 9~9.5L. Then screw oil filling plug.
10. Check there is no error. Try to step down clutch plate to check journey of clutch pedal and
journey of booster pump on the condition of engine flame out. Change gear to check the
condition of shifting pull rod.
11. Ensure all examine has no error. Try to start engine. As raise clutch slowly as listen sound of
58
transmission working. If there is no abnormal sound, make transmission work for 10 mintes on
neutral gear position.
ATTENTION
1. Make sure assembly of primary shaft and guide bearing is in place. Slight resistance
is normal when pushing. If there is no resistance, shaft may be too short to be in place.
If resistance is too large, primary shaft may withstand guide bearing.
2. Ensure standard of spline of primary shaft and spline of clutch friction palte is same.
3. Make sure release bearing is not out when assembling.
4. Screw bolts of clutch housing. Install retarder holder and bolts when transmission has
retarder.
5. Lift down transmission and pull lifting equipment out of vehicle.
6. Screw other bolts. Fix bolts in specified torque according to diagonal tighten torque.
7. Install clutch booster and connect high pressure air pipe and oil pipe well.
8. Connect flexible shaft control system of transmission.
59
7 Cleanout and Inspection of Parts
7.1 Cleanout of parts

Cleaning method of common transmission parts: steam cleaning, pressure cleaning, acid solution
cleaning, aqueous alkali cleaning, neutral medium cleaning, PE steam cleaning and Magnus
solution cleaning.
Cleaning of metal parts:
Light oil: it’s different from other solution. Light oil doesn’t have permeation and dissolving sludge
ability. So except finish machining of surface, we can use wire brush or other tool to remove sludge.
And use this way to clean twice.
Alkaline solution: its effect is well to clean steel and iron casting. If part is alloy product, please not
to use alkaline cleanout fluid.
ATTENTION
If use alkaline cleanout fluid, neutralize medium should be prepared. Once skin or eyes
contact with alkaline solution, use neutralize medium to wash alkaline solution off
immediately.
Cleaning of rubber parts:
Don’t use mineral oil to clean it. Use alcohol or cleaning wiping rag to wash fatlute off.
On account of exposing damage of parts in cleaning process, so watch out for cleaning.
7.2 Parts Inspection

Before reassembling, every part should be inspected carefully. Check if there is damage, abnormal
wear or transition wear to avoid installing unserviceable parts into transmission. Cause unnecessary
loss.
Bearing
1. Check if steel ball, roller and ball track have pockmark or plateout.
2. Check axial direction and radial clearance of bearing. Change bearing which has excessive
clearance.
3. Check assembling clearance of bearing and housing hole. If bearing can rotate freely, please
change housing.
60
4. Measure axial clearance of ball bearing: wear limit 0.5mm

5. Measure radial clearance between needle bearing and gear inner ring:
Maintain standard 0.049mm
Wear limit 0.20mm
Gear
1. Check if tooth surface of gear has pitting. Change gear which has pitting on tooth surface.
2. Check if all mesh gears have abnormal wear and impact damage. If there has it, please must
change.
3. Check axial clearance of gear. In excessive clearance part we should check if retainer ring of
gear has transition wear.
Spline
1. Check if all splines in shafts have abnormal wear. If transition wear cause part looseness,
change wear-out part.
Thrust washer
1. Inspect all thrust washer surface. Washers which have scratch or transition wear must be
changed.
Reverse idler gear
1. Check if reverse idler gear and needle bearing has transition wear.
Grey cast iron parts
1. Check if all grey cast iron parts have crack or damage. Change or repair them in necessity.
Repair crack of heavy castings by fusion welding or brazing. But castings which crack growth
has reach jointing face of bearing hole and bolts must be changed.
Clutch detach component
1. Inspect the wear condition of clutch detach component. Change release fork and release bearing
which have transition wear.
2. Inspect the wear condition of clutch detach fork shaft.
Upper cover assembly
1. Check the wear condition of all shifting forks, guide blocks and locating slot of fork shafts.
Change transition wear inspect parts.
2. Check transformation condition of gear shift fork. Change fork which has transformation.
Bearing cap
1. Inspect the wear condition of bearing cap. Change bearing cap which is crushed bad by bearing
61
outer ring. Inspect the wear condition of bearing cap hole. Change transition wear parts.
Sealing element and oil seal
1. Check oil seal of primary shaft and second shaft bearing cap. If oil seal doesn’t work, change it.
2. Inspect the fracture and wear condition of O seal ring. Change it if necessary.
Synchronizer
1. Check if synchronizer has rag, transformation and transition wear.
2. Check id gear sleeve and simultaneous observation loop Herringbone angular have transition
wear. If so, change them.
3. Check if contact surface and toothholder have transition burning loss. If so, change them.
62
ATTACH: CAGF5-90 Transmission Assembly

Outline Dimension Figure
Fig10-1
63
64

CAGF5-90 Transmission Service Manual

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CAGF5-90 Transmission Service Manual

SHANDONG LINGONG CONSTRUCTION

Address: Linyi Economic Development Zone

5.3.5Disassembly of Primary Shaft Assembly .................................................... 19

1.1 Safety Precautions

Important Safety Notes

rod, be sure to wear goggles.

Be careful for the safety during the operation.

Oil, water Fill a certain amount of water, oil and fuel.

Be careful for the parts where water and oil need to be

1.3 Tightening Torque of Main Bolts of Transmission

Number Section Specification Tightening Quantity

1.4 Special tool for service

Pull device for rear

Installation of rear bearing of

Disassembly of oil seal of

Disassembly of oil seal of input

2.1 Main Technical Parameters of Transmission

Centre distance Centre distance of main tank160 mm

Max input torque 800Kgm

Weight 400Kg(containing clutch housing but not lubricating oil)

Maneuver form Parallels remote manipulation

Gear stage Three forward gears, two reverse gear

Shifting way The synchronizer gear shift lock ring synchronizer

Oil number Gear oil of medium load vehicle80W/90 或 85W/90(GL-4)

Lubricant Main tank9.0-9.5 L Auxiliary tank5.5-6.0 L

2.2 Summary of Transmission

2.3 Structure Description of Transmission

1/2gear Shift fork- Reverse1/2gear

Fig2-2 schematic diagram of structure of transmission

2.4 Shifting Principle of Transmission

2.4.1 Structure of Transmission

Fig2-3 Schematic diagram of structure of transmission

2.4.2 Transmission Line of Each Gear

3. KF gear III transmission line 4 KR gear I transmission line

5 KR gear II transmission line

3 Lubrication and Maintenance of Transmission

3.1 Lubrication of Transmission

3.2 Maintenance of Transmission

3.3 Precautions of Transmission Use

4 Fault Diagnosis of Transmission and Analysis

4.1 Base Program of Fault Diagnosis

4.2 Analysis of Common Failure Cause and Elimination Methods

Random Miss or wear of self-locking steel ball or Overhaul ,replace, complement

Abnormal Lubricating oil is too dirty; Replace

5.1 Announcement of Disassembly and Dismantlement of

5.2 Disassembly of Transmission

5.3 Disassembly of assembly

5.3.1 Disassembly of Rear

1. Screw out castle nuts of transmission and bolts

2. Disassemble rear cover, castle nuts and

3. Remove rear housing of rear transmission.

4. Remove all bearings and front housing of rear

5.3.2 Disassembly of Clutch

1. Screw out oil filling pipe of release bearing by

2. Remove fixed bolts of release fork.

4. Screw out bolts of clutch housing. And knock

5.3.3 Disassembly of Top Cap

1 1. Screw out connecting bolts of top cap and

1. Screw out connecting bolts of upper cover and

5.3.5 Disassembly of Primary Shaft

1. Screw out connecting bolts of front bearing

2. Knock journal of primary shaft by copper rod