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CONTENTS

前言 Preface

安全事项 Safety Information

工作原理 Operating Principle

技术参数Technical Specifications

标准公制螺纹拧紧力矩表 GeneralTorque Specifications

计量单位表 Denomination ofStandard Dimensions

单位转换表 Conversion Table

装配工具 Tool Table

部件清洗和检查 Cleaning andInspection

部件拆解 Parts Disassembly

双变总成附件 Transmission and TorqueConverter Accessories ....................................29

变矩器组件 Torque Converter Group ..............33

变矩器壳体组件 Torque Converter HousingGroup .............................................................40

制动器 Brake ...................................................55

接头及档位软管总成 Connectors and Hose Assembly .......................................................59

电液变速操纵阀、端盖组件、离合器总成ShiftControl Valve, End Cap Group and Clutch

Assembly ........................................................ 67

输出轴组件Output Shaft Group ....................115

部件装配 Parts Reassembly

方向档轴总成 CV&CR Assembly .................. 122

Ⅰ -Ⅲ档轴总成 C1&C3 Assembly ................ 141

Ⅱ -Ⅳ档轴总成 C2&C4 Assembly.................159

输出轴组件 Output Shaft Group ...................180

电液变速操纵阀、端盖组件、离合器总成ShiftControl Valve, End Cap Group and Clutch

Assembly ....................................................... 189

接头及档位软管总成 Connectors and Hose Assembly ..................................................... 210

制动器 Brake ................................................ 217

变矩器壳体组件 Torque Converter HousingGroup ............................................................ 221

变矩器组件 Torque Converter Group ........... 240

双变总成附件 Transmission and TorqueConverter Accessories ................................. 248

变速箱维修完毕后检查机器 Checkthe Machine after Repairing

润滑 Lubrication

油品Oil Brand................................................ 254

油位检查 Transmission Oil Level--Check ......254

换油 Transmission Oil--Replace ....................254

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更换滤油器 Transimission oil Filter--Replace.255

故障及排除 Troubleshooting

所有档位控制油压都低Oil Pressure in All Gearsis Low ...........................................................256

在某几个档位控制油压太低Oil Pressure inCertain Gears is Too Low .............................257

所有档位换档时间都太长Shifting Intervals for All Gears are Too Long ......................................257

所有档位换档时间都太短Shifting Intervals for AllGears are Too Short ...................................258

所有档位都无动力输出No Power Output for AllGears ...........................................................258

油温太高Oil Temperature is Too High .........260

常见故障排除 Troubleshooting ......................262

附件 Appendix传动路线图 Transmission Route Chart ..........265

电控线路连接图 Electrical Control Circuit ......269

PT300箱液压原理图 Hydraulic Schematic forPT300 Transmission ....................................271

PT300箱测量点布局 PT300 TransmissionMeasuring Points Layout ..............................272

PT300箱进油口PT300 Transmission Oil Inlet.......................................................................273

索引 Index

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前言 Preface

前言 Preface

本维修手册包含所有关于产品拆卸及安装方面详细的操作说明。在对产品进行维修时请保持零件的清洁并按正确的步骤进行，而且拆除零件只能在零件损坏而必须拆除时进行。在安装有密封件的地方，如松开螺栓或螺钉、松开盖子或壳体零件时，要用塑料的锤子或铜棒轻轻敲打，并使用合适的拉马等设备来进行安装在轴上紧固件的拆除，例如：轴承、轴承外圈等零件。

This service manual includes the detailed

operation instructions concerning productdisassembly and reassembly. Before performing

any service on this product, all the parts should

be kept clean and all the operations should be

carried out in correct procedures. Remove the

parts only when it is damaged and necessary to

remove. When you are going to loosen a bolt or

a screw, or remove a cover or housing where

seals are, you must tap with a plastic hammer or

copper bar and use a proper tool to remove the

parts such as bearing, bearing cup, ect which are

mounted on the shaft.

请在干净、平坦的地方使用专用工具进行零件的安装和拆除，在装配前要先清洗所有零件，清除壳体和盖连接面上残留的密封胶，用油石修补任何被烧伤或磨损的平面。在操作中用专业的眼光去判定零件是否损坏或严重过疲劳而必须更换或重新设置，例如轴承、止动垫圈等零件。

Select a clean and flat place and use special

tools to install and remove the parts. Before

assembling, all parts should be cleaned

thoroughly, no residual sealant is allowed on the

contact surface of housing and cover, and the

burnt or abrasive surface should be burnish withan oil stone. Always use your professional

experience to judge the parts like bearing, lock

washer, etc. and see if they are damaged or

seriously fatigued. If so, replace with a new one.

像密封环、锁紧螺母、纸垫等零件在拆装后都要更换，而烧伤或损坏唇缘的径向密封圈则必须更换。特别地，不能让铁屑和杂物遗留在箱壳体内。检查孔和槽内的润滑油。

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

should be replaced at once after removing.

Replace the seal if it is burnt or its lip isdamaged. Particularly care must be taken to

ensure that no iron scurfs or foreign matters

leave inside the transmission. Check the

lubricant in the holes or grooves.

所有轴承在安装前都应该按照产品润滑剂的要求先进行润滑。

Lubricate all the bearings according to the

requirements of lubricant before assembling.

在拆卸或安装不同的零部件时需要不同的专用工

具，这些工具您都可以在“专用工具表”里找到。

Different special tools are needed when installing

or removing different parts. All these tools are

available in "Tool Table".

本维修手册是为经过培训的专业人员对广西柳工机械股份有限公司的产品进行维修及维护而专门编写的。由于产品的技术改进，在您进行产品维修时也许会遇到不相同的拆卸和安装步骤及测试数据。所以本公司建议你找经过我们公司专业培训的人员对产品进行操作及维修。这些遍布全球

的维修及维护服务点将为你提供 :This service manual is written for those trained

professional personnels to perform maintenance

or repair to LiuGong products. Due to product

improvement, the disassembly or reassembly

procedures or testing data presented in this

publication might be different from that on your

product when you are repairing the machine. We

recommend repairing the machine only by a

trained person. The Service Stations, established

by LiuGong all over the world, will offer you:

1. 经过专业培训的服务队伍。Trained service team.

2. 专用的设备，如专用工具。

Professional equipment, e.g. special tools.

3. 广西柳工机械股份有限公司最新且原装的产品配件。

Newest and original Liugong Parts.

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前言 Preface

在这里您还将得到最可靠的服务，另外，在广西柳工机械股份有限公司指定的维修服务点进行维

修，您可以得到可以信赖的服务保证。

You also can receive excellent service if you

repair or maintain the machine in a designated

Liugong Service Station.

任何由于不按照本手册规定的步骤及程序进行操作而导致的损害，本公司将不负任何责任。这也适用于广西柳工机械股份有限公司销售的其他产品。

Guangxi LiuGong accepts no liability for any

damage resulting from failure to observe the

operations and procedures stipulated in thisservice manual.

工业安全作业说明：Safety operation instruction:

1. 对广西柳工机械股份有限公司的产品进行维修及维护的单位要承担全责的工业安全责任。

People who repair or maintain Liugong

product should bear the safety

responsibilities.

2. 遵守现有的法规及制度是保证人身及产品安全所必须的。

Obey the laws and regulations to preventpersonnel injury and harm to product.

3. 进行维修及维护的人员在进行操作前必须熟悉这些规则。

The repairer should be familiar with these

regulations before working.

4. 经过培训且技能熟练的专业的人员才能对广西柳工机械股份有限公司的产品进行正确维修及维护。

Only trained or experienced personnel is

allowed to operate or maintain this machine.

5. 维修机构有责任组织相应的培训。

The service center should provide training to

his people.

本手册使用下列安全标识：

This service manual uses the following safetysigns:

危险：这个词表示即刻出现的危险，如果不避免将会导致死亡或严重的人身伤害。

Danger: this word denotes an impending danger,

failure to observe instructions could result indeath or serious injuries.

警告：这个词表示潜在的危险，如果不避免将会导致死亡或严重的人身伤害。

Warning: this word denotes potential danger,

failure to observe instructions could result indeath or serious injuries.

注意：这个词表示潜在的危险，如果不避免将会导致轻微或中等程度的伤害。

Caution: this word denotes potential danger,

failure to observe instructions could result in

minor to medium degree of injury.

在本手册中的插图、简图或零件图，它们显示的通常不是零件的实际外形、尺寸或重量，而是操作的程序。

All the photographs, illustrations and parts

drawings in this manual show the operating

procedures of the parts, not its exterior drawing,dimension or weight.

注意：经过维修及检测后，必须经过专业的

人员证实机器的性能是完好的。

CAUTION: The machine should be

rechecked by a professional person after it is

repaired.

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安全事项 Safety

Information

关于安全的一般注意事项

General Hazard Information

请阅读和熟悉所有的安全事项，否则将导致严重伤亡事故的发生。

Be familiar with all safety cautions, failure toobserve could result in property damage, serious

injury or even death.

唯有受过培训并具备相应资质的人员方能操作和保养本机器。

Only trained and qualified personnel should be

allowed to operate or maintain the machine.

如果您在身体不舒服的时候，或者服药后觉得发困或喝酒以后，不要操作机器。在这种情况下，将会导致您的判断错误和发生事故的可能。

Do not operate the machine if you feel sick,sleepy or after taking some medication. Check

with your doctor if unsure. Never operate

machinery while under the influence of drugs or

alchohol.

在维护和修理机器前，在启动开关或操作杆上挂上“不能工作”或类似的警告标签。

Attach a DO NOT OPERATE or similar warning

tag to start switch or control levers before

servicing or repairing the machine.

不穿宽松衣服、不佩带首饰、留长发。它们可能卡入或卷入控制系统或移动部件，造成重伤或死亡。

Do not wear loose fitting clothing, dangling

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

操作或保养机器时应戴硬质材料的帽子和安全眼镜，穿安全鞋、戴面罩和手套。

Wear relevant personal protective equipment

(PPE) such as a hard hat, ear protection, safety

glasses, safety shoes and gloves when

operating or servicing the machine.

d o n o t

o p e r a t e

O p e r a

t e r :

D a t e :

W A R N I N G

!

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使用护目镜、安全眼镜或面罩可以保护您的眼睛

在保养蓄电池时不受高压液体的伤害，在发动机运转和使用工具时不受飞屑的伤害。当您拆卸弹簧或弹性的零部件或给蓄电池加酸时，要戴上防护面罩。当您在焊接或用焊枪切割时，要带上安全帽或者护目镜。

Using goggles, safety glasses or full face mask

can protect your eyes from being injured by high

pressure liquids, when maintaining storage

batteries, by flying scraps when the engine is in

operation or you are using tools to strike objects,

remove springs or resilient parts, add acid/

electrolyte to batteries, you should wear a fullface protective mask. When carrying out welding

operations or gas cutting operations with a

welding torch, wear specific safety goggles

suitable for the task being performed. Consult

your welding equipment dealer for moreinformation.

若处于大噪音下工作，带上适当的保护听觉装置，例如耳套或耳塞，以避免大噪音对听觉的伤害。

When working under high noise conditions, wear

appropriate safety equipment to protect your

hearing, such as approved earmuffs or plugs. Avoid the damage caused by exposure to high

noise on your hearing.

保证机器上所有的防护板和盖板固定在机器上。保证机器上，尤其是仪表板，通道和扶梯上无碎片，油污，工具和与机器无关的杂物等。放好散物，例如饭盒、工具等。

Make sure all protective guards and covers are

secured in place on the machine. Keep the

machine, especially the panels, accesses, step

and ladders, free of foreign material, such as

debris, oil, tools and other items which are notpart of the machine.Secure all loose items such

as lunch boxes, tools and others.

在检查敞开的油箱、水箱时，要防止异物进入系统部件。在拆开盖子之前，要掏空衣服口袋，十分小心地移动扳手和螺母。

Pay attention when opening fluid compartments,

prevent foreign materials from entering the

system. Always remove loose materials fromnear caps and plugs.

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了解工场的手势信号和信号的来源，仅从一个人处接收信号。

Know the appropriate worksite hand signals and

who gives them. Accept signals from one person

only.

保养空调或可能存在制冷剂气体时不得吸烟或靠近明火，吸入与制冷剂接触的火焰或点着的香烟散发出来的烟雾会造成人员伤亡。

No smoking and keep open flames away when maintaining air conditioner or if there is

refrigerant gas, the flames contact the refrigerant and the cigarette smoke will cause personal

injury or death.绝不能把维护保养溶液装在玻璃容器内中。

Never put maintenance fluids into glass

containers.

当处理有害物质如润滑油、燃油、冷却液、溶剂、过滤器、蓄电池和其他物质时，要遵守有关的法律和法规。

Observe the relevant laws and regulations when

handling harmful articles such as lubricants,

fuels, coolants, solvents, filters, batteries and

other matterials.

使用清洁剂时要小心 ,不要使用易燃材料作为清洗零件的清洗剂，如柴油或汽油等，它有着火的危险。

Use all cleaning solutions with care. Do not use

any flammable material to wash components, for

example, diesel oil or gasoline. They may easily

catch fire.

及时报告所有需要修理的内容。

Report all required repairs in time.

不允许未经许可的人在机器上或机器周围。

Do not allow unauthorized personnel on oraround the machine.

禁止未经柳工许可对机器进行改装，对此造成的后果柳工不负担任何责任。

Guangxi Liugong bear no resposibility for failures

caused by modifications to machine structure

without Liugong’s permission.

压缩空气 Compressed Air

压缩空气可能造成人身伤害。使用压缩空气清洁

时，要穿戴好面具，防护衣服和安全鞋。用于清洁的压缩空气最大压力应低于 0.2MPa。

Compressed air can cause personal injury. When

using compressed air for cleaning, wear a

protective face shield, protective clothing,

hearing protection and protective shoes. Never

direct compressed air at yourself or others.

Compressed air could penetrate your skin and

cause serious injury or death. The maximum air

pressure used should not exceed 25psi(0.2Mpa).

高压溶液 High-pressure Fluid

警告 :要避免高压油的烫伤。当检修或更换

液压系统的管子时，要将载荷放低并泄压，并确

定油已冷却。压力下的液压油溅到皮肤上会给皮

肤造成严重的伤害。

WARNING: Avoid injury from

highpressure oil. When repairing hydraulic

lines, ensure that system pressure is

completely released before beginning the

repair. Hydraulic oil under pressure

contacting the skin could cause serious

injury or damage.

拆开液压管道或接头时应小心。当油喷出时，被释放的高压油可能引起软管扫动。

Use cautiion before disconnecting hydraulic lines

or connectors. High pressure oil that is released

can cause a hose to whip.

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检查泄漏时，要戴上安全眼镜和皮手套，不要用裸手来检查泄漏，要使用板或纸板来检查泄漏。

Wear safety glasses and leather gloves. Never

check for a high-pressure leaks with your

unprotected hand. Use a board or cardboard

when checking for leaks.

即使针孔大小的压力液体泄漏也可能穿透肌肉，造成人身伤亡。如果被喷出的高压油射中，应立即与医生联系进行治疗。

Even a pin-hole size leak can cause serious

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

安全处置废液Disposal of Waste Fluids

不适当的废料液体处理将危害环境和生态。处理废液时要遵守当地法规。

Improper handling of the waste fluid will cause

pollution of the environment. Obey all local

regulations for disposal of waste fluids.

必须将机器在检查、保养、试验、调整和修理时洒出的液体用容器盛放好。

Collect all waste fluids when performing

inspections, maintenance, testing, adjusting and

repairs to the machine.

在打开任何液腔或分解任何含有液体的部件之前，事先准备好收集液体的适当容器。

Prepare to collect fluids with suitable containers

before opening any compartment or

disassembling any component that containsfluids.

当排出液体时利用适当的容器。不可使用食物或饮料容器，因为它可能导致误被他人饮用。

Use suitable containers to collect waste fluids.

Do not use food containers or beverage bottles

as they could mislead people to drink thecontents.

石棉 Asbes tos Danger

若吸入石棉粉尘，对健康是个威胁。本产品不含石棉，柳工机械股份有限公司推荐使用纯正的柳工备件。如果您需要处理含有石棉纤维的材料时，请遵守以下准则：

Breathing asbestos dust can be hazardous to

your health. Equipment and replacement parts

shipped from Liugong have no asbestos in them.

Liugong recommends the use of genuine factory

spare parts only. Observe the following rules if

you are handling any spare parts that contain

asbestos or asbestos fibers:

● 清洁时绝对不能使用压缩气体。可用水来使粉尘下沉。

Never use compressed air to clean up

asbestos. Use a wet method in order to clean

up asbestos materials. Water the area down

to clear asbestos dust.

● 可使用具有高效过滤性能的吸尘器。

A vacuum cleaner that is equipped with a

high efficiency particulate air filter (HEPA)

can also be used.

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● 不要研磨含有石棉粉尘的物质。

Do not grind materials that contain asbestos.● 在可能的情况下，应在上风口操作机器。

Operate the machine in upper tuyere area as far as possible.

● 处理石棉时要遵守环境保护法规。

Obey environmental regulations for the

disposal of asbestos.

● 在接触石棉后要洗澡。

Shower after contact with asbestos.

● 如有需要，可使用有效的防护面具。

Wear an approved respirator if there is no

other way to control the dust.

防止挤压或切断

Crushing and Cutting Prevention

勿将手、胳膊或身体的任何其他部位置于可移动的部件之间。如工作装置和油缸之间、机器和工作装置之间。

Don't put hands, arms, or any other parts of thebody in the way of removable parts.

在工作装置下面工作时要正确地支承好设备。不要依靠液压油缸来支撑工作装置。如果控制机构移动或液压管路泄漏，会导致工作装置掉下来。

Support equipment and attachments properly

when working beneath them. Do not depend on

hydraulic cylinders to hold up the implement/

attachment. The implement/attachment can fall if

a control lever is accidentally moved, or if a

hydraulic line breaks.

如果在维修过程中有必要拆掉护罩，实施维修后一定要将护罩安装好。

If it is necessary to remove shields in order to

perform maintenance, always install the shieldsafter the maintenance is performed.

旋转和运动的部件对身体有剪切或挤压的危险，在维修时保持安全距离或关闭发动机。

Rotating or moving parts have cutting or crushing

hazard. Keep clear or stop engine before

servicing.

要保证发动机风扇扇叶中没有杂物。风扇扇叶会把落进或推进其间的工具、杂物抛出或切断。

Keep hands and objects away from moving fan

blades. They can throw or cut any object that

contacts the moving blades.

除非另有说明，否则不能在机器运转或发动机开动时做任何调节。

Never attempt adjustments while the machine is

moving or the engine is running unless otherwise

specified.

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如果维修程序必须在机器运转下实施时，不可让机器处于无人操作状态。安排一人坐在操作人员

座椅上，并准备随时关闭发动机。

If the machine must be repaired with engine

running, make sure that a qualified operator is

available in the cab to shut down the engine if

required.

不要使用扭绞或磨损了的钢丝绳。在使用和搬运时戴上手套。

Do not use a kinked or frayed wire cable. Wear

gloves when handling wire cables.

用力压出卡销时，应确保周围无人。为了避免伤

眼睛，应戴上防护眼镜。

Retainer pins, when struck with force, can fly out

and injure nearby persons. Make sure the area is

clear of people when driving retainer pins. Wear

protective glasses when striking a retainer pin to

avoid injury to your eyes.

用锤敲击物体时要确保飞出的碎屑不会伤着人。

Chips or other debris can fly off objects when

struck. Make sure no one can be injured by flying

debris before striking any object.

防止烧伤 Burn Prevention

机器运转经过一段时间，某些部件会发热，应在这些部件冷却后再进行维修或检查。

Some parts of the machine become hot during

normal operation. Use caution when maintaining

the engine and hydraulics. Allow the machine to

cool after it has been operating for a long period

of time.

油 Oil

热的油和热的部件可能使人受伤，不要让热油和热的部件接触到皮肤。

Hot oil and components can cause personal

injury. Do not allow hot oil or components to

contact the skin.

在拆卸所有管子、接头或有关零件之前都应释放其系统压力。

Relieve all residual pressure in air, oil, fuel or

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

灭火器和急救箱

Fire Extinguishers and First-aid

Ki t

一定要备有灭火器，仔细阅读使用说明，一定要知道怎样使用。

A fire extinguisher that meets with all local fire

extinguisher laws and regulations should be

available on the machine.

在作业工地一定要备有急救箱。要定期检查，如有必要则增补一些药品。

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

Periodically check the contents of the kit and

replace used medical supplies as necessary.

发生火灾或受伤时应该知道怎样做。

Know how to use the fire extinguisher and firstaid

kit.

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要选定好一些人员的电话号码（如医生、急救中心、消防站等），以便在紧急情况时联系。把这

些联系电话号码贴在规定的地方，确保所有的人员都知道这些号码和正确的联系方法。

Keep telephone numbers of doctors, first-aid

centers or fire stations etc with you so you can

contact them in case of an emergency. Post the

contact telephone numbers in regulated places.

Ensure that all persons know where the

telephone numbers are located and know thecorrect contact method.

要经常对灭火器进行检查和维护。遵照说明面板上的推荐使用方法。

Inspect and service the fire extinguisher

regularly. Obey the recommendations on the

instruction plate and all local laws and

regulations relating to fire extinguishers.

转向架的锁紧装置

Steering Frame Lock

吊装及运输机器时要连接好转向架的锁紧装置。在铰接点附近进行保养工作时也要连接好转向架的锁紧装置。

Connect steering frame lock when the machine

is being lifted and shipped. Also connect the

steering frame lock when performing repairs

near the articulation joint.

操作机器之前应将转向架的锁紧装置分开。

Disassemble the steering frame lock before

operating the machine.

附件的注意事项

At tachment Caut ions

必须由有相关资质的人员进行安装调试；操作人员应经过培训，严格按照附件的使用说明书进行操作和保养。

Attachments should only be installed by

authorized people who have been trained to

operate and maintain the attachment according

to the operator’s manual.

安装和使用备用附件时，请阅读有关附件的说明书、手册和手册内与附件有关的信息。

Refer to the instructions in the operation manual

and any other related information when installing

and using attachments.

不正确的安装附件或选购件，不仅会导致安全问题，而且还会对机器的操作及设备的使用寿命产生不利影响。

Incorrect installation of attachments or optional

parts not only will result in safety problems, but

also will negatively influence the operation and

sevice life of the machine and the attatchments.

勿使用柳工未许可的附件。使用未经许可的附件，可能会产生安全问题，不利于机器的正常操作，影响使用寿命。

It is forbidden to use unauthorized attachments.

Otherwise, product safety problems might be

involved and the machine service life could be

affected.

未经允许，严禁对附件进行任何改制，否则后果自负。

It is forbidden to modify the machine or anyattachments without permission from your

Liugong dealer.

由于使用未经许可的附件而导致的损伤、事故和机器损坏，柳工机械股份有限公司概不负责。

Liugong bears no responsibility for injuries,

accidents or machine damage resulting from the

use of unauthorized attachments.

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存放附件 Store Accessor ies Safely

安全存放附件和工具，以免倾倒造成严重伤害或死亡。让玩耍的小孩和旁观者远离存放区域。

Store accessories and tools safely so as to

prevent them from falling and causing serious

injury or death. Keep playful children and

bystanders away from the storage area or anyarea accessories are being stored while in use.

正确地支撑机构

Support the Machine Correctly

工作时，附件或器械一般总是处于离地面较低的位置。如果您必须在被提升的机构或附件上或下工作时，请安全地支撑机器或附件。

Lower to the ground or support any attachments

with stands or other methods. Ensure that any

attachment can not move during maintenance or

repair work, use wheel chocks or other devices

to prevent machine movement.

必须在坚固的支撑物上支撑机构。

Use stands or other measures that are secure

and can support the weight being applied to

them.

不可在只有单支撑物支撑的机构下工作。

Do not work under any part of the machine or

attachment that is not adequately supported.

部件的吊装 Lift ing The Parts

如果一个已吊起来的负载落下，附近的人有可能被下降的负载碰撞，或可能被压在下面，导致严重伤害或死亡。

Falling of the lifting parts could hit or crush the

persons nearby. Serious personal injury or even

death could be resulted.

不要使用已破损的铁链或擦伤的钢索、吊具或绳索。

Never use a broken iron chain or an abrasive

steel rope, lifting tool or rope to lift parts.

要缓慢、小心地移动部件，决不能突然移动。

Move the lifting parts slowly and carefully, never

move it suddenly.

决不能让吊装的部件从人员的头上经过。

Never hoist the parts over a person.

不容许任何人靠近吊装的部件，直到它已安全而稳妥地在支承块上就位或降到地面上。

Keep all persons clear of the lifting parts until it

has been steadily placed on the supporting block

or safely lowered to the ground.

焊接操作Welding Operation

进行电焊作业的人员必须持有专业证书，在装备有适当设备的地方进行。在焊接时操作人员必须遵守下列注意事项：

Any personnel engaging in welding operations

must have occupational certificates and carry out

the operation at a place with appropriate devices

equipped, When carrying out the weldingoperation, the personnel must follow the

instructions below:

● 为避免电器元器件的损害，在对机器焊接时，将机器停在平整地面上，实施停车制动，断开电源总开关及仪表系统的插接头，否则会烧坏仪表板上的元件。

Before carrying out the welding operation,

turn off the battery isolator switch, disconnect

the battery, disconnect the controllers, GPS

and other electrical parts.

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● 清除需要焊接的地方的油漆，以防止有害气体的产生。

Remove all paint from the place to be

welded, so as to prevent harmful gas from

being produced.

● 不要吸入油漆的烟尘。

Do not inhale smoke produced buy burning

paint.

● 禁止在靠近橡胶软管、电线或有压力的管道上焊接。

Never weld pipes, close to rubber hose and

electrical wires.● 焊接时要戴防护眼罩穿防护衣。

Always wear correct PPE for welding, protect

bystanders by using screens and signs

advising of the operation being performed.

● 电焊作业场地的通风要保证良好。

Ensure good ventilation.

● 清理所有的易燃材料，并且作业场地一定要配备灭火器。

Remove all the flammable materials, supplythe work area with a fire extinguisher.

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工作原理Operating Principle

工作原理 Operating

Principle

发动机启动时，变速箱变矩器总成上的变速泵通过吸油软管 (7)和粗滤油器 (3)，不断地从变速箱油池吸油，变速泵 (8)出口油液经过软管总成(6)、弯管 (5)、精滤油器 (1)过滤后，通过软管总成 (2)提供给变速箱变矩器系统的电液变速操纵阀 (4)和变矩器。

After the engine is started, oil is continuously

sucked out from the transmission oil sump

through suction hose (7) and coarse filter (3) of

charging pump. Then oil comes out from outlet of

charging pump (8) and passes through hose

assembly (6) and elbow (5) and filtered by oil

filter (1). Finally it is supplied to shift control valve

(4) and torque converter through hose assembly

(2).

从变速箱的油池流经变矩器的油液由于在变矩器内做高速、复杂的流动而产生大量的热，这些油

液经过软管总成 (10)输送到变矩器油散热器 (11)中，油液流过变矩器油散热器后，油温得到降低，油液通过变矩器油散热器出口处经过软管总成 (9)流回变速箱变矩器总成，对变速箱内的离合器和轴承进行润滑。

When oil flows into the torque converter, it

produces a lot of heat due to its high and

complicated flowing speed. The heated oil

passes through hose assembly (10) and reaches

torque converter oil radiator (11). After being

cooled in the oil radiator, it comes out and returns

to the transmission torque converter throughhose assembly (9) to lubricate the clutches and

bearings inside the transmission.

液力变矩器安装在发动机与变速箱之间，由泵轮、涡轮、导轮 (反射元件 )组成，这三个叶轮位于一个环形系统中，液体按顺序循环流动。

The torque converter is installed between the

engine and transmission, which consists of

impeller, turbine and stator. These three

impellers are arranged in a loop system and the

fluid inside them flows circularly.1. 精滤油器Oil filter

2. 软管总成Hose assembly

3. 粗滤油器 Coarse filter

4. 电液变速操纵阀Electro-hydraulic shiftcontrol valve

5. 弯管Elbow


7. 吸油软管Suction hose

8. 变速泵Charging pump

1 2 3 4

5

6

7

8


10.软管总成Hose assembly

11.变矩器油散热器Torque converter oil radiator

9 1110

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泵轮与发动机相连，涡轮与变速箱相连，泵轮由发动机带动，与发动机飞轮以相同转速旋转，迫使工作腔内油液按规定方向以巨大的速度和压力冲击涡轮，把发动机的机械能转换为油液的动能；涡轮吸收液流的动能，以涡轮转速旋转，并将工作油的动能转化为涡轮的机械能，将动力经齿轮传送给变速箱。

The impeller is connected with the engine while

turbine is connected with the transmission. The

impeller is driven by the engine and rotates withthe same speed as the flying wheel of the

engine, forcing the oil inside the working

chamber to impact on the turbine with a fast

speed and huge pressure in the given direction.

By this way, the mechanical energy of the engine

is converted into the kinetic energy of the fluid;

then the turbine absorbs the kinetic energy of the

fluid and rotates to obtain its speed. The kinetic

energy of the working fluid is then converted into

the mechanical energy of the turbine to transmit

the power to the transmission through the gear.

变速泵从变速箱油池不断地为液力变矩器输送液力传动油。液体从泵轮流出后进入涡轮，液体流动被反向，液流自涡轮流出冲向固定的导轮，并被导轮叶片折向前方，当液体沿导轮叶片流回泵轮时，绝对流线冲击泵轮的正面，与液体在泵轮内的原绝对流线是一致的，液体在上一循环的残余能量非但不再阻碍泵轮的旋转，而且有利于它的回转，因此涡轮所受的总转矩为泵轮作用于液体的转矩和导轮对液流的反作用转矩的矢量和，变矩器增大了发动机输出的扭矩作用，同时，通过液体的流动带走所产生的热量。

Charging pump continuously supplies the

transmission oil from the oil sump to the torque

converter. After coming out from the impeller, oilenters into the turbine. Then oil direction is

changed, oil comes out from the turbine and runs

to the stator and being baffled to run forward

continuously by the stator vane. When the oil

flows back to the impeller along the vane of the

idler, its absolute streamline strikes the front

surface of the impeller and its absolute

streamline is identical with the original one. The

residual energy of oil in the last circle helps the

impeller rotating. Therefore, the total torque of

the turbine is equal to the vector sum of the

torque from impeller impacting on the fluid andfrom the stator’s reaction on the fluid. The torque

converter has increased the output torque of the

engine and takes away the heat through the

running fluid.

随着整机工作载荷的变化，变矩器涡轮输出速度自动作相应的变化，以满足整机工作扭矩要求。

The output speed of the turbine of torque

converter changes accordingly as the change ofthe machine work load in order to meet the

torque requirements of the machine.

变速箱中所有的齿轮为常啮合齿轮，并在轴承支承下运转。齿轮、轴承和离合器采用冷却油润滑。 PT300变速箱具有四个前进档和四个后退档。由六个多片式离合器、传动齿轮、轴、轴承、箱体以及电液变速操纵阀及其他附件组成。

12.泵轮 Impeller 13.导轮 Stator

14.涡轮 Turbine

12

13

14

12.泵轮 Impeller 13.导轮 Stator

14.涡轮 Turbine

12 13 14

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All gears inside the transmission are constant

meshing gears and running under the support of

the bearings. Gears, bearings and clutches arelubricated by cooling oil. Four forward gears and

four reverse gears are available on PT300

transmission, which consists of six multi-plate

clutches, drive gear, shaft, bearing, transmission

housing, electro-hydraulic shift control valve and

other attachments.

发动机动力经输入端传给液力变矩器，经变矩器转换后作为变速箱输入。变速箱输出轴通过前后法兰和传动轴分别驱动前、后驱动桥。

The power of the engine is transferred to the

torque converter from its input end, and is finallytransferred to the transmission. The output shaft

of the transmission drives the front and rear axle

through the front and rear flange and drive shaft.

变速箱档位控制是通过离合器结合、脱离实现的。离合器的结合、脱离通过电液变速操纵阀控制，压力油通过电液变速操纵阀的电磁阀控制相应的阀芯，到达相应的离合器中。

Transmission gears are controlled by the

engagement and disengagement of the clutches,

which is controlled by the electro-hydraulic shift

control valve. The pressurized oil can reach thecorresponding clutches when the solenoid valve

of the electro-hydraulic shift control valve

controls the corresponding spools.

压力控制阀调整离合器换挡压力。在换挡过程中，控制压力短时间下降，完成换档操作后，又升高到调定压力。

Pressure control valve adjusts the gear pressure

of clutches. During shifting, the pressure will drop

for a very short time; after finishing shifting, it will

rise to the setting value.

档位变换信号由车速确定，并由柳工控制器发出。当换挡时，复位阀将压力控制阀复位到其开始位置，使活塞为下一次换挡作准备。

The gear change signal is determined by the

speed of the machine and is sent out by a

LiuGong controller. During shifting, the pressure

control valve will be reset to its initial position by

the resetting valve and make the piston prepare

for the next shifting.

换挡过程中，从电液变速操纵阀过来的压力油，推动离合器活塞，使回位弹簧压缩，摩擦片组沿

轴向方向移动，摩擦片和钢片结合。当电液变速操纵阀切断压力后，活塞在回位弹簧的作用下，压缩弹簧推动活塞，释放摩擦片和钢片。因此变速箱通过离合器的结合、脱离，可以实现不同的档位。

During shifting, the pressurized oil from the

electro-hydraulic shift control valve pushes the

clutch piston to move, the return spring is thus

forced to compress and the outer clutch disc is

forced to move in the axial direction and finally

engages with inner clutch disc. When the

pressure of the electro-hydraulic shift controlvalve is cut off, the outer clutch disc and inner

clutch disc are forced to disengage under the

pressure of return spring. Therefore, different

gears can obtain through the engagement and

disengagement of clutches.

安全阀安装在变矩器入口处，防止变矩器内部产生过高压力 (开启压力为 0.8MPa)。为了避免气穴现象，变矩器必须一直完全充满油。由变矩器的背压阀保证，变矩器的开启压力大约为0.25MPa。

A relief valve is provided at the inlet of the torqueconverter to prevent the pressure produced in

the torque converter is too high (cut-in pressure

supposed to be 0.8MPa). To avoid the

occurrence of cavitations, the torque converter

should be fully filled with oil. The cut-in pressure

of the torque converter is about 0.25MPa

maintained by the backup valve.

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技术参数 Technical Specifications

技术参数 Technical Specifications

名称 Item 单位 Unit 数量 Q’ty

发动机额定输入功率Rated engine input power

KW 130

发动机最大输入转速Max. engine input rev. speed

rpm 2500

发动机最大输入扭矩Max. engine input torque

N.m 800

变矩器最大输出扭矩Max. torque converter output torque

N.m 1100

变矩器出口阀开启压力

The cut-in pressure of the outlet valve of torque converter MPa 0.25

变矩器安全阀开启压力The cut-in pressure of the relief valve of torque converter

MPa 0.80

变矩器最大变矩比Max. torque ratio of torque converter

3.15

变矩器工作温度Working temperature of torque converter

°C 80～ 100

电液变速操纵阀系统压力System pressure of electro-hydraulic shift control valve

MPa 1.8～ 2.0

电液变速操纵阀电磁阀额定电压Rated voltage of electro-hydraulic shift control solenoid valve

V 24

电液变速操纵阀电磁阀额定电流Rated current of electro-hydraulic shift control solenoid valvemA 350

电液变速操纵阀油液清洁度Oil cleanliness of electro-hydraulic shift control valve

不低于NAS1638 9级

≥ NAS1638 Grade 9

传动速比 Speed ratio (F1) 4.020




传动速比 Speed ratio (R1) 4.017




变速泵额定压力Rated pressure of charging pump

MPa 2.0

变速泵额定转速Rated speed of charging pump

rpm 2200

变速泵额定排量Rated displacement of charging pump

mL/r 45

变速箱油（SAE15W-40美孚黑霸王 1300）

Transmission oil (SAE15W-40 MOBIL 1300)L 40

重量（不含油）Weight (without oil) Kg 580

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标准公制螺纹拧紧力矩表General Torque Specifications

标准公制螺纹拧紧力矩表 General Torque Specifications

除非有特别的声明，PT500箱用到的螺纹按下表扭矩要求进行拧紧。

Tighten the bolts used on PT500 transmission according to the torque requirements shown in the

following table unless otherwise specified.

公称直径

Nominal

Diameter

标准扭矩 Standard Torque (N.m)

4.6级强度

Grade 4.6

Strength

4.8级强度

Grade 4.8

Strength

5.8级强度

Grade 5.8

Strength

6.8级强度

Grade 6.8

Strength

8.8级强度

Grade 8.8

Strength

10.9级强度

Grade 10.9

Strength

12.9级强度

Grade 12.9

Strength

M6 4.5± 0.5 4.5± 0.5 6± 1 6± 1 10.5± 1.5 14± 1.5 18± 2M8 11± 1 11± 1 13± 1.5 13± 1.5 26± 4 33± 3 45± 6

M10 22± 2 22± 2 28± 3 28± 3 52± 7 72± 6 90± 10

M12 40± 4 40± 4 50± 5 50± 5 90± 12 120± 10 150± 20

M14 62± 7 62± 7 80± 10 80± 10 145± 20 195± 15 245± 30

M16 100± 10 100± 10 125± 15 125± 15 225± 35 305± 25 380± 50

M18 135± 15 135± 15 170± 20 170± 20 310± 45 415± 35 520± 70

M20 190± 20 190± 20 240± 30 240± 30 410± 50 600± 50 750± 100

M22 260± 30 260± 30 320± 30 320± 30 600± 80 800± 70 1000± 140

M24 340± 35 340± 35 410± 40 410± 40 760± 100 1020± 100 1280± 180

M27 490± 40 490± 40 630± 70 630± 70 1100± 150 1500± 100 1850± 250

M30 610± 70 610± 70 800± 50 800± 50 1500± 200 1850± 150 2500± 300

M33 780± 100 780± 100 960± 140 960± 140 2050± 300 2900± 400 3450± 500

M36 1000± 100 1000± 100 1260± 140 1260± 140 2650± 350 3100± 250 4500± 500

M39 1100± 130 1100± 130 1300± 240 1300± 240 3400± 470 4800± 650 5700± 800

M42 1520± 140 1520± 140 1900± 200 1900± 200 3500± 350 4600± 350

M48 2200± 200 2200± 200 2900± 350 2900± 350 4700± 290 7100± 640

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工具名称

Description 工具名称 Picture Number 工具号备注 Note

安装架

Mounting rack A00

变速箱拆装

Transmission

disassembly and

reassembly

拉马

Two-armed

puller

A01

拆卸输出轴油封座

Remove the oil

seal seat of

output shaft

间隔套

Spacer sleeve A02

安装离合器弹簧压盖挡圈

Install the circlip

of spring pressure

cap in clutch

压装套筒

Pressing socket A03

安装离合器复位弹簧

Install the clutch

return spring

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压装套筒

Pressing socket A04

拆卸离合器弹簧压盖挡圈

Remove the

circlip of spring

pressure cap in

clutch

油封工装

Tool for seals A05

安装输出轴油封

Install oil seal of

output shaft

油封工装

Tool for seals A06

安装连接套油封

Install the oil seals

of adapter sleeve

轴承工装

Tools for

bearings

A07

拆装轴承

Remove and

install bearings

工具名称


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吊环

Eye bolt

A08

（M10、M12）

通用件

Universal use

钢丝绳

Steel rope A09

通用件

Universal use

白综绳

White sisal rope A10

拆装离合器总成

Remove clutch

assembly

记号笔

Marker pen A11

通用件

Universal use

工具名称


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榔头

Hammer A12

通用件

Universal use

螺丝刀

Screwdriver A13

通用件

Universal use

平面密封胶枪

Gun for plane

sealant

A14通用件

Universal use

撬棍

Tommy bar A15

通用件

Universal use

工具名称


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锁扣

Locker A16

通用件

Universal use

铜棒

Copper bar A17

通用件

Universal use

铜棒

Copper bar A18

装离合器活塞总成

Install the clutch

piston assembly

錾子

Punch A19

通用件

Universal use

工具名称


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测扭扳手

Torque spanner

A20

（20~100N.M、

60~300N.M）

通用件

Universal use

风扭矩扳手

Impact wrench A21

通用件

Universal use

开口扳手

Open spanner

A22

（9/16″、 14、 17、

19、 21、 22、 24、

27、 32、 36、 41、

55）

通用件

Universal use

活动扳手

Adjustable

wrench

A23通用件

Universal use

工具名称


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24


梅花扳手

Ring spanner

A24

（9/16″、 14、 17、

19、 21、 22、 27、

41）

通用件

Universal use

内六角扳手

Inner hexagon

spanner

A25

（S8）

通用件

Universal use

风枪

Air gun A26

通用件

Universal use

套筒

Socket

A27

（9/16″、 14、 17、

19、 22）

通用件

Universal use

工具名称


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套筒

Socket

A28

（S6）

拆装变速操纵阀

Remove and

install the shift

control valve

套筒

Socket

A29

（50）

拆装输出轴锁紧螺母

Remove and

install the locknut

of output shaft

套筒接杆

Socket

extension

A30通用件

Universal use

拉马

Three-armed

puller

A31通用件

Universal use

工具名称


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内卡环钳

Pliers for inner

circlip

A32通用件

Universal use

外卡环钳

Pliers for outer

circlip

A33通用件

Universal use

多用深度尺

Depthometer

A34

(0~300mm)

通用件

Universal use

游标卡尺

Dial caliper

A35

(0~200mm)

通用件

Universal use

工具名称


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27

部件清洗和检查 Cleaning and Inspection

部件清洗和检查 Cleaning

and Inspection

清洗 Cleaning

使用清洗液彻底清洗所有零件。零件清洗时应完全浸入清洗液中，上下缓慢移动，直至所有旧的润滑剂和杂质全部溶解。

Clean all parts thoroughly using solvent type

cleaning fluid. It is recommended that parts be

immersed in cleaning fluid and moved up anddown slowly until all old lubricant and foreign

material is dissolved and parts are thoroughly

cleaned.

注意：使用易挥发、易着火的清洗液时，应

小心谨慎，避免皮肤出疹，火灾隐患和吸入溶剂

蒸汽。

CAUTION: Care should be exercised to

avoid skin rashes, fire hazards and inhalation

of vapors when using so lvent type cleaners.

轴承 Bearings

轴承在清洗液中浸泡一段时间后，取出轴承，去除凝固在轴承上的润滑剂颗粒，再次浸泡在清洗液中冲洗。重复上述操作，直至轴承彻底清洗干净。

Remove bearings from cleaning fluid and strike

flat against a block of wood to dislodge solidified

particles of lubricant. Immerse again in cleaning

fluid to flush out particles. Repeat above

operation until bearings are thoroughly clean.

使用干燥压缩空气吹干轴承。干燥压缩空气气流穿越轴承时，应避免旋转。

Dry bearings using moisture-free compressed

air. Be careful to direct air stream across bearing

to avoid spinning. Do not spin bearings when

drying.

壳体 Housings

变速箱箱体和变矩器壳体的内部、外部及轴承安装部位应在清洗液中进行彻底清洗。

Clean interior and exterior of housings, bearing

caps,etc., thoroughly.

铸造类零件可在带碱溶液的热溶液罐清洗。如果这些零件表面没有加工或抛光，零件应放在溶液中足够长的时间以进行彻底清洗和加热，清洗液由于蒸发原因需要及时添加。溶液罐中清洗干净的零件必须用干净的水进行彻底地冲洗以去掉所有碱的痕迹。铸造类零件也可以用清洗机清洗。

Cast parts may be cleaned in hot solution tanks

with mild alkali solutions providing these parts do

not have ground or polished surfaces. Parts

should remain in solution long enough to be

thoroughly cleaned and heated. This will aid the

evaporation of the cleaning solution and rinsewater. Parts cleaned in solution tanks must be

thoroughly rinsed with clean water to remove all

traces of alkali. Cast parts may also be cleaned

with steam cleaner.

注意：使用易挥发、易着火的清洗液时，应

小心谨慎，避免皮肤出疹，火灾隐患和吸入溶剂

蒸汽。

CAUTION: Care should be exercised to

avoid inhalation of vapors and skin rashes

when using alkali cleaners.

所有清洗干净的零件必须立即用干燥压缩空气吹干或没有研磨材料（如金属屑，污油或研磨剂）的软吸水擦拭抹布擦干净。

All parts cleaned must be thoroughly dried

immediatley by using moisture-free compressed

air or soft, lintless absorbent wiping rags free of

abrasive materials such as metal filings,

contaminated oil or lapping compound.

检查

Inspection

过分强调仔细、彻底地检查所有部件的重要性也不为过。及时更换已损坏的零件，这样可避免将来的因更换零件造成的误工损失和金钱损失。

The importance of careful and thorough

inspection of all parts cannot be overstressed.

Replacement of all parts showing indication of

wear or stress will eliminate costly and avoidable

failures at a later date.

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部件清洗和检查 Cleaning and Inspection

轴承 Bearings

仔细检查轴承的滚动体、内圈、外圈有无磨损、缺口或划痕，以确定轴承是否适合进一步使用。不能单独更换轴承的滚动体、内圈、外圈。检查完毕后，将合格的轴承浸泡在液力传动油中直至安装。

Bearings Carefully inspect all rollers; cages and

cups for wear, chipping or nicks to determine

fitness of bearings for further use. Do not replace

a bearing cone or cup individually without

replacing the mating cup or cone at the same

time. After inspection, dip bearings in Automatic

Transmission Fluid and wrap in clean lintlesscloth or paper to protect them until installed.

油封、密封垫等Oil seals, gaskets, etc.

当零件被拆卸重新装配时，同时更换与其配用的油封、O形圈、密封环、密封垫、挡圈等，这比在将来过早检修这些零件时需要更换时才更换要经济得多。一个旧的密封圈可能会引起其它较昂贵的总成部件故障。

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

metal sealing rings, gaskets and snap rings is

more economical when unit is disassembled

than premature overhaul to replace these parts

at a future time. Further loss of lubricant through

a worn seal may result in failure of other more

expensive parts of the assembly.

密封件在安装时应谨慎处理。密封件边缘的切口、刮伤、卷曲将严重损害其效率。安装油封时在其唇口涂上一层薄薄的液力传动油，以保证油封紧密配合；安装密封环时，在其周围涂上一层润滑脂，将其固定在密封环凹槽内；安装O形圈时根据需要在其表面涂上一层薄薄的液力传动油

或润滑脂，以保证O形圈紧密配合。

Sealing members should be handled carefully,

particularly when being installed. Cutting,

scratching, or curling under of lip of sealseriously impairs its efficiency. Apply a thin coat

of Permatex No. 2 on the outer diameter of the

oil seal to assure an oil tight fit into the retainer.

When assembling new metal type sealing rings,

same should be lubricated with coat of chassis

grease to stabilize rings in their grooves for ease

of assembly of mating members. Lubricate all "0"

rings and seals with recommended type

Automatic Transmission Fluid before assembly.

齿轮和轴 Gears and shafts

如果有磁力探伤仪器，使用该仪器检查齿轮和轴。仔细检查所有齿轮的齿有无磨损、点蚀、划伤、裂痕。如果齿轮齿出现疲劳变形、开裂时，更换为新齿轮。用合适的珩磨机可消除细小的裂口。检查轴和衬套以确定它们是否变形、弯曲，或轴上花键扭曲，从而确认轴是否完好。

If magna-flux process is available, use process

to check parts. Examine teeth on all gears

carefully for wear, pitting, chipping, nicks, cracks

or scores. If gear teeth show spots where case

hardening is worn through or cracked, replacewith new gear. Small nicks may be removed with

suitable hone. Inspect shafts and quills to make

certain they are not sprung, bent, or splines

twisted, and that shafts are true.

壳体、端盖等Housing, covers, etc.

检查变速箱箱体、变矩器壳体、端盖和轴承外圈，以确定它们彻底清洗，并且变速箱箱体配合面、变矩器壳体配合面和轴承内圈等应无裂痕。仔细检查所有部件，找出存在的裂缝或可能会导

致随后的漏油或故障情况的迹象。

Inspect housings, covers and bearing caps to be

certain they are thoroughly clean and that mating

surfaces, bearing bores, etc., are free from nicks

or burrs. Check all parts carefully for evidence of

cracks or condition which would cause

subsequent oil leaks or failures.

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部件拆解 Parts Disassembly双变总成附件 Transmission and Torque Converter Accessories

部件拆解 Parts Disassembly

双变总成附件 Transmission and Torque Converter Accessories

双变总成附件 Transmission and Torque Converter Accessories

件号 No. 名称 Description 数量 Q’ty 件号 No. 名称 Description 数量 Q’ty

1 软管总成 Hose assembly 1 9 粗滤油器 Coarse filter 1

2 接头Connector 1 10 O形圈O-ring 1

3 放油螺塞Oil drain plug 1 11 盖板Cover plate 1

4 O形圈O-ring 1 12 垫圈Washer 4

5 磁铁Magnet 1 13 螺栓 Bolt 4

6 圆形油标 Sight glass 1 14 垫圈Gasket 4

7 O形圈O-ring 1 15 接头Connector 2

8 可调接头 Adjustable connector 1 16 软管总成 Hose assembly 1

1

23

4

5

6

7

8

9

10

11

12

13

14

14

15

14

14

15

16

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30


注意：清洁是一项非常重要的事情，在开始拆卸零件前，零件的外部应该全部清洗，这有助于防止

泥土、灰尘等外部物质进入零件内部。

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

disassembling to prevent mud and dust etc. coming inside.

1. 将变速箱水平地放在安装架上，锁紧安装架的锁紧装置。

Place the transmission levelly on the mounting

rack, lock the locking device of the mounting rack.

2. 从放油口处拆下放油螺塞 (3)，放出液力传动油，并用容器盛装。

Remove the oil drain plug (3) from the oil outlet to

release transmission oil, and collect with a

container.

注意：请将废弃液力传动油回收，避免废弃液

力传动油对环境造成污染。

CAUTION: Recycle all waste transmissionoil with suitable containers to avoid polluting

the environment.

3. 从放油螺塞 (3)上拆下磁铁 (5)和O形圈 (4)。

Remove the magnet (5) and O-ring (4) from the oil

drain plug (3).

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4. 拧松粗滤油器 (9)，从变速箱上移走粗滤油器(9)。

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

transmission.

5. 拆下圆形油标 (6)。

Remove the sight glass (6).

6. 从圆形油标 (6)上拆下O形圈 (7)。

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

7. 拧开软管总成 (1)两端接头，取下软管总成(1)。

Unscrew the hose assembly (1) connectors at both

ends, remove the hose assembly (1).

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8. 从变矩器上拆下可调接头 (8)。

Remove the adjustable connector (8) from thetorque converter.

9. 从变速箱上拆下接头 (2)。

Remove the connector (2) from the transmission.

10.从变矩器上拆下软管总成 (16)的连接接头(15)、垫圈 (14)。

Remove the hose assembly (16) connector (15)

and gaskets (14) from the torque converter.

11. 从变速操纵阀上拆下软管总成 (16)的连接接头(15)、垫圈 (14)，并移走软管总成 (16)。

Remove the hose assembly (16) connector (15)

and gaskets (14) from the shift control valve, and

then remove the hose assembly (16).

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33

部件拆解 Parts Disassembly变矩器组件 Torque Converter Group

变矩器组件 Torque Converter Group

1

2

3

4

4

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22 23

24

20

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34


变矩器组件 Torque Converter Group



CAUTION: Cleanliness is quite important. Clean the component sur face before


件号 No. 名称 Description 数量 Q’ty 件号 No. 名称 Description 数量Q’ty

1 螺栓 Bolt 12 13 齿轮Gear 1

2 垫圈Washer 12 14 挡圈 Circlip 1

3 调整套 Adjusting sleeve 1 15 纸垫 Paper gasket 1

4 弹性板 Flexible plate 3 16 盖板 Cover plate 1

5 螺栓 Bolt 8 17 垫圈Washer 2

6 垫圈Washer 8 18 螺栓 Bolt 2

7 过渡套 Shaft 1 19 吊环 Lifting eye 1

8 O形圈O-ring 1 20 垫圈Washer 12

9 油封 Seal 1 21 螺栓 Bolt 2

10 连接套Housing 1 22 螺栓 Bolt 10

11 纸垫 Paper gasket 1 23 铆钉 Rivet 4

12 变矩器芯 Torque converter 1 24 铭牌 Nameplate 1

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弹性板、连接套及过渡套 Flexible Plate, Housing and Shaft

1. 拆下调整套 (3)的连接螺栓 (1)、垫圈 (2)。

Remove bolts (1) and washers (2) from the

adjusting sleeve (3).

2. 移走调整套 (3)。Remove the adjusting sleeve (3).

3. 取出弹性板 (4)。

Remove the flexible plates (4).

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4. 拆下过渡套 (7)的连接螺栓 (5)、垫圈 (6)。

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

5. 用铜棒轻敲过渡套 (7)，取出过渡套 (7)。

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

remove the shaft (7).

6. 从过渡套 (7)上取出O形圈 (8)。

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

7. 拆下连接套 (10)的连接螺栓 (22)、垫圈 (20)。

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

(10).

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8. 拆下吊环 (19)的连接螺栓 (21)、垫圈 (20)，并移走吊环 (19)。

Remove bolts (21) and washers (20) from lifting

eye(19), and then remove the lifting eye (19).

9. 向上起吊连接套 (10)，并移走连接套 (10)。

Lift up the housing (10) and remove it.

10.取下纸垫 (11)。

Remove the paper gasket (11).

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11. 拆下盖板 (16)的连接螺栓 (18)、垫圈 (17)。

Remove bolts (18) and washers (17) from coverplate (16).

12.移走盖板 (16)、纸垫 (15)。

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

13.从连接套 (10)上拆下油封 (9)。

Remove seal (9) from housing (10).

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变矩器芯 Torque Converter

1. 在变矩器芯 (12)的对角安装两个吊环，向上起吊变矩器芯 (12)，使变矩器芯 (12)与变速箱上的变矩器壳体分离，移走变矩器芯 (12)。

Screw two eye bolts onto the opposite angles of

the torque converter (12), lift the torque converter

(12) upward to separate it from the torque

converter housing, and then remove it.

2. 从变矩器芯 (12)上拆出齿轮挡圈 (14)。

Remove the gear circlip (14) from the torque

converter (12).

3. 从变矩器芯 (12)上移走齿轮 (13)。

Remove the gear (13) from the torque converter

(12).

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41

部件拆解 Parts Disassembly变矩器壳体组件 Torque Converter Housing Group

变矩器壳体组件 Torque Converter Housing Group





件号 No. 名称 Description 数量 Q’ty 件号 No. 名称 Description 数量 Q’ty

1 密封环Casting iron seal 2 20 球轴承 Ball bearing 4

2 导轮座 Stator seat 1 21 垫圈 Spacer 2

3 涡轮轴 Turboshaft 1 22 取力齿轮 P.T.O gear 2

4 密封环Casting iron seal 1 23 挡圈Circlip 2

5 球轴承 Ball bearing 1 24 取力器轴 P.T.O shaft 1

6 挡圈 Circlip 1 25 调整垫片 Shim 2

7 挡圈 Circlip 1 26 挡圈Circlip 2

8 螺栓 Bolt 7 27 O形圈O-ring 1

9 垫圈Washer 7 28 螺栓 Bolt 6

10 进口阀 Inlet valve 1 29 法兰 Flange 1

11 O形圈O-ring 1 30 O形圈O-ring 1

12 变矩器壳体Torque converter housing 1 31 管接头Connector 1

13 螺栓 Bolt 24 32 取力器轴 P.T.O shaft 1

14 垫圈Washer 40 33 纸垫 Paper gasket 1

15 O形圈O-ring 1 34 接头Connector 1

16 螺塞 Plug 1 35 垫圈Gasket 1

17 圆柱销 Pin 2 36 变速泵Charging pump 1

18 出口阀Outlet valve 1 37 螺栓 Bolt 6

19 螺栓 Bolt 2 38 螺栓 Bolt 2

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变速泵、法兰、出口阀 Charging Pump, Flange, Outlet Valve

1. 拆下变速泵接头 (34)、垫圈 (35)。

Remove connector (34) and gasket (35) from the

charging pump.

2. 拆下变速泵管接头 (31)、O形圈 (30)。Remove connector (31) and O-ring (30) from the

charging pump.

3. 拆下变速泵 (36)的连接螺栓 (38)、垫圈 (14)。

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

4. 拆下变速泵 (36)的连接螺栓 (37)、垫圈 (14)。


charging pump (36).

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5. 用铜棒轻敲变速泵 (36)四周边缘，直至变速泵(36)与变矩器壳体 (12)分离，移走变速泵(36)。

Tap the edges around the charging pump (36) with

a copper bar until the pump and the torque

converter housing (12) are separated, remove the

charging pump (36).

6. 移走变速泵密封纸垫 (33)。

Remove paper gasket (33) from the charging

pump.

7. 拆下转向泵法兰 (29)的连接螺栓 (28)、垫圈(14)。


steering pump flange (29).

8. 用铜棒轻敲转向泵法兰 (29)四周边缘，直至转向泵法兰 (29)与变矩器壳体 (12)分离，移走转向泵法兰 (29)。

Tap the edges around the steering pump flange

(29) with a copper bar until the flange (29) and thetorque converter housing (12) are separated,

remove the flange (29).

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9. 从转向泵法兰 (29)上取出O形圈 (27)。

Remove the O-ring (27) from the steering pumpflange (29).

10.拆下出口阀 (18)的连接螺栓 (19)、垫圈 (14)。

Remove the outlet valve (18) bolts (19) and

washers (14).

11. 移走出口阀 (18)。

Remove the outlet valve (18).

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变矩器壳体 Torque Converter Housing

1. 拆下变速箱上的连接螺栓 (13)、垫圈 (14)。


transmission.

2. 拆下变矩器壳体 (12)上的连接螺栓 (13)、垫圈(14)。


torque converter housing (12).

3. 向上起吊变矩器壳体 (12)，同时用铜棒向上敲打变矩器壳体 (12)，直至与变速箱分离，移走变矩器壳体 (12)。

Lift up the torque converter housing (12).

Meanwhile, tap the torque converter housing (12)

upward with a copper bar to separate it from the

transmission, and then remove the torque

converter housing (12).

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导轮座组件 Stator Seat Group

1. 拆下导轮座 (2)的连接螺栓 (8)、垫圈 (9)。

Remove bolts (8) and washers (9) from the stator

seat (2).

2. 在导轮座 (2)的起盖螺栓孔上拧入起盖螺栓，直至导轮座 (2)与变矩器壳体 (12)分离，移走导轮座 (2)。

Screw the bolts into the bolt holes of the stator seat

(2) until the stator seat (2) is separated from the

torque converter housing (12), remove the stator

seat (2).

3. 从导轮座 (2)上拆下球轴承 (5)的外圈挡圈 (6)。

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

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4. 用铜棒向下敲涡轮轴 (3)，直至导轮座 (2)与涡轮轴 (3)分离。

Tap the turboshaft (3) downwards with a copper

bar until it is separated from the stator seat (2).

5. 从导轮座 (2)上拆下密封环 (1)。

Remove the casting iron seal (1) from the stator

seat (2).

6. 拆下球轴承 (5)的内圈挡圈 (7)。

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

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7. 从涡轮轴 (3)上拆下球轴承 (5)。

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

8. 从涡轮轴 (3)上拆下密封环 (4)。

Remove the casting iron seal (4) from the

turboshaft (3).

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进口阀、取力齿轮、取力器轴

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

1. 拆下进口阀 (10)。

Remove the inlet valve (10).

2. 从进口阀 (10)上拆下O形圈 (11)。

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

3. 拆下转向泵取力器轴挡圈 (26)。

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

steering pump.

4. 取出调整垫片 (25)。

Remove the shim (25).

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5. 拆下变速泵取力器轴挡圈 (26)。

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

6. 取出调整垫片 (25)。

Remove the shim (25).

7. 用铜棒敲击变速泵取力齿轮 (22)侧面，直至球轴承 (20)与变矩器壳体 (12)分离。

Tap the side surface of the charging pump P.T.O

gear (22) with a copper bar until the ball bearing(20) is separated from the torque converter

housing (12).

8. 用錾子将球轴承 (20)从变速泵取力器轴 (32)上分离开。

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

(32) with a punch.

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9. 从变速泵取力器轴 (32)上取出变速泵取力器轴球轴承 (20)。

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

(32).

10.从变速泵取力器轴 (32)上取出变速泵取力器轴垫圈 (21)。

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

11. 用錾子向下崭变速泵取力器轴 (32)的台阶周围，直至变速泵取力器轴 (32)与取力齿轮 (22)上分离开。

Tap the steps around the P.T.O shaft (32)downwards with a punch until the P.T.O shaft (32)

is separated from the P.T.O gear (22).

12.从变速泵取力器轴 (32)上移走变速泵取力齿轮(22)。

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

(32).

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13.从变矩器壳体 (12)上取出变速泵取力器轴(32)。

Remove the P.T.O shaft (32) from the torque

converter housing (12).

14.从变速泵取力器轴 (32)上取下变速泵轴挡圈(26)。

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

15.从变速泵取力器轴 (32)上拆下球轴承 (20)。

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

(32).

16.用铜棒敲击转向泵取力齿轮 (22)侧面，直至球轴承 (20)与变矩器壳体 (12)分离。

Tap the side surface of the steering pump P.T.O

gear (22) with a copper bar until the ball bearing

(20) is separated from the torque converter

housing (12).

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17.用錾子将球轴承 (20)从转向泵取力器轴 (24)上分离开。

Separate the ball bearing (20) from the steering

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

18.从转向泵取力器轴 (24)上取出转向泵取力器轴球轴承 (20)。

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

19.从转向泵取力器轴 (24)上取出转向泵取力器轴垫圈 (21)。

Remove the shaft spacer (21) from the steering

pump P.T.O shaft (24).

20.用錾子向下崭转向泵取力器轴 (24)的台阶周围，直至转向泵取力器轴 (24)与取力齿轮 (22)上分离开。

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

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

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21.从转向泵取力器轴 (24)上移走转向泵取力齿轮(22)。

Remove the P.T.O gear (22) from the steering


22.从变矩器壳体 (12)上取出转向泵取力器轴(24)。

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

23.从转向泵取力器轴 (24)上拆下挡圈 (23)。

Remove the circlip (23) from the steering pump

P.T.O shaft (24).

24.从转向泵取力器轴 (24)上拆下球轴承 (20)。Remove the ball bearing (20) from the steering


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部件拆解 Parts Disassembly制动器 Brake

制动器 Brake

制动器 Brake





件号 No. 名称 Description 数量 Q’ty 件号No. 名称 Description 数量 Q’ty

1 制动器组件 Brake group 1 8 螺栓 Bolt 4

2 法兰 Flange 1 9 垫圈 Washer 4

3 螺栓 Bolt 8 10 螺栓 Bolt 1

4 垫圈 Washer 8 11 垫圈 Washer 1

5 制动鼓 Brake hub 1 12 螺母 Nut 1

6 锁紧螺母 Locknut 1 13 拉杆 Handle 1

7 O形圈 O-ring 1

1

2

7

6

3

4

5

8

9

10

11

12

13

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1. 拆下制动鼓 (5)的连接螺栓 (3)、垫圈 (4).

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

(4).

2. 移走制动鼓 (5)。

Remove brake hub (5).

3. 拆下锁紧螺母 (6)。

Remove locknut (6).

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4. 取出O形圈 (7)。

Take out the O-ring (7).

5. 移走输出法兰 (2)。

Remove the flange(2).

6. 拆下制动器组件 (1)的连接螺栓 (8)、垫圈 (9)。

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

(9).

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7. 移走制动器组件 (1)。

Remove brake group (1).

8. 拆下拉杆 (13)的连接螺栓 (10)、垫圈 (11)、螺母 (12)，移走拉杆 (13)。

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

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部件拆解 Parts Disassembly接头及档位软管总成 Connectors and Hose Assembly

接头及档位软管总成 Connectors and Hose Assembly





件号 No. 名称 Description 数量Q’ty 件号 No. 名称 Description 数量 Q’ty

1 接头 Connector 3 14 软管总成 Hose assembly 1

2 垫圈 Gasket 6 15 软管总成 Hose assembly 1

3 软管总成 Hose assembly 1 16 软管总成 Hose assembly 1

4 O形圈 O-ring 1 17 接头Connector 3

5 接头Connector 1 18 垫圈Gasket 6

6 O形圈 O-ring 1 19 呼吸器 Breather 1

7 软管总成 Hose assembly 1 20 透气管 Breather pipe 1

8 O形圈 O-ring 3 21 O形圈O-ring 1

9 接头Connector 3 22 管接头Connector 1

10 O形圈O-ring 9 23 软管总成 Hose assembly 1

11 软管总成 Hose assembly 1 24 软管总成 Hose assembly 1

12 接头Connector 6 25 O形圈O-ring 1

13 垫圈Gasket 6 26 接头Connector 1

1. 拆下透气管 (20)。

Remove breather pipe (20).

2. 从透气管 (20)上拆下呼吸器 (19)。

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

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3. 拆下管接头 (22)、 O形圈 (21)。

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

4. 从方向档配油盖上拆下软管总成 (7)的连接接头(1)、垫圈 (2)。

Remove the hose assembly (7) connector (1) andgaskets (2) from the cover of the CV&CR

assembly.

5. 从Ⅰ -Ⅲ档配油盖上拆下软管总成 (7)的连接接头 (1)、垫圈 (2)，移走软管总成 (7)。

Remove the hose assembly (7) connector (1) and

gaskets (2) from C1&C3 cover. Take off hoseassembly (7).

6. 从Ⅱ -Ⅳ档配油盖上拆下软管总成 (3)的连接接头 (1)、垫圈 (2)。

Remove the hose assembly (3) connector (1) and

gaskets (2) from C2&C4 cover.

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7. 从方向档配油盖上拆开软管总成 (3)连接，移走软管总成 (3)。

pt300维修手册 en

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