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YD13/YD133/YL13 Transmission Service Manual

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1. 33 Se REMO OU 34 3 1 4 Removal of auxiliary PTO hub 34 So IREMOY al Or I pu J vi veeuuu u uu am askaanhawsbahaspapaqahayaqaqakaqapaeqaspawhaqhpaqa 35 3 1 6 Removal of transmission oil pipe and auxiliary PTO 36 3 1 7 Removal of three sets of clutch components 38 3 1 8 Removal of parking brake and Output devtce 39 3 1 9 Removal of torque converter pressure regulating valve 43 3 2 Removal of transmission assembly 44 5 2 1 INCIMOY al OL mamn PIO Lu uu awana lt pasapaqayqunpaqwaqaqaaswqasasqpuqqaqq 44 A WRIS T YD13 YD133 YL13 Transmission Service Manual SDLG 3 2 2 Removal of input assembly 45 3 2 3 Removal of three sets of clutch assemblltes 49 JI O Ti o O TWO 58 4 1 Refitting of transmission assembly 58 4 1 1 Refitting of three sets of clutches 58 2 Refntime Of tia POG oo 70 4 1 3 Refitting of input components 70 4 2 Refitting of transm
2. SDLG YD13 YD133 YL13 Transmission Service Manual the engaged The vehicle runs as normal in poe gear but not in 3th 4th gear There is no high speed gear and the speed in 2 gear is equal to that in 3 74 gear is thus resulted the control unit will input a warning signal i e indicator H2 flashes and clicks can be heard from the control unit inside 3 Gear selector lever DW 4 is damaged or its plug Is poorly connected 4 EST 4 control unit is damaged or its plug is poorly connected 5 Non electrical faults such as oil circuit fault or mechanical fault occur 1 Brake switch BR or emergency brake switch BR2 gets seized 2 Short circuit occurs between signal wire BR and 24V wire 3 Solenoid valve M4 is damaged 1 This fault often occurs to the engine equipped with output speed sensor when the sensor is not or poorly connected or damaged 2 poorly connected plug or damage Selector DW 4 incurs 90 gear If it can be determined that the fault not replace the faulty solenoid valve 2 Check the connecting cable for any wear and replace the faulty cable when necessary 3 Check if the incoming cable plug of DW 4 and EST is dislodged and clamp it when necessary 4 Replace DW 4 selector or EST control unit 5 Replace hydraulic control valves 1 Check if the two switch can be opened and closed flexibly and if not do troubleshooting
3. Aw WRIS I YD13 YD133 YL13 Transmission Service Manual SDLG 6 Fault Diagnosis and Troubleshooting 6 1 Fault diagnosis and troubleshooting for transmission EST controller Table 5 1 Fault S N Analysis Fault diagnosis and troubleshooting phenomenon 1 Check power voltage and in case of power insufficiency charge the battery at the very first 2 Check 1f the starting circuit of the engine involves poor connection or damaged elements 1 Power voltage is not correct 3 Place the gear selector lever to the 2 Starter relay or other related neutral position when the starter relay electric appliances is failed on the control unit should pull in Engine fails 1 3 Gear selector lever DW 4 is 4 If no AS signal is received i e the to be started not placed in neutral position voltage on the O circuit is not 24V 4 EST control unit incus the output signal of the control unit poor contacted plug or failure may involve problems In this case disconnect the plug of EST control unit and connect it again always clamped forcibly by hand to ensure that both ends are clamped tightly and properly connected If it does work replace the EST control unit The vehicle 1 Open circuit or short circuit 1 Disconnect the plug and measure fails to run occurs the resistance of solenoid valves on the regardless of 2 The solenoid valve is damaged control valve is within 600Q 70Q If 89 AX wis x
4. Oil pressure test points 3 Torque converter 4 Torque converter 8 Control oil pressure 11 KV clutch pressure inlet oil pressure outlet oil pressure 10 KR clutch pressure 6 K1 clutch pressure 5 K2 clutch pressure 7 K3 clutch pressure 9 K4 clutch pressure 2 Temperature measuring point 4 Torque converter outlet 3 Flow test points 1 Filter inlet 2 Filter outlet a minimum flow of 50 L min Connecting threads for all points 20 A WR IS I YD13 YD133 YL13 Transmission Service Manual SDLG No 3 5 6 7 8 9 10 11 M10x1 1 2 M26x1 5 Table 2 5 Control valve Gear Solenoid valve Z Mmmim re A l i F dI V 1 i l i Fw e e v 2 KP aKa Foam Ive re Ta O cg Fow e dals o o Pr U Tiy Reverse I an es po fe Revesem e fe Ria 2 1 6 YD13 Operation and maintenance of powershift transmission 1 Precautions for use 1 Regularly change transmission oil and replace the filter in strict accordance with the maintenance requirements 2 Before starting the engine ensure that the control lever is at neutral position 3 Before each driving release the parking brake to relieve braking 4 In the case of combining or separating the engine with or from the transmission and the transmission needs to be lifted always avoid the torque converter from falling off 5 When stopping the vehicle always keep the gear lever at neutral position 6 The working tempera
5. Service Manual SDLG Fig 3 3 1 Control valve K2 Kr Fig 3 4 1 Oil duct plate pipe joint 2 Clutch shaft oil duct joint 3 1 2 Removal of transmission control valve 1 Use M8 hexagon socket wrench to remove ten M8x45 and six M8x75 hexagon socket bolts respectively Jr NOTE Bolts must be removed from outside to inside diagonally The valve pad should be in good condition during the removal of the control valve 2 Remove the six oil pipes from top to bottom are K2 K1 K3 K4 KV and KR from the oil duct plate in turn NOTE KV and KR are subject to change according to different rear axle steering of OEMs Meanwhile remove the oil duct joint on each clutch shaft to remove six oil pipes Jr NOTE Oil pipe joints should be protected properly and serial number of each pipe should be marked with a marker Removed joints should be cleaned and protected properly 33 A WR IS YD13 YD133 YL13 Transmission Service Manual SDLG 3 Take off three M8x45 and six M8x35 hexagon socket bolts for connecting oil feed plate and housing then remove the oil feed plate and partition and put them aside NOTE Bolts must be removed from outside to inside diagonally Fig 3 5 il late shoul l 1 Oil duct plate Removed oil duct plate should be cleaned and protected properly 3 1 3 Removal of oil filter 1 Use the strap wrench to remove the oil filter and take off the O ring Fi
6. T YD13 YD133 YL13 Transmission Service Manual SDLG torque converter changes speed the vehicle itself can overcome the braking torque to run forcefully even in the case of a rather normal operation Consequently the torque converter oil temperature will rise and the brake will be overheated The torque converter influence may result in the engine speed increase when shifting from high gear to low gear especially the skipping gear Therefore if possible depress the service brake first to reduce the speed slowly and then shift gear when shifting from high gear to low gear First to reduce the engine speed when the vehicle runs at high speed and driving direction is required 3 Temporary stop and stop There is no rigid coupling between the engine and the torque converter output shaft so when the vehicle is to be stopped on a slope either uphill or downhill and the driver intends to leave it 1s recommended to apply the parking brake and put wedges under the wheels to prevent the vehicle sliding 4 Towing The maximum towing speed is 10 km h and the maximum towing distance is 10 km For a long distance the broken down vehicle should be loaded on another vehicle for transport 5 Oil temperature The transmission oil temperature must be monitored by a temperature sensor The maximum oil temperature at the torque converter outlet should not exceed 120 C and for the faultless control assembly and the transmission with sufficient ope
7. disc Then install spacer sleeve and insert output shaft 3 Place adjusting washers in turn NOTE Adjusting washers with different thickness should be selected for replacement such that the axial clearance of bearing is 0 1 0 3 mm 76 A W R IS YD13 YD133 YL13 Transmission Service Manual SDLG 4 Install snap ring Fig 4 54 1 Adjusting washer 2 Snap ring 120 4 5 Use tool to install oil seal into housing Jr NOTE New oil seal should be installed after the removal Fig 4 55 1 Oil seal 2 Assembling tool for oil seal 2938001833 6 Install output flange and pressure plate and tighten two M10x30 bolts Nm 46 Nm Fig 4 56 1 Output flange 7 A WR IS I YD13 YD133 YL13 Transmission Service Manual SDLG 7 Use special assembling tool to install lock plate Fig 4 57 1 Assembling tool for lock plate 2938001838 8 Install parking brake flange Fig 4 58 1 Brake flange 9 Install brake drum wheel and pressure plate tighten bolt and lock the lock plate Fig 4 591 1 Parking brake 18 A WR 1S YD13 YD133 YL13 Transmission Service Manual SDLG 4 2 2 Refitting of countershaft assembly 1 Install roller bearing into bearing hole of countershaft gear and fix it with grease for subsequent use k 2 3 Fig 4 60 1 O ring 2 Countershaft 3 Roller bearing 4 Countershaft gear 2 Place countershaft gear assembly into g
8. never apply too much operating force Marks 1 2 3 and 4 on the lever refers to four gears among which 1 is the lowest speed and 4 is the highest speed b As the controller has kickdown KD function when DW 4 selector is put at Forward II gear pressing the lever forward can shift to I gear and meanwhile the indicator lamp H1 comes on This function does not work at other gears other than II gear Any method of the followings can cancel the kickdown 1 press the lever again 2 rotate the lever to shift gear 3 change directions 4 shift to neutral c When the vehicle runs at I or II gear if the service brake or emergency brake is applied the gear signal from the electric control unit remains the same as the corresponding neutral and the previous gear will be recovered immediately after releasing the brake switch But at III and IV gears the brake has no this function d When stopping the vehicle the DW 4 gear selector should be put at N e In case the vehicle sends out an alarm when running the vehicle stops running the indicator lamp H2 is flashing and the electric control unit is clicking first pull the gear selector lever to neutral N and if the alarm stops at this moment continue the normal operation If not the line may be faulty and in this case switch off the power inspect carefully clear the fault and lastly switch on the power again to continue the operat
9. position should be tapped by the copper bar and the oil distributor flange and transmission pump assembly should be tapped in order to prevent against dropping 3 1 6 Removal of transmission oil pipe and auxiliary PTO 1 Screw off the fixing bolts of transmission oil pipe in turn and then take out the pipe 2 Remove the transmission oil inlet cover A LU R IS T YD13 YD133 YL13 Transmission Service Manual SDLG 3 Use circlip pliers to take off the snap ring from the PTO shaft Fig 3 13 1 Snap ring 45 1 75 2 Circlip pliers 4 Use copper bar to tap out the PTO shaft and then take off the PTO driving gear Fig 3 14 1 Driving gear 2 PTO shaft 3 Retainer ring p 5 At this time the PTO has been removed completely Fig 3 15 1 Ball bearing 37 A W Z IS T YD13 YD133 YL13 Transmission Service Manual SDLG Fig 3 16 1 K3 amp K4 clutch shaft 2 KR amp K2 clutch shaft 3 KV amp K1 clutch shaft Fig 3 17 1 Removal tool for clutch shaft 2938001828 2938001829 38 3 1 7 Removal of three sets of clutch components 1 Remove the bolts for connecting the three pieces of clutch shaft and the housing in turn 2 Use the removal tool for clutch shaft to take off K1 K2 and K3 clutch shafts in turn and take out three clutch assemblies simultaneously About 15kg NOTE After the removal of every set of clutch the clutch adjusting shim should be plac
10. shaft 2 Plunger ring 3 2 3 Removal of three sets of clutch assemblies J NOTE The three sets of clutch assemblies are similar in structure and the removal process of K3 and K4 clutch assemblies is here described as an example 49 W RIST YD13 YD133 YL13 Transmission Service Manual 1 Take off K4 cutch gear bearing and put it aside Fig 3 49 1 Needle roller bearing 2 Remove the face seal assembly and roller from K3 clutch gear inner needle roller bearing Fig 3 50 1 Roller 12 pcs 2 K3 clutch gear 3 Remove the gear washer and thrust washer from K3 clutch Fig 3 51 1 Washer 2 Thrust washer 50 Fig 3 52 1 Thrust washer 2 K4 clutch gear 3 Thrust washer ww Fig 3 53 1 Elastic damping ring Fig 3 54 1 Bearing plate 5l 4 Remove the gear and thrust washer from K4 clutch 5 Remove the elastic damping ring from K4 clutch 6 Remove the bearing plate from K4 clutch YD13 YD133 YL13 Transmission Service Manual 7 Remove the outer and inner friction linings from K4 clutch Fig 3 55 1 Inner friction lining 2 Outer friction lining 8 Install the clutch tool onto the clutch l Fig 3 56 1 Removal tool for clutch spring 2938001826 2938001827 9 Tighten the tool nut and press the clutch spring Fig 3 57 1 Removal tool for clutch spring 2 Pressure spring 52 A WR ISI YD13 YD133 YL13 Transmission Service
11. 2 Thrust washer 30 Install needle roller bearing into K4 clutch gear Fig 4 31 1 Needle roller bearing 31 Install K4 clutch gear At this time K3 and K4 clutches have been assembled completely Jr NOTE Splines of inner friction lining in the clutch should be aligned before the gear installation Fig 4 32 1 K4 clutch gear 69 A WRIS YD13 YD133 YL13 Transmission Service Manual SDLG 4 1 2 Refitting of main PTO 1 Install needle roller bearing into output housing hub and then install retainer ring Fig 4 33 1 Retainer ring 2 pcs 2 Needle roller bearing 2 Install retainer ring into driving gear hole and install gear into output housing hub 3 Insert PTO shaft into gear hole tap in the ball bearing and install 2 elastic damping rings and retainer ring Fig 4 34 1 Driving gear 2 Retainer ring 4 1 3 Refitting of input components 1 Tap ball bearing onto auxiliary drive shaft k Fig 4 35 1 Ball bearing 2 Auxiliary drive shaft 70 WRIS IT YD13 YD133 YL13 Transmission Service Manual SDL 2 Install flat key of gear pump inner gear onto the shaft and install the oil pump Fig 4 36 1 Gear pump inner gear 3 Tap another ball bearing into the oil pump bearing hole Jr NOTE The auxiliary drive shaft must be able to rotate flexibly Fig 4 37 1 Ball bearing 4 Install shaft snap spring and snap in seal ring Fig
12. 4 38 1 Snap spring 30x1 5 2 Seal ring 71 AX wae Ws T SDLG YD13 YD133 YL13 Transmission Service Manual Fig 4 39 1 Oil seal O75 2 Needle roller bearing Fig 4 40 1 Roller bearing 2 Oil distributor flange x m Fig 4 41 1 Input gear 5 Tap needle roller bearing into bearing hole on pump impeller bearing seat and then install the oil seal Jr NOTE The oil seal should be replaced with new one 6 Install roller bearing into bearing hole on oil distributor flange Jr NOTE The oil distributor flange should be cleaned before the assembly 7 Install input gear into oil distributor flange and adjust the gear clearance properly 12 W Z IS T YD13 YD133 YL13 Transmission Service Manual Fig 4 42 1 Driving shaft 2 Seal ring Fig 4 43 1 Driving shaft 2 Ball bearing Fig 4 44 1 End face of oil distributor flange 2 End face of bearing cup 8 Install gear ring onto driving shaft 9 Insert driving shaft and install ball bearing 10 Install elastic damping ring and use depthometer to measure the distance between two end faces h T3 A W Z IS T YD13 YD133 YL13 Transmission Service Manual SDLG 11 Use depthometer to measure the distance between two end faces H amp NOTE Axial run out of output shaft bearing D H h Adjusting washers with different thickness should be selected such that D is 0 2 0 4 mm Fig 4 45 1 Step surface of trans
13. A WRIS T YD13 YD133 YL13 Transmission Service Manual SDLG EST 4 Output signal function table Table 2 3 Forward Reverse Neutral M o o sss lvhal wi wm s f feftet fete t_ It comes on under KD status It flashes when an alarm occurs For the model with speed sensor it comes on before connecting the speed sensor e Indicates that there is signal output and the lamp comes on 22 YD13 YD133 YL13 Transmission Service Manual AX URISI 6 7 5814 DAJLA plouayos fONUOD uontsod Softy Eb rus ap pennau y uteup suey SV HS BME SY Josuas aau oyn mdnO I peusis 1e28 asiaAol TH Ei I a Siti a dure soxetpur uey ZH oq Aryatuoury THI BR a UH RRX Ng dumy unepu TN IH IOUS aog YG EO TH XI yg UODPUP dxs TeuSrs EEEE ug Z 8u0T 9ATBA OTJUOO UOTSSTUSUBTY OJ 34TI5TII35aTa veins F ETH LS MABOEXE YR ra iy IH 0 grarryn H Q suaa g Q 0 angg E L yoeTg a 6 unorg ud g Crus us al O Tq OTTOA rr T g J wol A 9 At Poy 0 9 Ma pay yueTd aq Aq s1o9uuoo qed AJIST 109 S POTUPA A ORI UOT3BeATT 39ON 4H WEAG RL REEM HY TE BMOTION X 1drtsqns y 31IesuT 0 413tpur eqoN SHAKERNM HR 9 tT ueex9 ay S ko Wuwer ey wz 3UoT j tus By IOJIITAS Md OL ae ape Ou eng u 4 p 4 m H 314A H Id xp 9 PY
14. Hexagon nut M8 2 pcs Fig 4 68 1 KV amp K1 clutch assembly 2 KR amp K2 clutch assembly 4 Use depthometer to measure the height of bearing step on clutch shaft h and the height of K3 clutch bearing roller from the housing surface H NOTE Axial clearance of clutch assembly A H h Adjusting washer with appropriate thickness should be assembled such that A is 0 1 0 3 mm 5 Take out the tool install K4 amp K3 clutch shaft and tighten the nut for fixing clutch assembly NOTE K3 amp K4 clutch gear should be able to rotate flexibly A m 23Nm 4 2 5 Refitting of KR amp K2 and KV amp K1 clutches 1 Install K2 amp KR and KI amp KV clutch components into respective shaft holes on the housing and adjust the bearing clearance Then insert K2 and K1 shafts and use three M8x18 bolts to fix them Jr NOTE Adjusting washer with appropriate thickness should be assembled such that A is 0 1 0 3 81 A WR ISI YD13 YD133 YL13 Transmission Service Manual SDLG mm 4 2 6 Refitting of auxiliary PTO 1 Place transfer gear into the housing 2 Tap in PTO shaft to make the shaft retainer ring fit the gear Fig 4 69 1 PTO shaft 2 Retainer ring 3 Use circlip pliers to install bearing snap ring onto PTO shaft 4 Assembly PTO end cover install gasket and tighten the bolt for connecting PTO end cover and housing gt amp NOTE New gasket should be installed after the Fig 4 70 rem
15. II Reverse 0 964 1 90 N A III Type of Transmission Built in gear pump Built in gear pump Built in gear pump transmission Pump Pressure bar 13 17 13 17 14 17 2 1 3 Gearshift principle of transmission 1 Transmission structure principle Actuator in YD13 transmission is composed of 6 clutches 1 e K1 K2 K3 K4 KV forward gear clutch and KR reverse gear clutch and different gearshifts can be achieved through the intercombinations among them and each gearshift requires two clutches working simultaneously YD13 YD133 and YL13 transmission working principles are respectively shown in Fig 2 4 Fig 2 5 and Fig 2 6 Aw WRIS I YD13 YD133 YL13 Transmission Service Manual SDLG Fig 2 4 YD13 Fig 2 5 YD133 Fig 2 6 YL13 2 Principle of transmission hydraulic oil system take YD13 for example The gear pump to supply oil for the torque converter and control valve is installed inside the transmission and driven directly by the engine via PTO shaft with flow of Q 35 L 1000 r min The oil pump absorbs oil through the oil suction filter primary filter in the oil circuit pumping the pressurized oil into the spin on oil filter fine filter The oil filteration precision is 0 025 mm and the filteration area is 5 100 cm The oil flowing from the filter with the working pressure restricted by the pressure control valve main pressure regulating valve passes through the pressure control valve to th
16. Manual SDLG 10 Use circlip pliers to remove the retainer ring for fixing pressure spring Fig 3 58 1 Retainer ring 11 Remove the retainer ring and guide ring from K4 clutch In turn Fig 3 59 1 Retainer ring 2 Guide ring r 12 Remove the upper guide ring pressure spring and lower guide ring from K4 clutch 4 in turn Fig 3 60 1 Guide ring 2 Pressure spring 53 A WR IS YD13 YD133 YL13 Transmission Service Manual SDLG 13 Remove the piston and seal ring from K4 clutch Then K4 clutch has been removed completely Fig 3 61 1 Seal ring 2 K3 clutch piston 3 Seal ring 14 Remove the elastic damping from K3 clutch bearing plate Fig 3 62 1 Elastic damping ring 15 Remove the bearing plate from K3 clutch Fig 3 63 1 Bearing plate 54 YD13 YD133 YL13 Transmission Service Manual Fig 3 64 1 Inner friction lining 2 Outer friction lining Fig 3 65 1 Removal tool for clutch spring 2938001826 2938001827 2 Pressure spring Fig 3 66 1 Retainer ring 16 Remove the outer and inner friction linings from K3 clutch 17 Use the removal tool for clutch spring to press the pressure spring of K3 clutch 18 Use circlip pliers to remove the retainer ring for fixing pressure spring 55 A WRIS YD13 YD133 YL13 Transmission Service Manual SDLG 19 Remove the retainer ring and guide ring from K3 clutch in tur
17. TE jp aA gt si ae snTd Bp 1 4 9 8 MOTTA x By CH IH SY El tq ud L weiseIp uono uuoo Anjd pue alqe IN ut 1s s onuoo INAJ BSE ee Ue LERET 02 12 7 El pe c7 97 80 62 IB If qq ff pe f gt O 9 OIG UM OI OSIS BIA eliAaliOo Go O l gt G G UD GQ UD D D CI C GS DO XU CO OC Ge I cI 9 LI BI b I a a I 0 6 L 9 t l Zo YD13 YD133 YL13 Transmission Service Manual AX URISI 0T Z 5I a3ATeA prouajos onuo3 uontsod sg p W W IRE I EVA 7W LW duej JoleorpUIEUDETY ZH yt uteu3 sURIg SY TXB we s ZH APAY e SV XOQ O1 UOO 1nmnquo df Suneorpu sayy u eJ 0 s910 JH ayaq KAou di urg CH r N j I N td EE ni E Kri eR alg 8 LH Geld SH ug SATBA TOXWUOO GT b Sq feudis vad aaAry JY yams aug Hg aa P ERRAR dY FE ug MYA uoneurdxa TeUSTIS Hwag YI9T41991 S T Tu A Yas 24 rm co OO DD WeIseIP uono uuo2 twashs onuoo NAA 100 010 6009 UOT ROTJIOedS P LS9 ere SH 100 O10 6009 V LSH A WR 1S YD13 YD133 YL13 Transmission Service Manual SDLG 2 1 5 Functional test of transmission 1 Test of electro hydraulic control transmission CAUTION The test shall be carried out only when the transmission temperature is within 80 95 C and when the engine runs at full throttle 5 67 8 91011 Fig 2 12 Fig 2 11 1
18. YD13 YD133 YL13 YD13 YD133 YL13 Transmission Service Manual A WRIS T YD13 YD133 YL13 Transmission Service Manual SDLG Aw WRIS I YD13 YD133 YL13 Transmission Service Manual SDLG Foreword This service manual covers the removal and refitting procedures service technology and standard requirements for YD13 transmission so as to help service personnel understand the method of removing and refitting it and to lay a solid technical foundation for them concerning the fault determination and proper service The manual is applicable to YD13 YD133 YL13 transmission as they belong to the same serialized product This service manual mainly includes the following Chapter 1 Introduction This chapter mainly describes precautions for servicing transmission the meaning of all symbols which are included in the following text and the tightening torque for plain bolts Chapter 2 Transmission system This chapter mainly describes the gearshift principle of transmission electric control system functional test and the operation and maintenance of transmission Chapter 3 Removal of transmission This chapter describes how to remove each part properly and the relevant precautions in the process Chapter 4 Refitting of transmission This chapter describes how to refit each part properly and the relevant precautions in the process Chapter 5 Fault diagnosis and troubleshooting This chapter introduces common fault diagnosis and troublesho
19. accordingly 2 Disconnect the cable between Br and BR2 if the gear is normal check the relevant wirings and repair the faulty part 3 Replace the solenoid valve M4 Check the 1 described above and if it is damaged speed sensor as replace 2 Check the wire to sensor and if it is damaged repair 3 Replace selector DW 4 Aw WRIS I YD13 YD133 YL13 Transmission Service Manual SDLG No Jony 1 Any of internal elements of 1 Replace the selector forward selector DW 4 is damaged 2 Replace solenoid valve M3 gears 2 Solenoid valve M3 is damaged No reverse 1 Solenoid valve MI is damaged 1 Replace the solenoid valve M1 gear 2 Selector is damaged 2 Replace selector DW 4 1 Check the power supply system of 1 The power voltage is not stable vehicle and eliminate the factors Gears 2 The connector Is poorly related with voltage disappear connected somewhere 2 Check arrange and clamp all sometimes 3 The solenoid valve or electric connectors box works in an unstable state 3 Replace the electric box 6 2 Diagnosis and troubleshooting of common transmission faults Table 5 2 Fault Analysis Fault diagnosis and troubleshooting phenomenon The engine starting Check the engine circuits with circuit like power reference to the Instructions to starter relay Engine Starting Circuit supply starter motor etc IS Place the lever to the neutr
20. al Engine fails to be started faulty The lever is not placed in the neutral position The fuse to the control circuit on the engine is burnt out The lever involves poorly connected plug or faults 91 position Replace the fuse Arrange the connectors and check if the handle circuit is normally energized Arrange the connectors or eliminate the faults of electric box AX wis SDLG Pressure at all gears Oil pressure in 1 2 3 forward gears is low but normal In other gears Oil pressure in 1 2473 reverse gears is low but The electric box incurs poorly connected plug or faults The oil pressure gauge is faulty Bolt of transmission control valve is not sufficiently tightened Spring of main pressure valve Is broken Transmission pump wears out Chips invade into the transmission control valve or the valve gets seized Forward gear clutch incurs internal leakage Reverse gear clutch incurs internal leakage 92 YD13 YD133 YL13 Transmission Service Manual Replace the oil pressure gauge Tighten the control valve bolt M8 with a torque of 20Nm Replace the broken spring Replace the transmission pump Replace the filter and clean the control valve After the engine stops block the oil passage to the corresponding KV clutch and then start the engine and engage 1 2 3 forward gears If the pressure rises to a normal level it indic
21. ates that the clutch incurs internal leakage and should be repaired After the engine stops block the oil passage to the corresponding KR clutch and then start the engine and AX wir isc SDLG normal In other Oil pressure in 1 forward and reverse gears is low but normal in other gears The engagement time of all gears is too short The engagement time of all gears is too long Torque converter incurs high ol temperature Clutch of 1 gear incurs internal leakage O ring on the throttle plug is damaged Bolts of pressure control valve are not tightened with the torque specified Throttle plug IS blocked Pressure control valve gets seized The oil temperature sensor is faulty The oil temperature gauge is faulty The oil level is low 93 YD13 YD133 YL13 Transmission Service Manual engage 1 2 3 reverse gears If the pressure rises to a normal level it indicates that the clutch incurs internal leakage and should be repaired After the engine stops block the oil passage to the corresponding K1 clutch and then start the engine and engage 1 forward reverse gears If the pressure rises to a normal level it indicates that the clutch incurs internal leakage and should be repaired Replace O ring Tighten the transmission control valve bolt M8 with a torque of 20Nm Clean and unblock Clean and check Replace Replace Check the oil level correc
22. bleshooting as described above Check if resistance of solenoid valve is 65 5Q and if it is 0 or it 1 YD13 YD133 YLI3 Transmission Service Manual SDLG YD13 YD133 YL13 Transmission Service Manual The vehicle runs with a speed of 2 gear when the 3 4 gear is engaged No 3 forward gears Vehicle fails to run with 1 2 gear engaged vehicle are faulty Transmission involves low pressure The solenoid valve is damaged The gear selector lever is damaged The electric box faulty Pressure switch emergency brake parking brake damaged M4 The solenoid valve M4 1s In failure The speed sensor Is damaged The clutch of forward gears involves internal leakage The circuit in the gear selector lever incurs burnt out contract or poor connection 05 indicates that the solenoid valve is damaged and should be replaced Check the lever as per the corresponding troubleshooting method and replace when necessary Check the electric box as per the corresponding troubleshooting method or with a PR68 detector If the 1 2 gear of the vehicle is recovered after the emergency brake pressure switch or the parking brake pressure switch is disconnected indicates that the corresponding pressure switch is damaged Replace the solenoid valve Measure if the sensor resistance 1S 10204100 and if it is 0 or lt lt it indicates that th
23. ce Fig 4 2 1 Seal ring 2 Seal ring f Fig 4 3 Pressure oil face 2 Friction lining surface 3 Place the guide ring and pressure spring into the clutch cylinder Fig 4 4 1 Guide ring 2 Pressure spring 3 Guide ring 59 A WR 1S YD13 YD133 YL13 Transmission Service Manual SDLG 4 Place the guide ring and retainer ring into the clutch cylinder Fig 4 5 1 Guide ring 2 Retainer ring 5 Install the removal tool for spring onto the clutch Fig 4 6 1 Removal tool for clutch spring 2938001826 2938001827 6 Tighten the tool nut and press the clutch spring Fig 4 7 60 A WR ISIT YD13 YD133 YL13 Transmission Service Manual SDLG 7 Use circlip pliers to install the retainer ring into the clutch cylinder snap spring groove and remove the removal tool for clutch spring Jr NOTE In normal use the outer friction lining of clutch with the depth of grained groove worn Fig 4 8 more than 2 3 should be replaced in time 1 Retainer ring 2 Circlip pliers 8 Place the outer friction lining into K3 clutch firstly Jr NOTE Outer friction lining should be placed into the clutch firstly and then outer and inner friction linings placed into the clutch alternately Fig 4 9 1 Outer friction lining 9 Place the outer friction lining into K3 clutch Fig 4 10 1 Inner friction lining 61 A WRIS YD13 YD133 YL13 Transmission S
24. d screw it into place tightly then take it out after 3 s at least two measurements For the oil temperature of 40 C the oil level should be between the lower mark Cold and the center mark For the oil temperature of 80 C the oil level should be between the upper mark Hot and the center mark COLO L Ar 7 7 TONE MOT C 7 pagai DONE GOLD H Bee Fig 2 14 Oil level check in cold state can ensure the transmission and the torque converter with sufficient circulating flow but the final criteria to determine the oil level is to reach the oil level in hot state CAUTION If the oil level is below the minimum mark add the recommended lubricating oil as specified until the oil level is within the correct range for the corresponding temperature See Fig 2 16 2 Oil change Change oil for the first time when the vehicle runs for 100 hours initially After that change oil every 1 000 hours or at least once every year In order to change oil stop the vehicle at flat place with the transmission at the working temperature take out the oil drain plug and seal ring to drain off the used oil 29 A WRIS T YD13 YD133 YL13 Transmission Service Manual SDLG Start the engine and run it at idle speed Put the transmission control lever at N position Add oil to the upper mark of the Zone Cold Keep the parking brake at a safe position Sel
25. e control valve The pressure control valve regulates the boost pressure of the clutch cylinder at the moment of gear shifting i e the oil pressure will drop instantaneously when gearshifting but after gearshifting after clutch engagement it will return to 13 17 bar the pressure restricted by the pressure control valve This can reduce the impact of gearshifting and improve gearshifting efficiency the oil passed through the control valve flows directly to the clutch The shifter valve is positioned by steel ball spring and groove The oil inlet line of the torque converter is equipped with a by pass valve opening pressure of 8 bar to prevent the element damages due to high internal pressure of the torque converter According to the hydraulic transmission working principle the oil is the medium for energy transfer 15 A WRIS T YD13 YD133 YL13 Transmission Service Manual SDLG inside the torque converter To avoid oil cavitation the torque converter cavity should always be full with oil which is guaranteed by the torque converter pressure control valve back pressure valve installed on the torque converter oil outlet line opening pressure of 2 5 bar The oil spilled from the torque converter flows directly into the oil cooler The oil flowing from the oil cooler enters the transmission lubricating oil circuit providing all lubricating points with sufficient lubricating cooling oil An additional pressure cut off valve can be insta
26. e speed sensor is damaged and should be replaced Eliminate the clutch internal leakage as described above Arrange the lever wires or replace the lever Measure if the resistance of the solenoid valve is 100 10Q and if it is 0 or it indicates that the AX wis SDLG YD13 YD133 YL13 Transmission Service Manual 3 13 No reverse gear Gears disappear sometimes The solenoid valve M3 is in failure The transmission control valve gets seized The clutch of reverse gear involves internal leakage The circuit in the gear selector lever incurs burnt out contract or is not energized The solenoid valve M1 is in failure The valve gets seized The power supply provided to ECU is not stable The power supply circuit to ECU is poorly connected The gear selector lever works unstably or the connector Is poorly connector The transmission oil level is low The solenoid valve or 96 solenoid valve is damaged and should be replaced Clean the transmission control valve Eliminate the clutch internal leakage Arrange the lever wires or replace the lever Measure if the resistance of the solenoid valve is 65 5 and if it is O or S lt it indicates that the solenoid valve is damaged and should be replaced Clean the transmission control valve Check the power supply system of the vehicle Do troubleshooting to the circuit of engine Arrange the lever wires or replace t
27. e used in respect of important safety and quality requirements Table 1 1 During operation pay special attention to safety Safety During operation pay special attention to safety because of inside pressure During operation pay special attention to technical Note requirements so as to ensure operation quality Weight of component or device and removal amp refitting modes Weight Pay attention to the selection of sling and the posture during operation Tightening Pay special attention to tightening torque during assembly torque Application Points requiring the application of adhesive and grease Add a certain amount of oil water and fuel Position for draining oil or water as well as draining Draining amount 1 3 Tightening torque table for plain bolts Table 1 2 Strength Yield Nominal diameter of bolt mm Tightening torque Nm Aw WRIS I YD13 YD133 YL13 Transmission Service Manual SDLG class of strength 18 24 bolt Nm class of strength 30 39 bolt N mm Tightening torque Nm w9 oo 1400 1650 1700 2000 2473 3298 2800 3350 4111 5481 Ar W Z IS T YD13 YD133 YL13 Transmission Service Manual SDLG 2 Transmission system 2 1 Transmission 2 1 1 Description of transmission The YD13 type powershift transmission with the maximum input power of 130 KW consists of a hydraulic torque converter and a rear mounted fixed shaft transmission with multi disc friction clutch Our c
28. ear groove on housing insert countershaft and install shim 3 Install and tighten fixing bolt and install sealing washer Fig 4 61 1 Countershaft gear 2 Shim 4 2 3 Refitting of torque converter pressure control valve 1 Install pressure spring and valve core into hole on valve housing then install O ring onto screw plug and the valve housing assembly into the pressure retaining valve I 2 port of torque converter on the housing Fig 4 62 Afterwards tighten the screw plug 1 O ring 2 Screw plug CM30 1 5 19 A WRIS YD13 YD133 YL13 Transmission Service Manual SDLG 4 2 4 Refitting of K3 and K4 clutch assemblies 1 Install O rings and piston rings onto K3 and K4 clutch shafts Fig 4 63 1 Piston ring 3 pcs 2 O ring 49 3 2 Place clutch assembly into the housing and move the clutch to 3 shaft position then install nylon bar and thrust washer to clutch assembly lt a About 15 kg h NOTE The clutch should be supported under the t by the tool t Pe 1 K3 and K4 clutch assemblies ower part Dy the tool to prevent against HS 2 Assembling tool for clutch 29380017611 dropping 3 Tilt transmission to make it horizontal and install assembling tool for clutch Fig 4 65 80 A WRIS I YD13 YD133 YL13 Transmission Service Manual SDLG Fig 4 66 1 K3 amp K4 clutch shaft 2 K3 clutch bearing roller Fig 4 67 1 K3 amp K4 clutch assembly 2
29. ect all gears one by one Check the oil level again and add oil if necessary For the oil temperature of 40 C the oil level should be between the lower mark Cold and the center mark For the oil temperature of 80 C the oil level should be between the upper mark Hot and the center mark CAUTION The oil of the torque converter and cooler shall be drained off along with the used oil Oil change schedule Table 2 6 Oil level Part name Initial change Regular change Standard check After running for After running for 1 000 h Delvac Super Transmission Before 100 h and replace but no longer than 1 year 1300 CF 4 SAE YD13 daily use the oil filter and replace the oil filter 15W 40 Other optional oil Table 2 7 Acceptable oil specifications and standards when HC WGOlI special oil is not available in your region American Petroleum Institute API CF 4 CG 4 CH 4 15 W 40 European Automobile Manufacturers Association ACEA E2 96 SAE 15W 40 ZF TE MLO03 SAE 15W 40 Society of Automotive Engineers SAE 306 SAE 15W 40 Caterpillar TO 4 SAE 15 W 40 FUCHS TITAN SPECIAL HD CF 4 SAE 15W 40 3 Filter replacement Replace the oil filter while changing oil each time The requirements are as follows 30 Aw WRIS I YD13 YD133 YL13 Transmission Service Manual SDLG Apply the seal ring with a thin layer of oil Push the oil filter inward till it contact
30. ed on the shaft end for subsequent final assembly During the removal of clutch assembly the transmission should be put at proper position and taken out slowly to prevent against dropping A WRIS IT YD13 YD133 YL13 Transmission Service Manual SDLG 3 1 8 Removal of parking brake and output device 1 Remove the two M10x30 lock plates from the output shaft at the end of parking brake unscrew the bolts and use two crowbars to remove the parking brake together with the parking brake flange assembly mp Anor 1 Parking brake During the removal force should be applied slowly and protective measures should be taken 2 Remove the oil seal from the output device Fig 3 19 1 Oil seal 3 Take off the lock plate and remove the bolt for connecting pressure plate and output flange Fig 3 20 1 Lock plate 2 Hexagon screw M10 30 39 A WR IS YD13 YD133 YL13 Transmission Service Manual SDLG 4 Remove the pressure plate distance washer and O ring in turn 1 z B Fig 3 21 1 Pressure plate 2 Distance washer 3 O ring 5 Remove the output flange Fig 3 22 1 Output flange 6 Remove the oil seal J NOTE The oil seal should be removed with even force in order to prevent against damage or by the use of special removal tool Fig 3 23 1 Oil seal 40 A WR 1S YD13 YD133 YL13 Transmission Service Manual SDLG Fig 3 24 1 Snap ring 120 4 2 Compen
31. ervice Manual SDLG 10 Place the bearing plate into K3 clutch Fig 4 11 1 Bearing plate 11 Install the elastic damping ring into K3 clutch Fig 4 12 1 Elastic damping ring 12 Use screwdriver to set the friction lining of K3 clutch to the uppermost position and record the stroke of clutch piston measured by the dial gauge At this time K3 clutch has been assembled completely Jr NOTE The stroke should be measured several times Fig 4 13 1 Dial gauge more than 3 times at different positions by the use of dial gauge with the contact pressed against the bearing plate The reading of dial gauge is the stroke of K3 clutch piston Inner 62 A W R IS YD13 YD133 YL13 Transmission Service Manual SDLG friction linings with different thickness number of inner friction linings is fixed should be selected such that the piston stroke the same for three sets of clutches is between 1 8 2 2 mm 13 Tap the needle roller bearing of K4 clutch into the clutch bearing hole and install retainer ring l 2 Fig 4 14 1 Retainer ring 2 Needle roller bearing 14 Install seal rings into piston groove of K4 clutch Jr NOTE Seal ring should be installed with the sealing surface facing towards the pressure oil face See Fig 4 3 Fig 4 15 1 Seal ring 2 Seal ring 63 A WR 15 YD13 YD133 YL13 Transmission Service Manual SDLG 15 Install K4 clutch piston int
32. f K4 clutch lightly and record the stroke of clutch piston measured by the dial gauge Jr NOTE The stroke should be measured several times more than 3 times at different positions by Fig 4 25 h f dial ith th t 1 Dial gauge the use of dial gauge with the contact pressed against the bearing plate The reading of dial gauge is the stroke of K4 clutch piston Inner friction linings with different thickness should be selected such that the piston stroke is between 1 8 2 2 mm 25 Install the thrust washer into K3 clutch gear Jr NOTE The thrust washer should be greased Fig 4 26 1 K3 clutch gear 2 Thrust washer 26 Install the washer and thrust washer into K3 67 AA LU ie Ils T YD13 YD133 YL13 Transmission Service Manual clutch Fig 4 27 1 Thrust washer 2 Washer 27 Install K3 clutch gear Jr NOTE Splines of inner friction lining in the clutch should be aligned before the gear installation Fig 4 28 1 K3 clutch gear 28 Install the face seal assembly and roller to K3 clutch gear inner needle roller bearing Jr NOTE The roller should be greased in order to prevent against dropping during installation of clutch assembly to the housing Fig 4 29 1 Roller 68 WRIS IT YD13 YD133 YL13 Transmission Service Manual 29 Install the thrust washers into snap spring and gear of K4 clutch cylinder J NOTE Thrust washers should be greased Fig 4 30 1 Thrust washer
33. fied smoking area Never smoke during operation and it is required to provide fire extinguishing device 3 When welding operation is required it shall be done by a trained and experienced welding worker During welding operation it Is required to use shield and wear appropriate protective equipment such as welding gloves blind work cap and overall 4 Before removing transmission amp torque converter be sure to clean dirt from the external surface so as to prevent parts from being contaminated during removal 5 During operation do wear safety shoes and safety helmet Do not wear inappropriate overall The overall must be buttoned When striking parts with a copper rod wear goggles 7 A WR IS I YD13 YD133 YL13 Transmission Service Manual SDLG 6 Petrol kerosene and water based oil cleaner can be used to clean removed parts 7 When using a crane or other hoisting equipment first check the slings for damage It is required to use hoisting equipment with sufficient lifting capacity During lifting operation do lifting operation slowly at appointed position so as to prevent parts from colliding with each other Do not work under lifted parts h CAUTION As the torque converter can not be positioned axially avoid torque converter from sliding down during removal and refitting of transmission See Fig 1 1 as below Fig 1 1 8 When two or more persons are required to work simultaneously they shall be In agreement with t
34. g 3 6 1 Strap wrench 3 1 4 Removal of auxiliary PTO hub 1 Remove the bolt for connecting auxiliary PTO hub and housing 2 Use crowbar to push out the hub and take off the PTO hub and seal ring At this time the PTO hub has been removed completely Fig 3 7 Hexagon socket screw 2 Auxiliary PTO hub 34 A WRIS I YD13 YD133 YL13 Transmission Service Manual 3 1 5 Removal of input device 1 Remove the hexagon bolt for connecting pump impeller bearing seat and oil distributor flange Fig 3 8 1 Oil distributor flange 2 Pump impeller bearing seat 3 Hexagon screw 2 Use two jackscrews to push out the input device and then use the copper bar to tap and loosen the bearing seat Afterwards take off the bearing seat and gasket Fig 3 9 1 Pump impeller bearing seat 2 Gasket 3 Remove the bolt for connecting main PTO and housing and use two M8x20 bolts to push out the PTO assembly Fig 3 10 1 Main PTO hub 2 Hexagon screw 35 A LU Z IS T YD13 YD133 YL13 Transmission Service Manual SDLG Fig 3 11 1 Position to be supported by copper bar Fig 3 12 1 Transmission oil pipe 2 Transmission oil inlet cover 36 4 Support the transmission pump end cover with a piece of 30 400mm copper bar by the left hand and tap out the oil distributor flange and transmission pump assembly with another piece of copper bar by the right hand and put them aside Jr NOTE Appropriate
35. g driving gear on the PTO shaft 2 Remove the snap ring for fixing ball bearing cone on the PTO shaft Fig 3 31 1 Retainer ring 3 Use screwdriver to expand the elastic damping ring for fixing ball bearing and tap PTO shaft from the other side Fig 3 33 4 Take off the driving gear PTO shaft and ball bearing Fig 3 34 1 Driving gear 2 PTO shaft 3 Ball bearing 44 LU RIS I YD13 YD133 YL13 Transmission Service Manual 5 Take off the two retainer rings for fixing needle roller bearing on the PTO hub and remove the two retainer rings for fixing ball bearing Fig 3 35 1 Retainer ring 2 Needle roller bearing 3 2 2 Removal of input assembly 1 Remove the four bolts for connecting transmission pump and oil distributor flange Fig 3 36 Hexagon screw M8 85 2 Remove the four bolts for connecting transmission pump and oil distributor flange Fig 3 37 Hexagon screw M8 115 45 A WR 1S YD13 YD133 YL13 Transmission Service Manual SDLG 3 Use copper bar to tap the output shaft to tap out the transmission pump Fig 3 38 1 Copper bar 2 Output shaft 4 Take off the transmission pump gasket and output shaft and remove the bolt for connecting transmission pump cover and pump housing Fig 3 39 1 Hexagon screw 2 Output shaft 5 Use circlip pliers to take off the bearing snap ring from the output shaft and remove the ball bearing pi
36. g to the transmission control requirement the electric control unit outputs the corresponding voltage to the solenoid valve on the transmission control valve The solenoid valve assembly controls the corresponding oil circuit and the hydraulic oil drives the appropriate clutch 18 Aw WRIS I YD13 YD133 YL13 Transmission Service Manual SDLG thus achieving the direction and gear control The EST 4 electric control unit not only controls the direction and the gearshifting on the transmission but also provides four lines of output signals for the whole vehicle circuit including neutral gear signal AS for interlock start reverse gear signal RF for reverse indication kickdown indication H1 and alarm indication H2 See EST 4 output signal function table below for output signal status These output signals are all positive outputs 1 e the voltage is 24 V when signal is available The EST 4 electric control unit has detection and protection functions and all the outlet cable plugs should be connected before powering it for operation As for Vehicle electrical system the power positive and negative cables must be connected the signal AS for interlock start should be also applied and others are connected as needed If one of the solenoid valves on the transmission control valve fails to be connected or short circuit occurs or the power voltage appears abnormal the electric control unit will lock all outputs but only send
37. he lever Top up correctly Arrange connectors Clean AX wires 2c The transmission produces unusual noises The vehicle reverses with neutral position engaged remains still with 1 2 4 3 4 forward gear engaged and runs as normal with the electric box works unstably or their connectors are poorly connected The valve gets seized Bolts securing the engine with transmission get loose The transmission oil level is low The propeller shaft connecting the transmission 1s faulty The elastic plate connected between the engine and the torque converter is torn off The transmission incurs mechanical fault inside The clutch of reverse gear is ablated The valve gets seized The solenoid valve M1 is in failure The lever is faulty 97 YD13 YD133 YL13 Transmission Service Manual Check and tighten Add oil to the normal level Check the propeller shaft Replace the elastic plate Remove the propeller shaft and check if there is still unusual noise produced if were check if the transmission involves mechanical fault After the engine stops block the oil passage to the KR clutch and then start the engine and engage the reverse gear If the vehicle runs as normal it indicates that the reverse gear clutch is ablated and should be repaired mechanically Clean AX wis SDLG YD13 YD133 YL13 Transmission Service Manual reverse engaged The vehicle
38. he same operation procedure to avoid accident due to out of step 9 Be sure to keep all tools properly and get familiar with their operating methods 10 To align one hole with another do not insert your hand or finger into the holes As regards to parts requiring assembly with hands pay attention to the holding position and check it for risk of crushing 11 Be sure to perform inspection on the removed parts The part of which the defect has already affected the performance must be replaced 12 After each part is fitted no interference is allowed 8 Aw WRIS I YD13 YD133 YL13 Transmission Service Manual SDLG 13 When passing the oil seal and the seal ring through key groove threaded hole and step during installation take corresponding protective measures so as to avoid damaging them 14 In the process of assembling parts the tools used shall match corresponding threaded fasteners so as to prevent the fasteners from being damaged 15 To tighten fittings body and plug screw do not use a pneumatic wrench Be sure to rotate them to some extent by hand and then use a torque wrench of corresponding specification to tighten them to required torque 16 When draining oil from the transmission be sure to unscrew the drain plug slowly so as to prevent oil from spurting out A WRIS T YD13 YD133 YL13 Transmission Service Manual SDLG 1 2 Description of signs To make this Manual fully play its roles the signs in Table 1 1 ar
39. ing and torque converter into connecting casing and note the positions of splined holes gt About 20kg AX NOTE As provision is not made for axial fixing the installed torque converter should be fixed Fig 4 79 1 Torque converter 2 Intermediate ring properly to prevent against dropping 86 LU RIS IT YD13 YD133 YL13 Transmission Service Manual SDL 5 Troubleshooting 5 1 Removal and assembling tools for YD13 transmission Code 2938001832 Name Clutch nylon bar 1 Qty Purpose Output flange pressure plate lock plate tool for locking assembled output shaft lock plate Purpose Purpose For assembling needle roller bearing 4026 87 A WRIS YD13 YD133 YL13 Transmission Service Manual SDLG 2938001829 2938001828 Name Clutch shaft puller Clutch shaft puller 6 7 shaft sleeve Qty 1 Purpose For removing and assembling clutch piston return spring 2938001827 Name Clutch pressing tool pressure plate Qty I Purpose For removing and assembling clutch piston return spring 5 2 Inspection tools for YD13 transmission Transmission pressure joint Relief valve pressure joint 6410006224 Used with pressure testing joint Pressure tesing hose 4030000368 and pressure gauge Pressure gauge with a range 6430000943 of 25 bar sin 1 Clutch piston stroke and clearance 1 8 2 2 mm Axial clearance of three sets of 0 1 0 3 mm clutch shaft assemblies
40. ion Test methods for main components a Measurement of solenoid valve The resistance valve of the solenoid valve is about 60 70 Ohm and when measuring with a universal meter switch off the power firstly and remove the round plug connecting the control valve The resistance value out of the range above indicates that the solenoid valve is faulty and thus replacement is required 20 Aw WRIS I YD13 YD133 YL13 Transmission Service Manual SDLG b Test of speed sensor In order to measure the resistance value of the speed sensor with a universal meter remove the power plug firstly then measure between the two plug terminals and the resistance value within 1 02 K 1 2 K is normal The resistance value of O or infinity indicates that the sensor is damaged and thus replacement is required Besides inspect for its proper installation position the clearance between the sensor top surface and inspected gear peak should be within 0 5 0 8 mm Screw the sensor forward completely then loosen half turn and now the clearance should be basically appropriate c Test of brake switch The service brake and emergency brake pressure switches should apply normally open contact and the measured resistance should be infinite With the brake switch depressed the resistance value should be 0 d Test of DW 4 gear selector A special purpose test box is required for testing DW selector fit the 8 core socket of the test box with the DW 4 plug and con
41. ission assembly 76 4 2 1 Refitting of Output components 76 4 2 2 Refitting of countershaft assembly 79 4 2 3 Refitting of torque converter pressure control valve 79 4 2 4 Refitting of K3 and K4 clutch assemblies 80 4 2 5 Refitting of KR amp K2 and KV amp KI clutches 8 Re 82 4 2 7 Relittina ol INPUL ASSEMDLY ee re qa 82 4 2 8 Refitting of main PTO assembly 84 A A 0 7 84 4 2 10 Refitting of transmission Control valve 84 4 2 11 Refitting of torque converter 86 gt Troupes DOOU u E EE EE E EE 87 5 1 Removal and assembling tools for YD13 transmission 87 5 2 Inspection tools for YD13 transmission 88 5 3 Fit clearance of critical parts Of transmission 88 6 Fault Diagnosis and Iroubleshooting 89 6 1 Fault diagnosis and troubleshooting for transmission EST controller 89 6 2 Diagnosis and troubleshooting of comm
42. lled to the transmission upon operational requirements The pressure cut off valve can be easily controlled through a secondary brake pedal regulating the air pressure or oil pressure The hydraulically controlled pressure should be no less than 40 bar The pneumatically controlled pressure should be no less than 2 5 bar The pressure cut off valve functions to cut off the oil pressure of the clutch oil line and the clutch can be disengaged when the gearshift valve stops working So the engine output power can be supplied to the external pump completely If the pressure cut off valve is used there s no need to put the gearshift valve at the neutral position 16 A W R IS YD13 YD133 YL13 Transmission Service Manual SDLG ire thrott led di yWT1 pressi Shifter valve rter Input pressure ro itlon ii iff ont Return flow GS dH Lubrication pressure CZE par rc s Pe Re Set Valve HH E 0il pump Sure contre H JJ i Rq Pres Fig 2 7 Schematic of transmission control hydraulic system 2 1 4 Transmission electrical control system The gearshifting on the transmission is of electro hydraulic control and YD13 transmission with EST semi automatic gear controller is shown in Fig 2 8 Regulate the hydraulic slide valve through the solenoid valves connected the selector to shift gears in turn without skipping The gear pump
43. mission pump bearing 2 Joint surface of transmission pump 12 Install steel ball and pressure spring into torque converter safety valve hole on oil distributor flange Fig 4 46 1 Steel ball O20mm 2 Pressure spring 13 Place oil pump gasket onto the pump surface of oil distributor flange grease it and insert the pump assembly into the hole of oil distributor flange assembly Fig 4 47 1 Oil pump gasket 74 WRIS IT YD13 YD133 YL13 Transmission Service Manual SDL Fig 4 48 1 Hexagon screw M8 115 4 pcs Hexagon screw M8 85 4 pcs Fig 4 49 1 Gasket Fig 4 50 Hexagon screw M8 28 14 Tighten the bolt for connecting oil pump assembly and oil distributor flange assembly Nm 23 Nm 15 Place the gasket of pump impeller bearing seat onto the oil distributor flange face 16 Tap in the pump impeller bearing seat and tighten the bolt for connecting pump impeller bearing seat and oil distributor flange 23 Nm 19 A WR IS YD13 YD133 YL13 Transmission Service Manual SDLG Fig 4 51 1 Output shaft gear 2 Partition 3 Oil baffle disc Fig 4 53 1 Output shaft 4 2 Refitting of transmission assembly 4 2 1 Refitting of output components 1 Place output shaft gear install partition and oil baffle disc into the housing and use two bolts M8 16 and washers to fix them 2 Tap roller bearing to output gear shaft end and place it into oil baffle
44. n Ea Fig 3 67 1 Retainer ring 2 Guide ring E 20 Remove the upper guide ring pressure spring and lower guide ring from K3 clutch O in turn Fig 3 68 1 Guide ring 2 Pressure spring 21 Remove the piston and seal ring from K3 clutch Fig 3 69 1 Seal ring 2 K4 clutch piston 3 Seal ring 56 A W R IS IT YD13 YD133 YL13 Transmission Service Manual SDLG 22 Remove the needle roller bearing and one way valve from K3 amp K4 clutches Then K3 clutch has been removed completely Fig 3 70 1 One way valve 2 Needle roller bearing 57 A W Z IS T YD13 YD133 YL13 Transmission Service Manual SDLG 4 Refitting of Transmission 4 1 Refitting of transmission assembly 4 1 1 Refitting of three sets of clutches Jr NOTE The three sets of clutch assemblies are similar in structure and the assembling process of K3 and 4 clutch assemblies is here described as an example 1 Tap needle roller bearing into clutch bearing hole and install retainer ring Jr NOTE Each component should be cleaned before the assembling l 2 Fig 4 1 1 Retainer ring 2 Needle roller bearing 08 A WR IS YD13 YD133 YL13 Transmission Service Manual SDLG i 2 Install seal ring into the piston groove and then install piston assembly into the clutch 0 Se cylinder Jr NOTE The seal ring should be installed with the sealing surface facing towards the pressure oil fa
45. nect two power lines to DC 24 V power with the red line to 24 and the yellow line to ground The eight indicator lamps on the test box correspondingly display the eight position statuses of DW 4 Rotate the selector lever and four lamps for I to IV gears come on accordingly pull the lever and Forward Neutral and Reverse lamps come on accordingly press the lever and the KD lamp comes on accordingly The selector has no any fault if all the above are correct And the selector is faulty and should be replaced if one of the above is failed e Test of EST 4 electric control unit A special purpose test box is required for testing EST Connect the 35 pin plug of the outlet cable on the test box to the outlet line socket on the EST unit Allow the hook at one end of the plug to catch the pin on the unit end cap align the plug and press hard till the other end of the plug is clamped by the leaf spring Connect a DW 4 selector on the 8 core square plug of the outlet cable Connect the two power lines of the test box to DC 24 V power with the red line to 24 and the yellow line to negative pole Put the DW 4 at neutral II gear and at the moment of powering the four indicator lamps of M1I M4 on the test box flash once simultaneously and then only the indicator lamp M2 remains on Rotate or pull the selector lever and the eight indicator lamps on the test box should change in accordance with the function table below 21
46. o the clutch Fig 4 16 1 Piston 16 Install guide ring and pressure spring into the clutch cylinder Fig 4 17 1 Guide ring 2 Pressure spring 3 Guide ring 17 Install guide ring and retainer ring Fig 4 18 1 Guide ring 2 Retainer ring 64 A WR 1S YD13 YD133 YL13 Transmission Service Manual SDLG 18 Install the removal tool for clutch spring onto the clutch tighten the tool nut and press the clutch spring Fig 4 19 1 Removal tool for clutch spring 2938001826 2938001827 19 Use circlip pliers to install retainer ring into K4 clutch cylinder snap spring groove and remove the removal tool for clutch spring Fig 4 20 1 Retainer ring 2 Circlip pliers 2 I 20 Place the outer friction lining into K4 clutch firstly Jr NOTE In normal use the outer friction lining of clutch with the depth of grained groove worn more than 2 3 should be replaced in time l Fig 4 21 1 Outer friction lining 65 A W RIS IT YD13 YD133 YL13 Transmission Service Manual SDLG 21 Place the inner friction lining into K4 clutch Fig 4 22 1 Inner friction lining eg 22 Place the bearing plate into K4 clutch Fig 4 23 1 Bearing plate 23 Install the elastic damping ring into K4 clutch Fig 4 24 1 Elastic damping ring 66 A WR IS YD13 YD133 YL13 Transmission Service Manual SDLG 24 Use screwdriver to pick up the friction lining o
47. ompany provides Loader LG938L equipped with YD13 transmission 4 forward gears and 3 reverse gears road roller RS8220 equipped with YD133 transmission 3 forward gears and 3 reverse gears without torque converter and road roller RP9300 with YL13 transmission 2 forward gears and 2 reverse gears 1 Transmission control valve 2 Oil filter 3 Torque converter oil temperature measuring port 4 Oil outlet of torque converter to oil cooler 5 Oil suction pipe 6 Transmission body 7 Nameplate A WRIS T YD13 YD133 YL13 Transmission Service Manual SDLG 8 Eye screw 9 Auxiliary PTO 10 Main PTO 11 KVKI1 clutch shaft 12 KRK2 clutch shaft 13 K3K4 clutch shaft 14 Parking brake 1 Hydraulic torque converter 2 Transmission pump 3 PTO gear 4 Clutch triad 5 Output shaft oc nh P 6 Parking brake Fig 2 3 2 1 2 Basic parameters of torque converter and transmission assembly Table 2 1 pI wi ws ZFW305 Torque converter A W RIS I YD13 YD133 YL13 Transmission Service Manual SDLG amp maximum of 120 C __ maximum of 120 C Fixed shaft Fixed shaft Fixed shaft Type powershift powershift powershift Transmission 4 forward gears and 3 forward gears 2 forward gears and range 3 reverse gears and 3 reverse gears 2 reverse gears 3 036 Forward 2 304 4 543 1 603 II Forward 0 964 1 90 N A III Forward 0 617 N A N A IV 3 936 Reverse 2 304 4 543 1 603
48. on transmission faults 91 Aw WRIS I YD13 YD133 YL13 Transmission Service Manual SDLG Chapter 1 Introduction 1 1 Safety precautions Important safety notice Service and maintenance is essential to the safe operation of vehicle This Manual mainly states how to remove and refit transmission assembly To prevent relevant from being hurt this Manual takes A as a Safety sign With regard to precautions attached with this sign it is required to do operation carefully In case of potential hazard first take into account the safety of yourself and meanwhile take necessary protective measures Ad Safety notice In the process of removal and refitting improper operation methods will lead to part damage service life shortening and operating performance deterioration and in addition it may cause personal injury Therefore please read related content in this Manual carefully before removing and refitting any part 1 The parameters figures and content covered by this Manual apply to products of standard configuration As regard to variants please consult SDLG or relevant data 2 In the repair workshop a separate or special area shall be provided for removal and refitting of parts or for removed parts corresponding tools and parts shall be placed at an appropriate area and the operation area shall be kept clean and free of oil dirt and other contaminant Do not smoke at any place other than the speci
49. oting for the EST controller and the transmission Note The specifications of parts covered by this Manual may be subject to modification due to the improvement of this product and no further notice will be given upon such modification so please contact SDLG for the latest data A WRIS T YD13 YD133 YL13 Transmission Service Manual SDLG Aw WRIS I YD13 YD133 YL13 Transmission Service Manual SDLG Contents OO 3 CnouUuuelae ere 0 0 7 Dae Eee u E E E T NA 7 Ti Op ool ST 10 1 3 Tightening torque table for plain bolts 10 J shoslonsyy 5 u usu manamya N 12 Zi PASTS OI uuu unn E EEE E E EE 12 2 1 1 Description Of tranSMiSsiON e000 ier Nn ESEN En Enin raias 12 2 1 2 Basic parameters of torque converter and transmission assembly 13 2 1 3 Gearshift principle Of tranSmlsSl1On 14 2 1 4 Transmission electrical control system 17 2 1 5 Functional test Of transmission 000 24 2 1 5 Functional test Of transmission L uuu u unas aaquasaasqa naqqa wuawaysun 25 2 1 6 YD13 Operation and maintenance of powershift transmission 26 FR OY o an 32 3 1 Removal of transmission assembly 32 3 1 1 emovaloltordueeconverter u imisa qayaqa kaaqsawqyqqs a2 3 1 2 Removal of transmission control valve
50. out the alarm signal signal lamp H2 will flash or the unit will click In this case switch off the power to clear the fault and then switch on the power again for normal operation For the operation of the control system in addition to pulling the DW 4 selector lever to shift gears and control directions the brake signal BR and emergency braking BR2 in the vehicle electrical system will also affect the output of the controller Under forward I and II gears or reverse I and II gears if one of the two signals is connected to 24V EST 4 output will remain the same as the neutral of the corresponding gear on the DW 4 Technical parameters Table 2 2 Rated voltage DC 24 V Working voltage range DC 20 32 V A maximum of 5 Output signal current A maximum of 0 5 A for each line Working temperature 20 70 C 2 Operation A WRIS T YD13 YD133 YL13 Transmission Service Manual SDLG Before starting the engine put the DW 4 gear selector lever at N position or the engine cannot be started After switching on the power put the DW 4 selector at neutral when using it for the first time then shift to another gear as required or the electric control unit EST 4 has no output a Push or pull the control lever of the gear selector horizontally to change the driving directions including F Forward N Neutral and R Reverse rotate the control lever to shift gears counterclockwise for upshift and clockwise for downshift but
51. oval 1 Snap ring 45 1 75 s Mn 16 Nm 4 2 7 Refitting of input assembly 1 Place input device onto the housing install gasket and use copper bar to tap it in NOTE During the assembling two bolts should be screwed into the fixing screw holes and new gasket installed after the removal Fig 4 71 1 Input assembly 82 A LU RIS I YD13 YD133 YL13 Transmission Service Manual Fig 4 72 1 Transmission oil inlet cover 2 Transmission oil pipe r r Fig 4 73 1 Tensioning pin 2 Hexagon screw 2 Assemble transmission oil inlet pipe assembly and transmission oil pipe and tighten the hollow screw of transmission oil pipe and housing Nm 3445 Nm 3 Assemble connecting housing and use copper bar to tap it in Jr NOTE During the assembling the locating pin holes Should be aligned and tapping force distributed evenly on the connecting casing 4 Tighten the bolts for connecting housing oil distributor flange and connecting casing Jr NOTE Pin holes should be aligned and bolts tightened several times diagonally 83 A W Z IS T YD13 YD133 YL13 Transmission Service Manual SDLG 4 2 8 Refitting of main PTO assembly 1 Install PTO assembly and tighten the bolts and nuts for connecting PTO and housing NOTE Bolts should be tightened several times diagonally Nm 23 Nm Fig 4 74 Hexagon screw 4 2 9 Refitting of oil filter 1 Screw up the oil filte
52. proceeds with neutral position engaged remains still with reverse gear engaged and runs as normal with 1 y2 73 forward gear engaged The vehicle can only proceed with 1 forward reverse gear engaged The clutch of forward gear 1s ablated The valve gets seized The solenoid valve M3 is in failure The lever is faulty K1 clutch is ablated The valve gets seized The solenoid valve is in failure The lever is faulty 98 Replace the solenoid valve Replace the lever After the engine stops block the oil passage to the KV clutch and then start the engine and engage the 1sV2 13 forward gear If the vehicle runs as normal it indicates that the forward gear clutch 1 is ablated and should be repaired mechanically Clean Replace the solenoid valve Replace the lever After the engine stops block the oil passage to the K1 clutch and then start the engine and engage the 1 forward reverse gear If the vehicle runs as normal it indicates that the clutch of the 1 gear is ablated and should be repaired mechanically Clean Replace the solenoid valve Replace the lever
53. r 4 2 10 Refitting of transmission control valve 1 Place paper washer lower partition paper washer and oil feed plate onto the valve plate plane of housing respectively and use three M8x30 bolts and three M8x45 and six M8x35 hexagon socket screws to fix them s 8 Jr NOTE Fig 4 76 1 Oil feed plate New paper washers should be installed after 2 Paper washer the removal 84 A WRIS IT YD13 YD133 YL13 Transmission Service Manual SDLG Fig 4 77 1 Transmission control valve 85 Before the assembling the housing valve plate oil duct plate and partition should be cleaned Nm 20 Nm 2 Place paper washer upper partition paper washer and control valve onto the oil feed plate and use ten M8x45 and six M8x75 hexagon socket screws to fix them NOTE New paper washers should be installed after the removal Bolts should be tightened several times diagonally Nm 20 Nm 3 From top to bottom the six oil holes on oil feed plate are for K2 K1 K3 K4 KV and KR among them KV and KR pipes are subject to rear axle differential gear steering of each OEM pipes respectively connect them with various oil duct holes on K1 K2 and K3 shafts respectively r NOTE Bolts should be tightened after the proper adjustment of hose position Nm 55 5 5 Nm A W Z IS I YD13 YD133 YL13 Transmission Service Manual SDLG 4 2 11 Refitting of torque converter 1 Install intermediate r
54. rating range the temperature will not be higher If the oil temperature is higher than 120 C stop the vehicle to check if there is oil leakage and the transmission should be at neutral and the engine run at a speed of 1200 1500 rpm in which case the oil temperature will drop soon to a normal valve within approx 2 3 min If the oil temperature still keeps high somewhere in the system is faulty so clear the fault before the operation The oil pressure during gear shifting is normally within 13 17 bar and to monitor the control pressure a pressure gauge or pressure monitor must be installed If some gear is engaged and after applying the clutch the pressure drops to a value lower than the specified minimum pressure the pressure drops temporarily right at the moment the gear is shifted eliminate the cause of the 28 AX wis x SDLG YD13 YD133 YL13 Transmission Service Manual pressure drop A low control pressure will result in the clutch damage as the clutch lacks the sufficient contact pressure resulting in the friction plate keeping slipping and therefore being overheated 3 Maintenance 2 Oil level check Stop the vehicle at flat place Put the transmission gear lever at N position and the parking brake at applied position Run the engine at an idle speed of 1000 rpm Loosen the oil dipstick counterclockwise and take it out for wiping Insert the oil dipstick into the oil pipe an
55. s the sealing surface of the transmission and then tighten by 1 3 1 2 turn with hand Add oil and start the engine When the engine runs at an idle speed about 1 000 rpm and the transmission oil temperature is just the working temperature check the transmission oil level For the oil temperature of 40 C the oil level should be within the Zone Cold For the oil temperature of 80 C the oil level should be within the Zone Hot Check for tightening Tighten with hand again when necessary al AX wie r YD13 YD133 YL13 Tran SDLG smission Service Manual Fig 3 1 1 Transition plate 2 Transition tube 3 Bolt Fig 3 2 1 Hexagon screw 2 Tensioning pin 3 Connecting casing 32 3 Removal of Transmission NOTE The removal and Refitting of YD13 transmission is described here as an example which can be served as reference for YD133 and YL13 transmissions 3 1 Removal of transmission assembly 3 1 1 Removal of torque converter 1 Remove transition plate and torque converter from the transmission drain off the oil in the torque converter and put them aside lt a About 20 kg 2 Remove the bolt 3 for connecting transition tube and transmission 3 Remove the bolt for connecting casing and the transmission and adjust the transmission to the appropriate position then use two bolts to push the casing out and remove it A W R IS T YD13 YD133 YL13 Transmission
56. sation washer Fig 3 25 1 Rear end of output shaft 2 Copper bar Fig 3 26 1 Bearing 2 Output shaft 3 Shaft sleeve 7 Use circlip pliers to remove the bearing snap ring and compensation washer at the front end of output shaft 8 Use copper bar to tap the rear end of output shaft 9 Remove the output shaft bearing and shaft sleeve 41 SDLG A LU Z IS T YD13 YD133 YL13 Transmission Service Manual a ni A e CaN E iz Fig 3 27 1 Output gear 2 Connecting baffle 3 Hexagon screw M8 16 Fig 3 28 1 Output gear 2 Oil baffle disc 3 Baffle 42 10 Take out the output gear and remove the bolt for connecting baffle oil baffle disc and housing 11 Remove the oil baffle disc and baffle A WR IS I YD13 YD133 YL13 Transmission Service Manual SDLG 3 1 9 Removal of torque converter pressure regulating valve 1 Remove the screw plug for fixing valve housing assembly Fig 3 29 1 Valve housing assembly 2 Screw plug CM30 1 5 3 O ring 2 Remove valve housing assembly from the torque converter pressure valve port on the housing namely the valve housing valve stem pressure spring and washer Fig 3 30 1 Pressure spring 2 Valve stem 3 Valve housing 43 A W Z IS I YD13 YD133 YL13 Transmission Service Manual SDLG 3 2 Removal of transmission assembly 3 2 1 Removal of main PTO 1 Use circlip pliers to remove the retainer ring for fixin
57. ston ring and compensation washer Fig 3 40 1 Ball bearing 2 Piston ring 30x2 3 Snap ring 30x1 5 4 Compensation washer 46 W Z IS T YD13 YD133 YL13 Transmission Service Manual Fig 3 41 1 Transmission pump housing 2 Transmission pump cover Fig 3 42 1 Transmission pump inner gear 2 Transmission pump cover l 2 Fig 3 43 1 Transmission pump housing 2 Outer ring gear 6 Use copper bar to tap the output shaft and take off the transmission pump cover inner gear and other assemblies 7 Remove the transmission pump inner gear output shaft transmission pump cover and ball bearing 8 Take out the transmission pump outer ring gear 47 A WRIS YD13 YD133 YL13 Transmission Service Manual SDLG 9 Take off the safety valve at the torque converter oil inlet on the oil distributor flange steel ball pressure spring Fig 3 44 1 Steel ball 2 Pressure spring 10 Use circlip pliers to take off the snap ring for fixing the ball bearing on the driving shaft Fig 3 45 1 Snap ring 11 Use copper bar to tap and remove the driving shaft Fig 3 46 1 Driving shaft 2 Copper bar 48 WR IS T YD13 YD133 YL13 Transmission Service Manual SDL 12 Take off the driving gear ball bearing and roller bearing Fig 3 47 1 Roller bearing 2 Driving gear 3 Ball bearing 13 Remove the plunger ring from the driving shaft Fig 3 48 1 Driving
58. t to allow dirt and deposits into the oil circuit Moreover put a cover plate so as not to wet the parking brake by the oil Note not to tighten the filter too tightly in the course of its installation 2 Driving and gearshifting To start the engine confirm the gear lever is at neutral position For safety reasons the parking brake should be kept in the applied state before starting the engine so as to prevent the vehicle moving in the case of an engine start After the engine is started release the parking brake select the driving direction and gear and then depress the accelerator slowly to move the vehicle Until the vehicle travels the torque converter functions instead of a main clutch Driving with a high gear is possible under good road condition If the engine still runs and the transmission engages gear while the vehicle has been stopped in which case surely the engine is not shut down the vehicle will creep on a straight road for that certain traction is generated through the torque converter during the engine idling Therefore it 1s reasonable to keep the parking brake in the applied state when stopping the vehicle each time To stop the vehicle for a long time the control lever must be put at neutral position When the vehicle is running always remember to release the parking brake Because as far as we know it 1s hard for the operator to realize this immediately and due to large output torque ratio when the Al A WRIS
59. tly and top up when necessary Bleed off the radiator via the exhaust AX wis Air invades into the radiator of torque converter Oil passage between the torque converter and the radiator is blocked The heat dissipating capacity of radiator is low Back pressure valve of the torque converter gets seized The oil level is low The elastic plate connected between the engine and the torque converter is torn off YD13 YD133 YL13 Transmission Service Manual outlet on the top for engines with exhaust outlet Check if the oil circuits between the radiator to the transmission and the radiator are blocked Check if the radiator can perform heat dissipation appropriately and check the tension of engine fan belt and check the radiator outside for adhered dirt Check if the hose joint between the transmission and the radiator is inserted deeply into the transmission so that the back pressure valve core is pressed the valve is seized and thus the oil passage is blocked Check the oil level correctly and top up when necessary Replace the elastic plate or the corresponding damaged part Check if the power supply is The vehicle fails to and the power damaged if the cable is worn out run regardless of connection between and if the cable connector is the gear engaged the torque converter and the transmission input gear Is failed seldom Power circuits of the 94 dislodged Do trou
60. to supply oil for the torque converter and control valve is installed inside the transmission and driven directly by the engine via PTO shaft The hydraulic transmission oil passed through the oil suction filter and the pressure control valve in the oil circuit flows into the transmission control valve and 17 A WRIS I YD13 YD133 YL13 Transmission Service Manual SDLG the transmission control pressure is 13 17 bar The pressure control valve regulates the boost pressure of the clutch cylinder at the moment of gearshifting reducing the impact of gearshifting and improving the gearshifting efficiency 1 EST semi automatic gear controller 1 Principle The EST series gear controller is an electric control system mainly composed of EST 4 4 valve electric control unit as shown in Fig 2 8 with the semi automatic control function for gearshifting This system mainly consists of the five components below a Gearshift lever DW 4 four gear selector installed under the steering wheel and operated by left hand b Electric control unit EST 4 c Special purpose wire harness and connector d Solenoid valve on the control valve This control system is currently used to control the YD13 type transmission for the loader Both the signals of DW 4 selector and the other signals of the whole vehicle circuit are transferred to EST 4 electric control unit After analysis and determination through combining all the signals and accordin
61. ture normally within 80 120 C is permissible to rise to 120 C in short time especially note the control oil pressure of the transmission When the transmission works abnormally in service stop the vehicle immediately for inspection 7 If a faulty vehicle needs to be repaired by electric welding remove the cable plug from the EST computer controller to cut off the circuit to the computer controller which otherwise will be burnt out due to impulse current during electric welding 26 Aw WRIS I YD13 YD133 YL13 Transmission Service Manual SDLG 2 Operation 1 Preparation and maintenance before driving Prior to transmission operation always add appropriate lubricating oil according to the specified lubricating oil specification For the transmission initial filling the oil cooler filter and connecting lines must be full with the oil So the initial filling amount is more than that of the later normal maintenance Since the installed torque converter oil flows through the oil cooler and pipe and returns to the transmission in a stationary state the correct oil level should be kept when stopping the vehicle at the neutral gear the engine running at idle speed and the transmission in a normally thermal equilibrium temperature Check the oil level only when the control lever is put at neutral Inset the oil dipstick to the oil tube bottom when checking the oil level When cleaning the filter of the main oil passage be cautious no

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