GROUP 2 TRANSMISSION

1. STRUCTURE AND WORKING PRINCIPLE OF TRANSMISSION

As illustrated in the page 2-3, figure 1, the transmission consists of transmission housing (1), large
end cover (2), reverse shaft assembly (3), input shaft assembly (5), countershaft assembly (6), output
shaft (8), range gear sleeve (9) and shoe brake (12).
A hydraulic clutch is attached each to reverse shaft assembly (3), input shaft assembly (5) and
countershaft assembly (6).
As illustrated in figure 2, a hydraulic clutch consists of clutch driving shaft (1), clutch housing (2),
piston (3), exterior friction plate (4), interior friction plate (5), return spring (6) and clutch emptying
valve (7). When flow of hydraulic oil enters head end of cylinder, piston is pushed to move forward
pressing drive and driven friction plate to make driving shaft and gear to rotate, cut off hydraulic oil,
and thus clutch emptying valve opens automatically to press spring (6) to return.
As illustrated in figure 2, the hydraulic clutch consists of 6 clutch drive plates and 5 driven plates. The
driven plate has a 0.5 mm crown and the crown side should face piston. Gap-clearance of piston ring
should be ground and its width within 0.05~0.1 mm.

Figure 2 Structure of hydraulic clutch

2-2
 10

8
11, 12

2
1

Figure 1 Structure of transmission

1 Transmission housing 5 Input shaft assembly 9 Range gear sleeve

2 Large end cover 6 Countershaft assembly 10 Oil tray
3 Reverse shaft assembly 7 Rear output flange 11 Front output flange
4 Input shaft flange 8 Output shaft 12 Shoe brake

2-3
2. WORKING OF TRANSMISSION
As enumerated in figure 3, the transmission route is as follows:
Forward gear Ⅰ transmission route : 1 - 15 - 7 - 9 - 3 - 11 - 13 - 17 - 4
Forward gear Ⅱ transmission route : 1 - 8 - 10 - 16 - 3 - 11 - 13 - 17 - 4
Forward gear Ⅲ transmission route : 1 - 15 - 7 - 9 - 12 - 17 - 4
Forward gear Ⅳ transmission route : 1 - 8 - 10 - 9 - 12 - 17 - 4
Reverse gear Ⅰ transmission route : 1 - 8 - 6 - 14 - 2 - 5 - 9 - 3 - 11-13 - 17 - 4
Reverse gear Ⅱ transmission route : 1 - 8 - 6 - 14 - 2 - 5 - 9 - 12 - 17 - 4

1 Input shaft
2 Rear gear shaft
3 Countershaft
4 Output shaft
5 Reverse shaft gear wheel
6 Reverse gear pinion
7 First & third gear input shaft
8 Second & forth gear input gear
9 First & third gear countershaft
10 Second & forth gear countershaft
11 Low gear countershaft
12 High gear output shaft
13 Low gear output shaft
14 Reverse gear clutch III
15 First & second gear clutch I
16 Second & forth gear clutch II
17 High & Low gear sliding sleeve

Figure 3 Working of transmission

Lever Gear selector lever High · low speed Low speed High.low speed
Gear Ⅰ Ⅱ Ⅲ selector lever selector lever

Forward 1 ● Low speed High speed

2 ● F
3 ● High speed Gear selector lever

4 ● R
II
Reverse 1 ● F I
2 ● R III 830KPT19

2-4
3. TECHNICAL DATA
Max. input speed 2500 rpm
Max. input torque 91.4 kgf·m (661 lbf·ft)
Max. input power 82 kW
Type of transmission housing Countershaft, constant mesh, hydraulic fork
Transmission ratio Forward gear 1 3.82
gear 2 2.08
gear 3 1.09
gear 4 0.59
Reverse gear 1 3.05
gear 2 0.87

Oil for transmission AFT (DEXRON Ⅲ)

Oil pump CB32 (no in transmission box)
Operating pressure 1.4 ~ 1.6 MPa
Allowable oil temperature of oil tray 100˚C
Operating pressure of brake relief valve >0.55 MPa

2-5
4. WORKING AND CONSTRUCTION OF HYDRAULIC OPERATING SYSTEM
Working of hydraulic operating system is as illustrated in figure 4. The right half of double dot dash
line is torque converter while the left half incorporates transmission control valve, hydraulic cylinder
(clutch), filter and tank (including a tank and a tray).
When charging pump of torque converter runs, pump (2) is driven by driving gear, sucking oil from
tank to output hydraulic oil, which enters combined valve of torque converter. Combined valve block
of torque converter consists of a reducing valve (3) and an overflow valve (4). The flow that enters the
combined valve will ensure supply in priority for transmission control by reducing valve (3) and then
for torque converter via reducing valve.

Torque converter
T/M T/C
part part
Brake Cooler
valve

Control valve
Torque converter
valve block

Lubrication

Oil
cooling

Figure 4 Schematic diagram of oil system

1 Suction filtering device 4 Overflow valve

2 Transmission pump 5 Transmission control valve
3 Transmission pressure valve 6 Brake relief valve

Transmission oil pressure and inlet oil pressure of torque converter are controlled by reducing valve (3)
and overflow valve (4) respectively. Set pressure of reducing valve is 1.4~1.6 MPa while that of overflow
valve is 0.5~0.65 MPa. When inlet pressure of torque converter becomes higher than the set value of
overflow valve (4), the valve opens to overflow spray oil for transmission. The flow from outlet is directed
to transmission lubricating system after cooling. High pressure oil delivered from pump is controlled to
1.4~1.6 MPa by reducing valve, which then enters transmission control valve (5) via brake relief valve (6)
to control gear shift clutch.

2-6
 5. TRANSMISSION CONTROL VALVE

M22×1.5

M22×1.5

M22×1.5

Figure 5 Transmission control valve assembly

ass’y

Transmission control valve includes brake relief valve and transmission control valve. Orifice A on the
valve body is connected to combined valve of transmission. When transmission valve spool moves, oil
under pressure from combined valve of torque converter can flow into orifice C, D or E (C for clutch Ⅰ,
D for clutch Ⅱ, E for clutch Ⅲ) to go forth or back for shift. Screw PT1/8” at E on the top of valve body is
for connection of output to reverse gear.
When the brake pedal is pressed down, compressed air from the brake master cylinder has an air
passage for brake valve spool to push the spool rod, cutting operating oil way (A and B is not
connected). At the time, transmission is in neutral to ensure reliable braking.

2-7
6. MOUNTING
Mount the transmission housing on the frame and fix with bolts. For mounting size, refer to the page
2-12.
1) CONNECTION
Input flange of transmission is connected with torque
converter by driving shaft. Front and rear flange of
transmission is connected to driving shaft and front & rear
axle respectively.
5 connections of transmission control valve are :
(1) Mounting sizes of transmission control valve lever are as
illustrated in the figure 5. After the lever is pulled to the most
outside gear, Neutral, gear I and gear II are gained in order
by moving inside. The sizes are Lmax=51 mm, Lmin=15 mm
and stroke per gear = 12 mm.
(2) Connection screw on the end of brake control valve is
connected to the air pipe of brake master cylinder.
(3) Inlet for transmission control is located in Ⅰ-Ⅰ as
illustrated in figure 5.
(4) Inlet for spray oil of transmission is located in Ⅱ-Ⅱ.
(5) Inlet for cooling transmission is located in Ⅲ-Ⅲ. (3) and (4)
is connected to each correct port on combined valve of
torque converter. (5) is connected to oil outlet of radiator.
For positions of shift rod of range gear, see attached figure
1. There are three gears. The outside is high gear, the
inside low gear, stroke between two adjacent gears is 15
mm. Connection sizes of handle are illustrated in figure 6. Figure 6

2) USING
After mounting the transmission on the frame, add AFT (DEXRON Ⅲ) for about 40 liter from the
filler and, 5 minutes after starting the engine, check the oil level for specified position on scale. After
each shift work, it’s required to check the oil level of transmission.
During operation of transmission, be careful to check that its operating pressure is within 1.4~1.6
MPa, oil temperature at outlet of torque converter doesn’t exceed 105˚C, and 115˚C in short time,
and that in the oil tray of transmission doesn’t exceed 100˚C.
Run in the transmission 12 hours after mounting on the frame, each 2 hours for 6 gears. The load in
run-in period should not exceed 70% of the rated value, and frequently check oil temperature, oil
level and tightness of bolts. After completion of run-in, clean the oil tray of transmission and oil-filter
strainer, and renew oil.
Moving into reverse gear from a forward gear, into a forward gear from reverse gear, or moving
between high and low gears must be conducted after parking.
Gear 1 and 2, or gear 3 and 4 can be changed with each other during travel.

2-8
7. MAINTENANCE AND TROUBLESHOOTING
1) MAINTENANCE
Maintenance is carried out after running for 10, 50, 250, 500,1000 and 2000 hours.
(1) 10 hours maintenance
maintenance
① Check oil level in transmission.
② Check transmission for normal operation and driving gear for noise.
③ Check the bolts and nuts for good tightness and check for oil leaks.
(2) 250 hours maintenance
① Inspect operation and noise of transmission.
② Clean the filter.
(3) 500 hours maintenance
maintenance
① Renew oil.
(4) 1000 hours maintenance
① Replace oil filter.
(5) 2000 hours maintenance
maintenance
① Inspect operation, input power, noise, oil temperature, oil leaks, etc.
② Clean air vent caps, fasten up screws and pipe fittings.

2-9
 2) TROUBLESHOOTING

Problem Cause Remedy

Too low oil pressure or 1. Transmission gear pump does not supply oil Repair.
zero 2. Failed reducing valve of torque converter. Repair.
3. Stuck brake valve. Repair.
4. Oil leaks in oil circuit. Repair.
5. Failed piston packing of clutch. Service and repair.
6. Failed O-ring of transmission valve. Replace.
7. Seal ring is failed. Replace.
8. Emptying valve for clutch has fallen off. Check and repair.
Too high oil pressure 1. Malfunction in overflow valve for torque converter. Repair.
2. Clogged oil circuit. Clean.
3. Incorrect oil is used. Renew oil.
Too high oil temperature 1. Clogged oil cooler. Clean.
2. Water has gotten into the oil circuit. Renew oil.
3. Insufficient oil amount. Replenish oil.
4. Incorrect gear selection in operation. Change to low gear.
5. Hand brake can not be normally released or Adjust.
braking drag.
6. Clutch friction plate can not be separated Replace.
completely.
Engine runs but vehicle 1. Insufficient oil. See “Too low oil pressure
will not move trouble”.
2. Incorrect range gear selector fork position. Reengage gear.
3. Brake spool has not response. Check brake spool.
4. Clutch friction plate collision. Replace.
5. Malfunction in control valve for transmission. Repair.
Weak traction 1. Low oil pressure. See “Too low oil pressure
trouble”.
2. Clutch friction plate can not be separated Repair.
completely and dragging.
3. Insufficient oil supply. Replenish oil.

2-10
3) NOTES IN REPAIR OPERATION
Following cares should be taken to reassemble the transmission after disassembly:
(1) Paper gasket and large end cover paper gasket must be of 0.5 mm, or too much axial clearance
of bearing may be formed to lead to damaged gear.
(2) Adjustment of bearing clearance for input shaft, countershaft and reverse shaft.
Axial clearance must be readjusted when reassembling input shaft, countershaft and reverse
shaft after disassembly. Perform adjustment as followings:
① If clearance of input shaft is too little, thickness of paper gasket may be increased or that of shaft
bushing decreased.
② For adjustment of clearance for countershaft and reverse shaft, you may first loosen stop plate,
and fasten adjusting screw, and then loosen a lock groove position (back for 0.125 mm axial
clearance) and lock up the lock plate.
③ Normal axial play of input shaft, countershaft and reverse shaft
Normal axial play of input shaft, countershaft and reverse shaft should be 0.1~0.13 mm.

2-11
 View K
7. STRUCTURE

Rear
Front
1) OUTSIDE VIEW

Range
Gear lever

Oil return port

Hi-Neutral-Lo

2-12
View K
Input flange A Flange C Output flange B
Pressure oil port
Oil spray port

Pressure tap Cooling oil port

 2) TRANSMISSION HOUSING (1/2)

66
9

3
4 2
62

65
7
6
5 63
12
11
10 64
9
8 1

21 15
22 14
13
17
23 7
11 6
24 16
9
8
27 29
25 4
30
32
26 33
20 5
13
22 19 31
28 9
15 18
14 52
9 34
8 35
830KPT05

1 Housing 15 Stop plate 29 O-ring

2 Name plate 16 Input shaft end cover 30 Gasket
3 Rivet 17 Seal 31 Sump
4 Bracket 18 Middle shaft end cover 32 Suction pipe
5 Hexagon bolt 19 Gasket 33 Magnetic
6 Spring washer 20 Regulating ring 34 Oring
7 Hexagon nut 21 Nut 35 Plug
8 Hexagon bolt 22 Washer 52 Hexagon bolt
9 Washer 23 Connector 62 Housing cover
10 End cover 24 Washer plate 63 Cover sheet
11 Gasket 25 Strainer core 64 Semi circular rivet
12 Regulating ring 26 Bolt 65 Gasket
13 Regulating screw 27 Flange joint 66 Hexagon bolt
14 Hexagon bolt 28 Hexagon bolt

2-13
 TRANSMISSION HOUSING (2/2)

67 52
46 9
54
56 53 67
44 45
57 55 48
9
39 43 52
59 58 42 9
68
60 41 45
61 40 44
38 43 67
22 42

47 52
37 9
36
46
45
44
43
51
51

8
9
50

49

830KPT06

8 Hexagon bolt 44 Washer 55 Vent plate

9 Washer 45 Bush 56 Sleeve
22 Washer 46 Input end cover 57 Plate
36 O-ring 47 Dowel pin 58 Sleeve
37 Pipe assy 48 Socket pin 59 Long screw
38 Hexagon bolt 49 Washer 60 Casing
39 Pipe & dipstick 50 Input sealing cover 61 Gasket
40 Seal 51 Input seal 67 Plug
41 O-ring 52 Hexagon bolt 68 Plug
42 Cover 53 Air vent
43 Bush 54 Square nut

2-14
3) OUTPUT SHAFT

7
18
7
6 17
5 16
17
4
3 15
1
2 2
1 13 3
14 4
13 5
12
11
21
8

6
11 24
10
9 12
13
20
13
19
23
22

830KPT07

1 Hexagon bolt 9 Hexagon bolt 17 Steel ball

2 Stop pad 10 Washer 18 Output shaft
3 Pressure plate 11 Ball bearing 19 Output gear
4 O-ring 12 Thrust ring 20 Ring
5 Output flange 13 Sliding bearing 21 Brake drum
6 Dust cover 14 Ring 22 Nut
7 Seal output 15 Gear 23 Spring washer
8 Output rear end cover 16 High-low sliding sleeve 24 Bolt

2-15
4) INTPUT SHAFT

13

12
11 14

8
9
10

9
8
33
32
6 31
7 25 26 30
5 29
4 23 5
22 28
3
12 27

24

21
20
19
18
17
16
15

830KPT08

1 Small ring nut 12 Outer end cover 23 Valve seat

2 Stop washer 13 External friction disc 24 Gear
3 Washer 14 Internal friction disc 25 Stop pad
4 Flange 15 Snap ring 26 Hexagon bolt
5 Taper roller bearing 16 Spring seat 27 Pin
6 Input shaft 17 Spring 28 Bush
7 Plug 18 Piston 29 Inner sealing sleeve
8 Hole ring 19 Sealing ring 30 Piston ring
9 Ball bearing 20 O - ring 31 Shaft end baffle
10 Gear 21 Clutch case assy 32 Stop pad
11 Snap ring 22 Steel ball 33 Hexagon bolt

2-16
5) INTERMEDIATE SHAFT

15

14
13
10
11
12 16
11
10

9
28
8 27
7
6 25
5 24
4
3
2
1 6
29
26

23

22
21
20
19
18
17
830KPT09

1 Hexagon bolt 11 Ball bearing 21 Sealing ring

2 Stop pad 12 Gear 22 O-ring
3 Shaft end baffle 13 Snap ring 23 Clutch case assy
4 Piston ring 14 Outer end cover 24 Steel ball
5 Inner sealing sleeve 15 External friction disc 25 Valve seat
6 Roller bearing 16 Internal friction disc 26 Gear
7 Gear 17 Snap ring 27 Stop pad
8 Plug 18 Spring seat 28 Hexagon bolt
9 Intermediate shaft 19 Spring 29 Pin
10 Hole ring 20 Pistion

2-17
 6) REVERSE SHAFT

15

14
13
16
10
12 11

11
10
28
27
9
8 25
7 24
6 6
5 29
4
23
1 26

23
22
21
20
19
18
17

830KPT10

1 Hexagon bolt 11 Ball bearing 21 Sealing ring

2 Stop pad 12 Gear 22 O-ring
3 Shaft end baffle 13 Snap ring 23 Clutch case aasy
4 Piston ring 14 Outer end cover 24 Steel ball
5 Inner sealing sleeve 15 External friction disc 25 Valve seat
6 Roller bearing 16 Internal friction disc 26 Stop pad
7 Sleeve 17 Snap ring 27 Hexagon bolt
8 Plug 18 Spring seat 28 Stop pad
9 Reverse shaft 19 Spring 29 Pin
10 Hole ring 20 Piston

2-18
7) HIGH-LOW SPEED SHIFT FORK

1
2
3
4

5
6
7

13
12
11
10 9

830KPT11

1 Pin 6 Washer 11 Washer

2 Socket screw 7 Hexagon bolt 12 Steel ball
3 HIgh-low shift fork 8 Seal 13 Spring
4 Gasket 9 Fork shaft
5 Fork support 10 Plug

2-19
8) CONTROL VALVE

12

9
10 12
11
1
2 27
7 5 3
8 6 4
28
13 7
14
15
16
17
18
22 19
11
23 10
9
24

21
26
20

25

830KPT12

1 Screw 11 Regulating washer 21 Plug

2 Washer 12 Control sliding valve 22 Valve body
3 Spring 13 Dust cover 23 Gasket
4 Steel ball 14 Plug 24 Bottom plate
5 Dust cover 15 O-ring 25 Socket screw
6 Pressure tap 16 Cup 26 Screw
7 Washer 17 Brake sliding valve 27 Hexagon bolt
8 Plug 18 Spring 28 Washer
9 Snap ring 19 O-ring
10 Seal 20 Spring seat

2-20
9) PARKING VALVE

3
2
1 4
2

1
22
19 21
20
14

13
14
3 6
18
27

17 23
16
7
11

7 28
29

8
15
9 12 24
10
10
25
26

830KPT13

1 Parking brake bracket 11 Nut 21 Bolt

2 Cam plate 12 Hexagon bolt 22 Iron wire
3 Washer 13 Upper fixed plate 23 Regulating spring
4 Split pin 14 Semi circular rivet 24 Bracket
5 Axis pin 15 Lower fixed plate 25 Bolt
6 Set screw 16 Rivet 26 Washer
7 Set screw spring 17 Friction pad 27 Bracket
8 Set screw spring 18 Bracket 28 Hexagon bolt
9 Washer 19 Steel band 29 Spring washer
10 Nut 20 Bracket

2-21
8. DISASSEMBLY
1) DRAINAGE FOR TRANSMISSION
(1) Hoist transmission up and put an oil
container under it.

830KTM10

(2) Unscrew the M20×1.5 bolts on the oil

pan with a spanner and make drainage
fully.

M20×1.5 bolts

830KTM11

2) OIL PAN OF TRANSMISSION

(1) Unscrew 20 - M10×30 bolts in sequence
on the oil pan with a spanner. As
disassembly, two diagonal bolts should be
removed finally to prevent from injury to
people due to falling oil pan.
(2) Be careful of remaining oil in the oil pan
when the last two bolts are removed.
(3) Put the oil pan removed in a clean place.
830KTM12
M10×30 bolts

830KTM13

2-22
3) HAND BRAKE ASSY
(1) Remove 4 - M12×30 bolts on the left
bracket of hand brake with a spanner.

830KTM14

(2) Remove 4 - M8×25 bolts on the right

bracket of handbrake with a spanner.
(3) Pull the total hand brake assy out and put
it in a clean place.

830KTM15

4) REMOVING FRONT & REAR OUTPUT

FLANGE
(1) Remove the bolt lock plate at the front
output flange with a screwdriver and
unscrew 2 - M10×25 bolts inside the front
output flange with a spanner. After
taking the pressure plate and O-ring out,
pull the front output flange assy out and
place it in a clean place.
830KTM16

(2) Remove the bolt lock plate at the rear

output flange with a screwdriver and
unscrew 2 - M10×25 bolts inside the rear
output flange with a spanner. After
taking the pressure plate and O-ring out,
pull the rear output flange assy out and
place it in a clean place.

830KTM17

2-23
5) REMOVING INPUT FLANGE
(1) Release the lock of stop plate on the input
shaft with a screwdriver and use a special
tool or iron piece to remove M - 20×1.5
round nut. After taking the pressure plate
out, pull the input flange (flange assy) out
and put it in a clean place.

830KTM18

6) REMOVING GEAR SHIFT FORK (HI

AND LO SPEED)
SPEED
(1) Put the transmission level, release the set
screw lock on the gear shift fork mount
and unscrew the M10 set screw with M14
spanner.
(2) Unscrew 4 - M10×30 bolts on the fork
mount with a spanner and tap lightly
the mount assy out with a copper bar and
put it in a clean place. 830KTM19

830KTM20

7) REMVING OUTER END COVER OF

TRANSMISSION
(1) Put the transmission level with the input
side up.
(2) Unscrew 4 - M10×25 bolts on the end
covers of input shaft, intermediate shaft
and reverse shaft with a spanner and
then use 2 - M10×25 bolts to push the
three end covers out and put them in a
clean place. 830KTM21

(3) Unscrew 8 - M10×30 bolts on the rear

end cover of output shaft and use 2
M10×30 bolts to push the rear end cover
out and put it in a clean place.

2-24
(4) Turn the transmission for other side and
place it level.
(5) Unscrew 5 - M10×30 bolts on the oil inlet
end cover of gear I, gear II and reverse
gear with a spanner and then use 2-
M10×30 bolts to push the three end
cover out and put them in a clean place.

830KTM22

830KTM23

(6) Unscrew 4 - M10×25 bolts on the seal

cap of front output shaft with a spanner
and use 2 - M10×25 bolts to push it out
and put in a clean place.

830KTM24

(7) Unscrew 13 - M10×30 socket bolts on the

large end cover with a socket wrench
and then use 2 - M10×45 bolts to push it
out and put in a clean place.

830KTM25

2-25
8) REMOVING CLUTCHES
(1) Take 3 sets of clutch par ts out of
transmission box and put them in a clean
place and mark outer ring of bearing to
prevent from miss assembly.

830KTM26

830KTM27

(2) Set the input parts up as illustrated in the

figure and use a flat chisel to release two
bolt locks and then unscrew 2 - M8×16
bolts with a spanner and use a copper
bar to tap the input shaft out.
(3) Use a flat taper to release the bolt lock
onthe clutch assy and unscrew 8 -
M10×25 bolts with a spanner.
(4) Remove the retainer with a screwdriver,
830KTM28
and then the outer end cover 6 outer
friction plates and 5 inner plates in order.
(5) Use a tool to remove 60 retaining ring
from clutch case, and then inner spring
seat, spring and piston in order.

830KTM29

2-26
9) REMOVING OUTPUT SHAFT
(1) Use a copper bar to tap on to the front end
of transmission to make the front end
output shaft to fall out from front bearing,
and then take the output shaft parts out
and put in a clean place.

830KTM30

830KTM31

2-27
9. ASSEMBLY
1) ASSEMBING INPUT CLUTCH PARTS

13

12
11 14

8
9
10

9
8
33
32
6 31
7 25 26 30
5 29
4 23 5
22 28
3
12 27

24

21
20
19
18
17
16
15
830KPT08

(1) Check the clutch valve seat (23) and internal steel ball (22) for looseness.
(2) Use a spanner to screw up 8 - M10×25 bolts to fasten gear I part drive gear (24) to clutch case
assy (21).
(3) Put up glue and knock in 2 straight pins (27).
(4) Unscrew 8- M10×25 bolts with a spanner and put up 4 stop plates (25) and fasten up 8 - M10
×25 bolts and lock up 4 stop plates with flat taper.
(5) Fit the oil seal ring (19) into piston (18) groove with the broken opening toward gear.
(6) Fit O-ring (20) into place on clutch case.
(7) Tap the piston assy into the oil cylinder of clutch case with a tool.
(8) Assemble the spring (17) and spring seat (16) onto the shaft of the clutch case and use the
special tool to mount the circlip for shaft (6).
(9) Put up 6 outer plates (13) and 5 inner plates (14) alternatively, and assemble outer end cover (12)
and retainer (11) finally.
(10) Knock 2 annular ball bearing into the bore of gear I drive gear (10) and mount two retainer (8) to
set.
(11) Mount the gear I drive gear assy into the clutch assy.
(12) Insert input shaft (6) into the bore of gear I drive gear assy.
(13) Knock the bearing (5) onto the input shaft with the special tool and mark on the inner and outer
ring of the bearing.
(14) Turn and mount sleeve (28) and knock the inner ring of bearing and oil seal (29) onto the input
shaft respectively.
(15) Apply glue and knock stop plug (7) in and then assemble end plate (31) and then stop washer
(32) and fasten up 2 - M8×16 with a spanner and make the two sides lock of stop washer with a
flat taper.

2-28
2) ASSEMBLING INTERMEDIATE SHAFT CLUTCH PARTS

15

14
13
10
11
12 16
11
10

9
28
8 27
7
6 25
5 24
4
3
2
1 6
29
26

23

22
21
20
19
18
17
830KPT09

(1) Check the valve seat (25) of clutch case assy (23) and internal steel ball (24) for looseness.
(2) Use a spanner to screw up 8 - M10×25 bolts to fasten gear II drive gear (26) to clutch case
assy.
(3) Put up glue and knock in 2 straight pins (29).
(4) Unscrew 8 - M10×25 bolts with a spanner and put up 4 stop plates (27) and fasten up 8 - M10
×25 bolts and lock up 4 stop plates with flat taper.
(5) Fit the oil seal ring (21) into piston (20) groove with the broken opening toward gear.
(6) Fit O-ring (22) into place on clutch case.
(7) Tap the piston assy into the oil cylinder of clutch case with a tool.
(8) Assemble the spring (19) and spring seat (18) onto the shaft of the clutch case and use the
special tool to mount the circlip for shaft (9).
(9) Put up 6 outer plates (15) and 5 inner plates (16) alternatively, and assemble outer end cover (14)
and retainer (13) finally.
(10) Knock two annular ball bearings (11) into the bore of gear II drive gear (12) and mount two
retainers (10) to set.
(11) Mount the gear II drive gear assy into the clutch assy.
(12) Insert intermediate shaft (9) into the bore of gear II drive gear assy.
(13) Push gear II idler gear (7) onto the spline of intermediate shaft and knock the bearing onto the
intermediate shaft with the special tool and mark on the inner and outer ring of the bearing.
(14) Knock inner seal (5) onto the intermediate shaft with special tool.
(15) Apply glue and knock stop plug (8) in and then assemble end plate (3) and then stop washer (2)
and fasten up 2 - M8×16 with a spanner and make the two sides lock of stop washer with a
flat taper.
(16) Put 2 piston rings (4) into inner seal groove.

2-29
3) ASSEMBLING REVERSE SHAFT CLUTCH PARTS

15

14
13
16
10
12 11

11
10
28
27
9
8 25
7 24
6 6
5 29
4
23
1 26

23
22
21
20
19
18
17

830KPT10

(1) Check the valve seat (25) of clutch case assy (23) and internal steel ball (24) 5 for looseness.
(2) Use M16 spanner to screw up 8 - M10×25 bolts to fasten reverse gear reverse gear (26) to clutch
case assy.
(3) Apply glue and knock in 2 straight pins (29).
(4) Unscrew 8-M10×25 bolts with a spanner and put up 4 stop plates (27) and fasten up 8 - M10
×25 bolts and lock up 4 stop plates with flat taper.
(5) Fit the oil seal ring (21) into piston (20) groove with the broken opening toward gear.
(6) Fit O-ring (20) into place on clutch case.
(7) Tap the piston assy into the cylinder of clutch case with a tool.
(8) Assemble the spring (19) and spring seat (18) onto the shaft of the clutch case and use the
special tool to mount the circlip for shaft (9).
(9) Put up 6 outer plates (15) and 5 inner plates (16) alternatively, and assemble outer end cover (14)
and retainer (13) finally.
(10) Knock two annular ball bearings (11) into the bore of reverse drive gear (12) and mount two
retainers (10) to set.
(11) Mount the reverse drive gear assy into the clutch assy.
(12) Insert reverse gear shaft (9) into the bore of reverse drive gear assy.
(13) Push reverse gear sleeve (7) onto the reverse gear shaft and knock the bearing onto the reverse
gear shaft with the special tool and mark on the inner and outer ring of the bearing.
(14) Knock inner seal (5) onto the reverse gear shaft with special tool.
(15) Apply glue and knock stop plug (8) in and then assemble end plate (3) and then stop washer (2)
and fasten up 2 - M8×16 with a spanner and make the two sides lock of stop washer with a
flat taper.
(16) Put 2 piston rings (4) into inner seal groove.

2-30
4) ASSEMBLING OUTPUT SHAFT PARTS
(1) Mount four composite bearings to high
speed gear and low speed gear
respectively.

830KTM35

(2) Insert high and low speed sleeve gear,

high speed gear and bearing onto the
output shaft.

830KTM36

5) ASSEMBLY
(1) Mount the left bracket and right bracket of
handbrake at the output side of
transmission onto the transmission box
and set with four M8×25 bolts and
M12×30 bolts respectively.
(2) Mount the bearing outer rings into the
bearing bore respectively and mark.
830KTM37

(3) Mount the intermediate shaft assy, reverse

gear shaft assy and output shaft assy into
their correct place on the box.

830KTM38

2-31
(4) Mount bearing into the bore for bearing on
the large end cover.

830KTM39

(5) Mount the large end cover into the box

and put up a paper gasket in the middle.
(6) Assemble the outer seal into the oil inlet
end cover.
(7) Mount the oil inlet end covers in place on
the box watching oil orifice position.

830KTM40

(8) Assemble the front output flange and

handbrake assy.

830KTM41

830KTM42

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(9) Assemble the low speed gear assy into
the box.

830KTM43

(10) Assemble the output shaft assy.

830KTM44

(11) Assemble rear end cover of output shaft

and rear output flange.
(12) Mount the output shaft rear end cover
and oil seal (45×62×12) on the box and
then input flange, and adjust the bearing
gap at the input side to meet requirements.
(13) Mount the intermediate shaft end cover
and reverse gear shaft end cover and
fasten up the screws and set the stop
830KTM45
plate.

(14) Mount the fork shaft in the fork bracket.

(15) Mount the fork bracket assy through the
holes on the box and fasten with 4 -
M10×30 bolts. Mount the for k for
high-low shift speed by inserting the fork
shaft into the fork hole and adjust the
p o s i t i o n o f fo r k s h a f t t o k e e p i t
perpendicularly and drill hole to match
assembly.
830KTM46

2-33
 830KTM47

(16) Mount the oil pan and set with 20 -

M10×30 bolts.

830KTM48

(17) Mount the control valve assy and top

plate and connect with 8-M10×45 and
4 - M10×35 bolts

830KTM49

2-34