Service Manual of Wheel Loader

Contents
4 Overview of transmission system ................................................................. 4-1
41 A30X and BX50 transmission system .......................................................... 4-1
411 Basic parameters of transmission and torque converter system ............... 4-1
412 Detection and adjustment of transmission and torque converter system . 4-1
413 Common faults and troubleshooting method of planetary transmission .. 4-2
42 VRT200 transmission system ....................................... 4-错误!未定义书签。
421 Basic parameters of transmission and torque converter system4-错误!未定
义书签。
422 Detection and adjustment of transmission and torque converter system4-错
误!未定义书签。
423 Common faults and troubleshooting method of VRT200 transmission4- 错
误!未定义书签。
43 Maintenance of transmission and torque converter system4-错误!未定义书签。
431 Precautions for disassembling and assembling transmission4-错误!未定义
书签。
432 Disassembly and assembly flow chart of transmission4-错误!未定义书签。
44 Transmission shaft system .......................................................................... 4-22
441 Precautions for maintaining transmission shaft ...................................... 4-22
45 Drive axle system ......................................................................................... 4-22
451 Fault diagnosis and troubleshooting of drive axle .................................. 4-22

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 Service Manual of Wheel Loader

4 Overview of transmission system

41 A30X and BX50 transmission system
411 Basic parameters of transmission and torque converter system
Table 4-1 Basic parameters of transmission
Item Parameter
Single-stage four –element double-turbine
Type
hydraulic torque converter
Torque Inlet oil pressure of torque
0.5~0.6
converter converter (MPa)
Outlet oil pressure of torque
0.21~0.26
converter (MPa)
Type Planetary power shift
Transmission gear Two forward and one reverse
Transmission
Transmission working pressure
1.1~1.5
(MPa)

412 Detection and adjustment of transmission and torque converter system

1. Detection of transmission pressure
Tool:
Test connector of transmission pressure: 6410006225
Test hose SMS20/M1/4-3000A: 4030000368
Pressure gauge CPG063-00025-01-S-B04: 6430000943

Fig. 4-1 Pressure detection tool
a) Place the loader at the service location, put down
the bucket on the ground and implement the
parking brake. Shut down the engine and operate
the control lever 3-5 times and then release residual
pressure. (Oil temperature: 45~55℃)
b) Disassemble the maintenance cover of the loader.
c) Disconnect the transmission pressure switch
connector.
d) Disassemble the pressure switch on the
transmission control valve as shown in the figure
and install the transmission test connector at the
disassembly location.

1 2
e) Connect one end of test pipe to the test connector
Fig. 4-2
of transmission pressure and the other end to the
1 Reverse pressure switch pressure gauge (range: 0~6MPa).

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 Service Manual of Wheel Loader
2 Alarm switch of transmission f) Start the engine, step on the brake, shift all gears
pressure and observe the table pressure value of oil pressure
gauge which is the current transmission pressure of
tested loader. Determine whether the oil supply
system is normal based on conditions.
g) After the test, repeat a) pressure discharging step
and then install transmission control lever pressure
sensor (switch) and pressure sensor connector and
then wipe out the transmission oil leaked outside.

Note:
 Pressure gauge pipe, instruments on both ends and pressure detection port should be connected
reliably so as to prevent the oil leakage from affecting measurement value during the test.
 During the test, the engine speed should increase gradually. Do not accelerate the engine
suddenly so as to avoid damaging the pressure gauge due to impact.
 The pressure gauge is the precise measuring instrument, so it should be detected regularly (half
a year or a year).
 Avoid impact and collision during the use and wipe it out and place it in the special storage
location in the tool kit after use.
2. Adjustment of transmission pressure
Adjustment of transmission pressure: remove plug screws on both ends of pressure regulating valve
and take down energy storage piston, pressure adjusting spring and pressure regulating valve
element. Adjust the transmission pressure by replacing pressure adjusting spring or increasing and
reducing gasket on the spring seat of pressure regulating valve element. The increase of spring
length or gasket will make the pressure rise; the decrease of spring length or gasket will lower the
pressure.

Note: Detect the pressure at the neutral gear after adjusting pressure so as to prevent
excessive pressure from damaging oil cylinder.

1
Fig. 4-3
1 Installation location of adjusting gasket
413 Common faults and troubleshooting method of planetary transmission
1. What are causes that the transmission oil level lowers, the junction of torque converter and
engine has oil leakage and sometimes the engine oil level rises?
Diagnosis:
If the rotary oil seal between the torque converter idler pulley seat and the transfer gear is damaged,
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 Service Manual of Wheel Loader
the torque converter oil will leak into four enclosed active wheels and torque converter shell along
the damaged part. Due to larger leakage, the oil-returning inclined holes in the torque converter
shell cannot be discharged immediately, so some oil will be thrown away by the active wheel
rotating at high speed, which will cause the oil leakage on the junction between the torque converter
and the engine. When the crankshaft oil seal of the engine loses efficacy, the hydraulic oil will enter
the engine to make the engine oil rise and lower the transmission oil.
2. What is the cause that the level of transmission oil pan automatically rises?
Diagnosis:
This is caused by the damaged oil seal of steering pump or working pump input shaft. The oil in the
hydraulic system flows into the transmission oil pan through the torque converter gearbox to make
the oil level rise. Replace new oil seal based on damage conditions.
3. What is the cause that the torque converter has higher oil temperature?
Diagnosis: If the engine operates normally, the torque converter can only work with the oil
temperature over 65℃. The optimum oil temperature is 85—95℃. When exceeding 120℃, the oil
temperature of torque converter will be regarded to be excessive. Faults are caused by:
(1) Lower level of transmission oil pan or blocked filter screen reduces the oil supply in the oil-way,
makes it difficult for hydraulic pump to absorb oil and generates cavity and erosion in the system
pipeline, which will the oil heating. When the transmission oil pan level is higher, the increased
stirring of moving parts in the transmission shell will also make the oil temperature rise. Check the
oil level and increase or decrease (replace) the oil to implement the troubleshooting.
(2) The transmission pressure is smaller. When the transmission pressure is less than 0.88Mpa, the
relative sliding friction of transmission friction plates at all gears will generate heat. Thinner friction
plates and faulted return spring will cause the clutch slide frequently to make the oil temperature
rise. Carry out the retrieval processing respectively.
(3) The oil cooler of torque converter cannot work normally (the radiator is blocked and oil sludge
between radiating fins is excessive). Check the cooler and clean the dust completely. When
necessary, clean and maintain the interior of cooler and timely adjust the operation load and shut
down for cooling. Carry out the operation after the oil temperature recovers to the normal state.
(4) The large overrunning clutch of transmission is broken. The sliding friction among inner ring
cam, large outer ring gear and 24 pin rollers generates heat.
(5) Continuous operation time of torque converter is too long. The poor-quality and deterioration of
oil will also cause the higher oil temperature of torque converter. Respectively eliminate these
causes.
4. What is the cause that the machine cannot start after the gear shift?
Diagnosis:
(1) The transmission oil level is not in conformity with requirements.
(2) The gear is not engaged. Re-adjust the transmission control lever.
(3) The parking brake is not released.
(4) The transmission pump is worn seriously. After the machine is set aside for a long time or the
transmission pump is removed, the oil in the pipeline will return to the tank. So the transmission
cannot pump out oil.
(5) Lower pressure in the transmission system and infirm connection between shifting friction plate
and clutch will also cause the machine unable to drive.
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 Service Manual of Wheel Loader
5. What are causes that the loader has insufficient driving force (no power for operation)? How to
eliminate?
Diagnosis: The insufficient driving force of machine means that the machine cannot overcome large
load. If the engine power is normal, following causes may be possible:
(1) If the pressure in the transmission system is lower, the machine with large load will slide. Check
the transmission pump and the transmission valve based on method to inspect low pressure.
(2) The transmission pressure is normal but the operation is still lack of power and oil overflows
from the motor. This is usually caused by the damaged rotary oil seal of the torque converter or the
damaged O-shape seal ring between cover wheel and pump impeller. Disassemble and inspect the
torque converter and at the same time check the wear in circular groove of idler pulley and inner
hole of transfer gear and then carry out replacement and maintenance as appropriate.
(3) The transmission pressure is normal, operation is lack of power, oil temperature is high and the
bottom of oil has aluminum skimmings. This is caused by damage in pump impeller, idler pulley or
Grade I, II turbine. Disassemble the torque converter for inspection.
(4) The transmission pressure is normal and the machine can drive but lack power. This is mainly
caused by damaged overrunning clutch. If three compressing springs of overrunning clutch lose
efficacy, the isolating ring breaks off, pin roller surface of inner ring cam or outer ring cam is worn
seriously, disassemble and replace parts or large overrunning clutch assembly.
(5) The transmission pressure can reach the normal condition, but the meter hand swings and loses
stability, the transmission pump has abnormal noise, the operation lacks power or works normally
at the beginning but still lacks power after a while. This is usually caused after the transmission
pump is replaced or the assembly of transmission and torque converter is serviced. The cause is that
the transmission low-pressure pipeline is not sealed tightly and the entered large amount of gas
makes the torque converter unable to provide sufficient oil. Check whether the joint paper washer of
transmission pump is flat and tight, whether the junction between the oil suction pipe and the pump
has gas leakage and whether the oil suction pipe is aging and has gas leakage.
(6) The transmission pressure is normal, the operation can be done at the first but lacks power after
a while. The vehicle cannot drive with accelerator stepped hard and can drive after the accelerator is
released or stopping a while. Firstly clean the transmission oil pan, because this fault is caused by
the dirt blocking the filter screen which causes the oil unable to be sucked up. The aging oil suction
pipe of transmission pump delaminates the inlayer and causes the suction become difficult.
6. What are causes that the transmission oil pan has lots of aluminum skimmings or metal filings
and the oil temperature rises?
Diagnosis:
(1) The numerous aluminum skimmings in the oil indicate that there exists abrasion between active
wheels of torque converter. By this time, the transmission efficiency lowers and the working oil
radiates.
(2) The numerous copper scales in the oil indicate that there exists dry friction or sliding between
active friction plate and driven friction plate. Check whether the level of hydraulic oil and the
transmission pressure are normal. If the above condition is normal, it may be caused by improper
assembly of active friction plate and driven friction plate or deformation.
(3) The numerous iron scraps in the oil indicate that the overrunning clutch slides. By this time, the
loader operates from high speed and light duty to low speed and heavy duty. The sound of metal
friction exists in the transmission and the operation lacks power. The pin roller of the overrunning
clutch gets stuck at the wedge-caulking position. In this circumstance, the operation has power at

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 Service Manual of Wheel Loader
gear I but the speed cannot increase at gear II. Disassemble and check the overrunning clutch.
(4) The oil pan with metal fragments indicates that the bearing in the assembly of transmission and
torque converter is damaged.
7. What is cause that transmission pressure at all gears is low?
Diagnosis: The optimum transmission pressure at all gears is 1.1—1.5MPa. The pressure lower than
0.88MPa cannot be used for the following reasons:
(1) The transmission oil level is lower or the oil inlet of transmission pump is not connected firmly,
which may cause the air enter the hydraulic pump and lead to serious cavitation. After the gear shift
lever is changed to the new gear, the machine delays to change speed and lacks power for operation.
Respectively check the connection between oil level and pipes.
(2) The transmission pump is worn seriously, the inner leakage is excessive or the pump speed is
lower, which all make the volume efficiency lower. Firstly check the connection part of pump and
then check the transmission pump.
(3) The setting pressure of pressure valve on the transmission control valve is lower or the pressure
spring loses efficacy (losing elasticity or broken). Re-adjust the pressure or replace the spring.
(4) The stuck pistons of transmission control valve or energy accumulator cannot contract the
pressure spring. Eliminate the fault by cleaning control valve.
(5) Main oil way has leakage or the oil filter is blocked. Check and clean the oil way.
(6) The gasket on the junction surface between the transmission valve and the transmission is
damaged. High pressure and low pressure at all gears are connected, so the pressure cannot rise.
Check the sealing gasket.
(7) The pressure loses efficacy and does not real pressure value of transmission at all gears. Check
the pressure gauge.
8. What is the cause that the pressure at gear I and reverse gear cannot rise and the pressure at gear
II is normal?
Diagnosis:
Generally, do not check the transmission pump or the transmission valve and just inspect the
transmission. Firstly check whether the connecting bolt between the central cover and the
transmission body is broken; then check and measure whether the axial clearance between central
cover and hydraulic cylinder at gear I is controlled within 0.3～0.4 mm.
9. What is the cause that the pressure at gear I cannot rise and the pressure at gear II and reverse
gear is normal?
Diagnosis:

(1) Check whether the oil seal of piston at gear I is damaged.

(2) Check whether the piston at gear I has sand hole.

10. What is the cause that the pressure at reverse gear cannot rise and the pressure at gear I and gear
II is normal?
Diagnosis:
Firstly check whether the reverse position of transmission has crack, which may be caused by
higher system pressure.
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 Service Manual of Wheel Loader
11. What is the cause that the pressure at gear II cannot rise and the pressure at gear I and reverse
gear is normal?
Diagnosis:
(1) Whether the rotary oil seal at the matching part between the center of rear transmission end
cover and hydraulic cylinder at gear II is damaged or lacks assembly.
(2) Whether the O-shape ring of oil outlet of oil way at gear II at the junction between transmission
and the rear end cover is damaged.
(3) Check whether 3 piston guide pins in the hydraulic cylinder at gear II falls off.
12. Why does the transmission have “chaotic” gears? How to resolve it?
Diagnosis:
(1) Two locking balls in the valve rod and the valve body of transmission valve do not align the slot.
(2) Spring of two locking balls loses efficacy.
(3) The deviation is caused by the lengthened control lever.
13. Why does the brake occur suddenly when the gear II is changed to gear I or the gear I is
changed to gear II?
Diagnosis:
The loader operates for a long time, so the control lever becomes inaccurate due to being stretched.
During the gear shifting, the pressure oil enters gear I and gear II at the same time, so gear I and
gear II generates interference phenomenon and causes sudden braking.
14. What are phenomena reflected by faults of transmission overrunning clutch?
Diagnosis:
(1) In case of low speed and heavy duty, sudden cause will occur;
(2) The vehicle drives normally at gear II and lacks power for operation suddenly;
(3) The transmission generates abnormal noise suddenly and the vehicle speed decreases suddenly;
(4) In case of starting or gear shifting, the machine reacts slowly;
(5) Speed at gear II and gear I has no difference and the vehicle speed cannot rise.
15. What is the cause that the transmission pressure at all gears is normal, but the loader cannot
drive?
Diagnosis:
(1) The axle shaft breaks off.
(2) The hand braking locks.
(3) The brake caliper and the axle lock.
(4) The clearance between the central cover and the oil cylinder at gear I and the clearance between
the end cover and the cylinder at gear II are too small. The bearing is pressed tightly and gears of all
shifts cannot drive normally.
16. What is the transmission pressure at all gears? What danger will be caused if the pressure is
higher or lower?
The transmission pressure should be controlled with 1.1-1.5 Mpa. The higher pressure will cause
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 Service Manual of Wheel Loader
the transmission cylinder break at the reverse gear; and the lower pressure will cause the friction
plates at all gears slide and the loader drive slowly. The higher or lower pressure will rise the oil
temperature of torque converter dramatically.
17. What is the cause that the loader sometimes does not drive, namely driving in the condition that
the engine temperature in conformity with the environment temperature but not driving in the
condition that the engine temperature higher than the environment temperature?
Diagnosis:
(1) Check the oil limit valve next to the transmission and fill new oil if finding the lack of oil.
(2) If the oil mass is normal. Check the transmission pressure gauge. If the pressure gauge point
swings vigorously, it means that the oil supply is insufficient. Check whether the oil inlet is
blocked, the rubber pipe gets blister due to aging inlayer, the torque converter filter is blocked and
the oil filter element is cleaned in turn.
(3) The working oil has poor cleanliness and the dirt sucked surrounding the filter screen gradually
blocks the filter screen and the dirt will disperse when the vehicle parks.
(4) The transmission pump is burnt out. In case of engine temperature in conformity with
environment temperature, the oil is dense and the inner leakage is small, which can meet
requirements at all gears. However, in case of engine temperature higher than environment
temperature, the oil is thin and the inner leakage is large, so the oil supply cannot meet requirements
at all gears and the vehicle cannot drive.
(5) Check the transmission oil pan and observe whether there is metal block and aluminum
shimming on the filter screen. If any, it means that torque converter and the transmission have
damaged parts inside and should be inspected after disassembly. Damaged parts should be replaced.
18. What is the cause that the loader can only moves forward but cannot move backward?
Diagnosis:
(1) Check whether the pressure indicated on the transmission pressure gauge is normal. If the
pressure lowers at the reverse gear, it means that oil leakage is too much at the reverse, which
causes the vehicle unable to drive at reverse gear. Disassemble and inspect the transmission, replace
the piston ring at reverse gear, check the wear in friction plate and replace the friction plate with
serious wear.
(2) If the pressure at reverse gear does not lower, it means that the forward gear gets stuck, which
causes the friction plate slide at the reverse gear and the vehicle unable to drive at the reverse gear.
Disassemble and inspect the transmission. Check whether the isolating ring on annular gear at gear I
is broken, because the broken plate will get the friction plate stuck at gear I and then make the
friction plate at reverse gear lose efficacy, which will lead to the condition that the vehicle can only
move forward but cannot move back.
19. What is the cause that the transmission pressure is normal, but the vehicle at gear I and reverse
gear cannot drive and can only drive normally at gear II?
Diagnosis:
The cause of this fault is directly shifting gear instead of stepping pedal, so the terminal pad at gear
I and reverse gear in the transmission will twist off or the connecting bolt breaks off, which causes
the power unable to be transferred. Therefore, the vehicle at gear I and reverse gear cannot drive.
The gear II is connected to the internal spline of sun gear directly and the power can be transferred,
so the vehicle at gear II can drive.

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 Service Manual of Wheel Loader
20. Why does the machine “nod” in case of the gear shift?
Diagnosis:
(1) The control valve element of gear shift does not move to the specified place, so oil way is not
cut off immediately and the gear shift of machine delays. Check and clean the control valve and
replace new valve when necessary.
(2) The shift piston twists and deforms and cannot return to the location completely. Check and
replace the piston.
(3) The shifting oil pressure of machine is higher and adjust the shifting oil pressure again.
(4) The system oil has serious inner leakage, so the piston cannot return to the location completely
after the oil pressure at this gear is released. Check and eliminate the inner leakage of oil.
(5) When the machine cannot reach the shifting speed, shift the gear again.
21. The vehicle with the gear engaged before being refueled drives slowly but cannot drive after
being refueled.
Diagnosis:
(1) The filter pipe of torque converter or the oil suction pipe of transmission pump is aging, so the
inside is peeling. Non-refueling belongs to natural state and the pipe is slightly blocked. However,
the oil will be sucked up to block the pipe in case of the refueling.
(2) The foreign matters falling into the pipe will be sucked up to block the pipe in case of the
refueling.
22. In case of the engine temperature higher than the environment temperature, the vehicle cannot
dive with heavy duty.
Diagnosis:
(1) The pin roller of overrunning clutch wears out, slides in case of the engine temperature higher
than the environment temperature and cannot fit in and the gears of inner and outer rings cannot
rotate in the same direction at the same time.
(2) The pump pulley of torque converter has tiny crack or sand hole. In case of the engine
temperature higher than the environment temperature, the oil leakage of torque converter will cause
the driving force insufficient.
23. The transmission pressure is normal after the machine is started, but the pressure at all gears
increases dramatically after the acceleration and exceeds the normal pressure.
Diagnosis:
The blocked main oil inlet of converter (near the overflow valve) causes the converter oil unable to
flow into the torque converter after supplying all gears. When the torque converter was delivered to
the factory, the main oil way had a white plastic plug. If the plug is not taken down in case of the
assembly, the above condition may occur.
24. In severe cold area, if the drive forgets to make water-proof preparations, the oil cooler of
torque converter will be frozen. After replacing damaged part and anti-freezing solution, when the
driver starts the machine on the second day, the transmission pump will have abnormal noise and
have no transmission pressure.
Diagnosis:
After the oil cooler of the torque converter is frozen, the water will flow into the transmission with
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 Service Manual of Wheel Loader
oil. After be placed for the whole night, the water will precipitate to the transmission oil pan (the
water specific gravity is larger than the torque converter oil) and will be frozen with the oil suction
pipe of transmission pump. Therefore, the oil cannot be sucked up when the machine is started.

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 Service Manual of Wheel Loader

42 YD13 transmission system

421 Basic parameters of transmission and torque converter system
Table 4-3 Basic parameters of YD13 transmission
Item Parameter
Single-stage three-element single-turbine
Type
hydraulic torque converter
Torque Inlet oil pressure of torque
0.85
converter converter (MPa)
Outlet oil pressure of torque
0.5
converter (MPa)
Type Fixed shaft power shift
Transmission gear Four forward and three reverse
Transmission
Transmission working pressure
1.3～1.7
(MPa)

422 Detection and adjustment of transmission and torque converter system

1. Detection of transmission pressure and gear pressure
Tool:
Test connector of transmission pressure: 6410006224
Test hose SMS20/M1/4-3000A: 4030000368
Pressure gauge CPG063-00025-01-S-B04: 6430000943
a) Disassemble the maintenance cover of the machine.
b) Break the transmission pressure switch connector.

c) Disassemble the pressure sensor (switch) and the

pressure sensor connector on the transmission control
Fig. 4-7 Pressure detection tool
lever as shown in the figure and then install the
transmission test connector on the disassembly location.
Specification of mounting hole: M10×1

d) Connect one end of test pipe to the transmission

pressure test connector and the other end to the pressure
gauge (range 0～6MPa)

Note:
 Pressure gauge pipe, instruments on both ends and
pressure detection port should be connected reliably
so as to prevent the oil leakage from affecting
measurement value during the test.
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 Service Manual of Wheel Loader
1 
234 5 6 7
Fig. 4-8 Pressure detection tool
1 Detection port of transmission
pressure
2 Detection port of clutch at gear II
3 Detection port of clutch at gear I
4 Detection port of clutch at gear III
5 Detection port of clutch at gear IV
6 Detection port of clutch at reverse b)
gear
7 Detection port of clutch at forward
gear
During the test, the engine speed should increase
gradually. Do not accelerate the engine suddenly so
as to avoid damaging the pressure gauge due to
impact.
e) Start the engine, step on the brake and shift gears to
observe the stable pressure value in the oil pressure
gauge which is the current transmission pressure of
measured loader. Determine whether the oil supply
system is normal based on conditions.
f) After the test, repeat a) pressure discharging step
and then install transmission control lever pressure
sensor (switch) and pressure sensor connector and
then wipe out the transmission oil leaked outside.
2. Outlet oil pressure detection of torque converter
a) Disconnect the oil temperature sensor connector of
torque converter.
Disassemble the oil temperature sensor on the outlet
of transmission torque converter as shown in the
figure and install the transmission test joint at the
disassembly location.
Specification of mounting hole: M14×1.5
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 Service Manual of Wheel Loader

3. Detection of gear selector

Tool: Multimeter
a) When the finished vehicle is powered on, as shown
in the left figure, remove the interior panel under the
steering wheel in the cab, dismantle the fixing bolt on
the gear selector and disassemble the gear selector.

Note: Separately detect the power supply of gear

selector cannot determine the good or the bad. The
detection can only be completed when the special
detection equipment or the computer control box is
connected to form the network loop.
Fig. 4-9 Pressure detection tool

b) Switch the multimeter to the gear measuring DC

voltage. The red probe connects the wire in the color
indicating different functions and the black probe
Function Green
Gear
Blue Yellow White Purple Brown Red Black connects the black harness.

Note: the working voltage of this gear selector is

5 VDC. Do not need to provide power supply for the
gear selector separately after the connection with
computer control box forms a network.

c) Check the voltage displayed on the multimeter to

determine the function of gear selector.

4. Detection of solenoid valve

Table 4-4 Definition and logics of a) Disconnect the power supply of finished vehicle,
YD13 transmission gear selector screw off the connector of transmission control valve,
output lead open the side cover, release the solenoid valve connector
and then connect the red end V/Ω of multimeter to one
end of solenoid valve and the other end to another
Control valve
terminal to measure the resistance value. The resistance
value should be within 60-70Ω. The resistance value not
within the range means that the solenoid valve has fault
and needs to be replaced.

Note: During the detection, consider the effect of

environment temperature on resistance value. When the
resistance value actually measured has little difference
from the specified resistance, the solenoid valve can still
operate normally.

Fig. 4-10 Solenoid valve

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 Service Manual of Wheel Loader

Gear IV Solenoid valve Clutch

The solenoid valve is on; The brake switch cuts off anode circuit.

Table 4-5 Logic diagram of solenoid

valve and clutch

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423 Common faults and troubleshooting methods of YD13 transmission

Table 4-6 Common faults of fixed shaft transmission
No. Fault feature Main cause
1. The starting circuit (like
power supply, electric lock,
start relay, start motor etc.)
of main engine breaks down.
2. The handle is not engaged
at neutral gear.
3. The fuse on the main
The engine cannot engine leading to the control
1
start. circuit is burned out.
4. The handle plug has poor
contact or the handle breaks
down.
5. The electronic control box
plug has poor contact or the
electronic control box breaks
down.
1. Oil pressure gauge breaks
down.
2. The tightening torque of
transmission control valve
bolt is insufficient.
Low pressure at 3. The spring of main
2
all gears pressure valve breaks off.
4. The transmission pump is
worn.
5. The scraps enter into the
transmission control valve or
valve clutch.
Oil pressure at
forward gear 1, 2,
1. Internal discharge
3 3 is low but at
clutch at forward gear
other gears is
normal.
Fault check and troubleshooting
1. Check the circuit of main engine and
refer to the instructions of starting
circuit of main engine.
2. The handle should be engaged at
neutral gear.
3. Replace the fuse.
4. Arrange the plug or check whether
the handle circuit is powered on
normally.
5. Arrange the plug or treat it as the
electronic control box fault.
1. Replace the oil pressure gauge.
2. M8 tightening torque of control
valve bolt is 20 Nm.
3. Replace the spring.
4. Replace the transmission pump.
5. Replace the filter and clean the
control valve.
1. After the engine shuts down, block
the oil-way leading to KV clutch and
then start the engine and engage gear 1,
of 2, 3 so as to make the transmission
pressure increase to the normal value. It
means that the clutch at this gear has
internal discharge and the transmission
needs to be repaired.

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 Service Manual of Wheel Loader

1. After the engine shuts down, block

the oil-way leading to KR clutch and
Oil pressure at
then start the engine and engage gear 1,
reverse gear 1, 2,
2, 3 so as to make the transmission
4 3 is low but at 1. Internal discharge of pressure increase to the normal value. It
other gears is clutch at reverse gear
means that the clutch at this gear has
normal.
internal discharge and the transmission
needs to be repaired.
1. After the engine shuts down, block
the oil-way leading to K1 clutch and
Oil pressure at then start the engine and engage
forward and forward and reverse gear 1 so as to
1. Internal discharge of
5 reverse gear 1 is make the transmission pressure
clutch at gear 1.
low but at other increase to the normal value. It means
gears is normal. that the clutch at this gear has internal
discharge and the transmission needs to
be repaired.
1. O-shape ring on the 1. Replace O-shape ring.
throttle plug screw breaks 2. M8 tightening torque of control
down. valve bolt is 20 Nm.
Short shifting time
6 2. The tightening torque of
for all gears
bolt on pressure control
valve is not within the
specified range.
1. The throttle plug screw is
Long shifting time blocked. 1. Wash and clear the screw.
7
for all gears 2. The pressure control valve 2. Wash and check the valve.
gets stuck.

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 Service Manual of Wheel Loader
1. Oil temperature sensor
breaks down.
2. Oil temperature gauge
breaks down.
3. The oil level is
insufficient.
4. Oil radiator of torque
High oil
converter has gas.
8 temperature of
torque converter 5. Oil-way from torque
converter to radiator is not
smooth.
6. The radiation capacity of
radiator is not enough.
7. The counter-balance valve
of torque converter gets
stuck.
1. The oil level is not
enough.
2. The elastic plate
connecting the engine and
the torque converter breaks
or the power connection
from torque converter to
transmission input gear has
fault (rarely occurring).
The vehicle 3. Circuit of finished vehicle
9 cannot drive at breaks down.
any gear.
4. Transmission pressure is
too low.
5. The solenoid valve breaks
down.
6. The shifting handle breaks
down.
7. The electronic control box
breaks down.
1. Emergency brake pressure
Vehicle cannot or parking brake pressure
10 drive at gear I and switch breaks down.
II. 2. Solenoid valve loses
efficacy (M4).
16
1. Replace part.
2. Replace part.
3. Check the oil level and refuel
according to correct method.
4. Exhaust the gas from the upper gas
vent on the radiator (for machine with
gas vent)
5. Check whether the oil pipe from the
radiator to the transmission and the
radiator are blocked.
6. Check whether the radiation capacity
is enough including inspecting the
looseness of engine fan belt and dirt on
the radiator surface.
7. Pay attention to checking the hose
joint from transmission to radiator. If
the joint stretches into the transmission
deeply, it will stand up to the
counter-balance valve element, get the
valve stuck and cause the oil-way
blocked.
1. Check the oil level and refuel
according to correct methods.
2. Replace the elastic plate or
corresponding damaged parts.
3. Check whether the power supply
voltage is normal, whether the cable is
worn and whether the cable plug is
loosened.
4. Implement the operation based on
above mentioned troubleshooting
method.
5. The solenoid valve is 65+5 Ω. If the
resistance value is 0 or ∝, it means
that the solenoid valve breaks down
and needs to be replaced.
6. Check and replace the handle based
on handle fault check method.
7. Check the box based on
troubleshooting method of electronic
control box or with PR68 detector.
1. If breaking the connection between
emergency brake pressure switch or
parking brake pressure switch and the
circuit recovers the gear I and II of
vehicle, it means that this switch needs
to be replaced.
2. Replace the solenoid.
 Service Manual of Wheel Loader

1. The measured resistance of speed

When gear III and
IV are engaged, 1. Speed sensor breaks
11
the vehicle drives down.
at gear II.
1. The clutch at forward gear
has internal discharge.
2. Circuit contact inside the
shifting handle is burnt out
Vehicle does not and the circuit has poor
12 have forward gear contact.
1, 2 and 3.
3. The solenoid valve loses
efficacy (M3).
4. The transmission control
valve gets stuck.
1. Internal discharge of
clutch at reverse gear.
2. Circuit contact inside the
shifting handle is burnt out
Vehicle does not and the circuit is not
13
have reverse gear. powered on.
3. The solenoid valve loses
efficacy (M1).
4. The valve gets stuck.
1. The voltage provided to
the electric control system is
not stable.
2. The power supply circuit
provided to the electric
control system has poor
contact.
3. The shifting handle cannot
operate stably or the
The gear is connection plug has poor
14
sporadic. contact.
4. The oil level of the
transmission is not enough.
5. Solenoid valve or
electronic control box cannot
operate stably or the
connection plug has poor
contact.
6. The valve gets stuck.
sensor is 1,020±100 Ω. If the resistance
is 0 or ∝, it means that the speed
sensor breaks down and needs to be
replaced.
1. Treat this fault as the above
mentioned internal discharge fault in
clutch.
2. Arrange the handle wire or replace
the handle.
3. The resistance value of the solenoid
valve is 100±10 Ω. If the resistance is 0
or ∝, it means that the solenoid breaks
down and needs to be replaced.
4. Clean the transmission control valve.
1. Treat this fault as the above
mentioned internal discharge fault in
clutch.
2. Arrange the handle wire or replace
the handle.
3. The resistance value of the solenoid
valve is 65±5 Ω. If the resistance is 0 or
∝, it means that the solenoid breaks
down and needs to be replaced.
4. Clean the transmission control valve.
1. Check the power supply system of
finished vehicle.
2. Check the circuit based on main
engine circuit.
3. Arrange or replace the shifting
handle connection plug.
4. Refuel according to correct method.
5. Arrange the connection plug.
6. Clean the valve.

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 Service Manual of Wheel Loader

1. The connecting bolt fixing

the engine transmission is
loosened. 1. Check and fix the bolt.
2. The oil level of the 2. Refuel to the normal oil level.
transmission is not enough. 3. Check the transmission shaft.
3. Transmission shaft 4. Replace the elastic plate.
Abnormal noise in
15 connecting the transmission 5. Remove the transmission shaft and
transmission
breaks down. check whether there is any abnormal
4. The elastic plate noise after the removal. If any, check
connecting the engine and whether the transmission has
the torque converter breaks. mechanical fault.
5. Mechanical fault inside
the transmission.
1. After the engine shuts down, block
The vehicle 1. The clutch at reverse gear the oil-way of KR clutch and then start
reverses at neutral is sintered. the engine. If the vehicle can drive at
gear, cannot drive 2. The valve gets stuck. reverse gear, it means that the clutch at
16 at forward gear 1, reverse gear is sintered and needs
2, 3 and drive 3. The solenoid valve loses mechanical maintenance.
normally at efficacy (M1). 2. Clean the valve.
reverse gear. 4. The handle breaks down. 3. Replace the solenoid valve.
4. Replace the handle.
1. After the engine shuts down, block
The vehicle moves the oil-way of KV clutch and then start
forward at neutral 1. The clutch at forward gear
the engine. If the vehicle can drive at
gear but cannot is sintered.
gear 1, 2, 3, it means that the clutch at
drive at reverse 2. The valve gets stuck. forward gear is sintered and needs
17
gear; The vehicle 3. The solenoid valve loses mechanical maintenance.
can drive normally efficacy (M3). 2. Clean the valve.
at forward gear 1, 4. The handle breaks down.
2, 3. 3. Replace the solenoid valve.
4. Replace the handle.
1. After the engine shuts down, block
the oil-way of K1 clutch and then start
The vehicle only 1. The K1 clutch is sintered. the engine. If the vehicle can drive at
has forward and 2. The valve gets stuck. forward and reverse gear 1, it means
18 reverse gear 1 and 3. The solenoid valve loses that the clutch at gear 1 is sintered and
cannot drive at efficacy. needs mechanical maintenance.
other gears. 4. The handle breaks down. 2. Clean the valve.
3. Replace the solenoid valve.
4. Replace the handle.

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 Service Manual of Wheel Loader

43 Maintenance of transmission and torque converter system

431 Precautions for disassembling and assembling transmission

Note:
● The machine must be placed at the maintenance position.
● The transmission can only be disassembled after cooling down.
● Contain the transmission with clean container to avoid the spraying of oil.
● During the disassembly, all pipe joints should be bound up and protected so as to prevent sundries
from entering the pipeline.
● The transmission should be hoisted steadily and vertically so as to prevent the slipping of torque
converter.
432 Disassembly and assembly flow chart of transmission

Note: The flow chart is just the cue for maintenance, disassembly and assembly. The specific
operation flow should be carried out based on specific model and configuration.
1. Disassembly of transmission

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 Service Manual of Wheel Loader

1. Maintenance
position
2. Disassemble
engine cover
Refer to 8 Cab and covering part system
3. Disassemble rack
and cab
4. Disassemble side
plates on both sides
of the machine
5. Disassemble the
Refer to 9 Working hydraulic system
hydraulic oil tank
6. Disconnect the oil
outlet hose of pump
7. Disconnect the
Transmission radiating oil inlet pipe
and oil return pipe
8. Disconnect the Line of transmission control
connecting harness. valve
9. Disassemble the
intermediate Pressure sensor
transmission shaft
10. Disassemble the
Oil temperature sensor of torque
rear transmission
converter
shaft
11. Discharge the
transmission oil.
12. Disassemble the
oil filling pipe.
13. Disconnect the
brake cylinder.
14. Disconnect the
connection with
engine.
15. Disconnect the
connection with the
frame.
16. Straighten the
pipeline and carry out
the hoist.

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 Service Manual of Wheel Loader
2. Assembly of transmission

1. Hoist transmission and

make preparation

2. Connect the engine

3. Connect the frame

4. Connect the oil outlet

rubber pipe of pump

5. Install the oil filling pipe

6. Connect the brake

cylinder

7. Install the transmission

shaft.

Line of transmission 8. Connect radiating oil

Assembly of
control valve inlet pipe and oiler turn
transmission
pipe

Pressure sensor 9. Connect harness and

sensor

Oil temperature sensor of 10. Install the hydraulic oil

torque converter tank

11. Hoist the cab

12. Hoist the engine cover

13. Install the side plate.

14. Connect the rack.

15. Fill the transmission

oil.

16. Check transmission

functions.

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 Service Manual of Wheel Loader

44 Transmission shaft system

441 Precautions for maintaining transmission shaft

Note: when delivered, the transmission shaft has been provided with dynamic balance and
arrow mark. Do not damage the balance during disassembly, wash or repair, or else carry out the
dynamic balance again.
45 Drive axle system

Note: refer to 024 Hoist and support safety for precautions of drive axle and see Service
Manual of Drive Axle for drive axle maintenance.
451 Fault diagnosis and troubleshooting of drive axle
1. Abnormal noise in drive axle
a) Phenomenon and danger
The abnormal noise in wheel drive axle has multiple phenomena: Some noise sounds continuously
or intermittently; other noise sounds when the speed changes or the vehicle drives normally; some
noise sounds uphill or downhill; others sound depressive or clear.
The abnormal noise in drive axle reflects the abnormal technical state between drive axle parts.
Therefore, find out the cause and eliminate the abnormal noise immediately, or else it may cause
larger fault and even accident.
b) Cause and elimination of abnormal noise in drive axle
The abnormal noise in drive axle is usually caused by the collision between parts in rear axle
(including wheel reducer).
Different parts can cause noise with different strength and properties in different states, therefore,
judge the source of abnormal noise and find out the cause based on condition and part where the
noise is generated.
● The noise generated from loosened connection and damage between parts mostly belongs to
abnormal friction and collision between parts, so it sounds clear.
● The noise generated from abnormal matching of bearing and abnormal engagement of gears.
● The abnormal engagement of gear means that the engagement clearance is too small or too
large, the engagement part is not correct and the engagement area is insufficient. By this time,
continuous and clear sound will be generated and will increase as the increasing speed. The
abnormal matching of bearing means that the bearing clearance is too large or too small. When
the clearance is excessive, continuous sound will be generated and will increase as the
increasing speed.
● When the rear axle packet generates sound, except checking whether the parts have looseness,
firstly check whether the engagement region of main transmission bevel gear is correct.
2. Heat in drive axle
a) Phenomenon and danger
Heat in the drive axle means that after operating for a while, the temperature of drive axle exceeds
the allowable range of normal temperature rise and when inspecting the drive axle by hand, it feels
hot. The heat is mainly generated in the drive axle packet (excluding main transmission and
differential mechanism) and wheel reducer. The heat in the drive axle is also the reflection of
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 Service Manual of Wheel Loader
abnormal technical state of drive axle parts, abnormal matching or abnormal lubrication. So
eliminate the heat immediately so as to avoid damaging relevant parts.
b) Cause and troubleshooting of heat in the drive axle
● Cause of heat in the drive axle: excessive heat; the heat cannot be radiated immediately.
● The heat source of wheel drive axle is mainly the friction heat which is caused by smaller
matching clearance between moving parts. Matching parts of drive axle are divided into
bearing and gear. Therefore, the root cause of heat in the drive axle is the smaller matching
clearance between bearings or engagement clearance between gears.
● The main reason why the heat in the drive axle cannot be radiated is that the drive axle (and
the wheel reducer) lacks oil or has poor-quality oil. Lack of oil or poor-quality oil not only
makes the friction heat generated by the drive axle not radiated immediately but also makes the
moving parts in the dry friction condition and increases the friction heat.
● For the heat in the drive axle, the cause of heat can be determined based on the heating part. If
the bearing is overheating, it means that the heat is caused by the bearing. If the overall drive
axle shell is heating, it may be caused by abnormal engagement of gear or lack of oil.
Therefore, fill standard lubricating oil immediately.
3. Oil leakage in the drive axle
a) Phenomenon and danger
The oil leakage of drive axle mainly occurs at the drive axle packet and wheel reducer through the
sealing point and the junction.
b) Cause and troubleshooting of oil leakage in the drive axle
● Oil leakage is mainly caused by the damage in sealing elements and sealing gasket. The former
is the oil leakage caused by damage of final transmission oil and the latter is the oil leakage on
junction of rear drive shell and wheel reducer.
● Check whether the oil seal is aging, cracked and damaged. Do not pull out the oil seal
vigorously so as to avoid the plastic deformation; try to immerse the oil seal into the fluid with
the temperature similar to the working temperature and then carry out the installation by
special tool.

23