Bs428 Transmission Workshop Mannual 20156

BYD4208
BS428 Transmission Service Manual
Foreword
This service manual mainly covers the removal and refitting process, service technology and
standard requirements for BS428 transmission (also applies to BYD4208 series 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 proper fault diagnosis and troubleshooting.
This service manual mainly includes the following:
Chapter 1 Introduction
This chapter mainly describes precautions for servicing transmission, explains the meaning of each
symbol which are included in the following text and specifies the tightening torque for plain bolts.
Chapter 2 Transmission system
This chapter mainly describes the gearshift principle of transmission, the transmission line of each
gear, and the operation and maintenance of oil supply line and 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 Service tools for transmission
This chapter describes special tools required in the process of servicing transmission.
Chapter 6 Fault diagnosis and troubleshooting
This chapter describes common faults and troubleshooting of 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.
Contents
1 Introduction ................................................................................................................ 1
1.1 Safety precautions ............................................................................................. 1
1.2 Description of signs ........................................................................................... 2
1.3 Tightening torque table for plain bolts .............................................................. 3
2 Transmission system .................................................................................................. 5
2.1 Description of transmission............................................................................... 5
2.2 Basic parameters of transmission & torque converter assembly ...................... 6
2.3 Structure and principle of transmission............................................................. 6
2.3.1 Structure of transmission ........................................................................... 6
2.3.2 Shifting principle of transmission.............................................................. 7
2.3.3 Gear transmission lines .............................................................................. 8
2.3.4 Structure and principle of shifting clutch ................................................ 10
2.3.5 Structure and principle of automatic emptying valve (oil drain valve) ... 11
2.4 Oil supply system ............................................................................................ 13
2.4.1 Structure and working principle of transmission & torque converter oil
supply system .................................................................................................... 13
2.4.2 Introduction to oil supply system main components ............................... 14
2.5 Transmission Operation and Maintenance ...................................................... 18
2.5.1 Installation and Application Notices for Transmission ........................... 18
2.5.2 Maintenance of Transmission .................................................................. 18
3 Removal of Transmission ......................................................................................... 20
3.1 Removal of assembly components .................................................................. 20
3.1.1 Removal of oil filler pipe and filter ......................................................... 20
3.1.2 Removal of parking brake assembly ....................................................... 21
3.1.3 Removal of transmission control valve ................................................... 22
3.1.4 Removal of breather and cover plate ....................................................... 23
3.1.5 Removal of input flange .......................................................................... 23
I
3.1.6 Removal of oil sump ................................................................................ 23

3.1.7 Removal of high/low gearshift fork mechanism ..................................... 24
3.1.8 Removal of output shaft ........................................................................... 24
3.1.9 Removal of three sets of clutch gear shafts ............................................. 26
3.2 Removal of assembly ...................................................................................... 28
3.2.1 Removal of transmission control valve ................................................... 28
3.2.2 Removal of three sets of clutch gear shaft assemblies ............................ 30
4 Refitting of Transmission ......................................................................................... 34
4.1 Refitting of assembly....................................................................................... 34
4.1.1 Refitting of clutch shaft assembly ........................................................... 34
4.2 Refitting of assembly components .................................................................. 38
4.2.1 Assembly of three sets of gear shafts ....................................................... 38
4.2.2 Refitting of input flange and rear end cover ............................................ 40
4.2.3 Assembly of countershaft and reverse gear shaft rear end cover ............ 41
4.2.4 Assembly of output shaft ......................................................................... 42
4.2.5 Assembly of high/low gearshift fork mechanism .................................... 42
4.2.6 Assembly of oil sump .............................................................................. 43
4.2.7 Assembly of transmission control valve .................................................. 43
4.2.8 Assembly of breather and cover plate ...................................................... 44
4.2.9 Assembly of parking brake assembly ...................................................... 44
4.2.10 Assembly of oil filler pipe and filter ...................................................... 45
5 Service Tools for Transmission ................................................................................ 46
6 Common Fault Diagnosis and Troubleshooting ....................................................... 47
II
1 Introduction
1.1 Safety precautions
Important safety notice
Service and maintenance is essential to the safe operation of vehicle. This Manual mainly
states the related techniques on how to remove and refit the transmission assembly properly.
To prevent relevant personnel from being hurt, this Manual takes
as 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.
Safety notice
In the process of refitting and removal, improper operation technique will lead to part damage,
service life reduction and deterioration in operating performance, and in addition, it may cause
unsafe factors. Therefore, please read related content in this manual carefully before refitting and
removing any part.
1. The parameters, figures and content covered by this manual apply to product of standard
configuration. As regard to variant, please consult our coMPany or relevant data.
2. In repair workshop, a separate or special area shall be set for placing removed parts,
corresponding tools and parts shall be placed at 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
specified area. Never smoke during operation, and it is required to have fire extinguishing device.
3. When welding operation is necessary, it shall be done by a trained and experienced welding
worker. During welding, it is required to wear and use appropriate protective equipment such as
welding gloves, baffle, goggles, work cap and overall.
4. Before removing transmission & torque converter assembly, make sure to clean the dirt from its
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 work coat.
The work coat must be buttoned. When striking parts with a copper rod, safety goggles shall be

worn.
6. Petrol, kerosene and water-based oil cleaner can be used to clean the removed parts.
7. To use 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 lift slowly at
appointed position so as to prevent parts from striking against each other. Do not work under the
lifted parts.
8. When two or more people are required to work simultaneously, they shall be in agreement with
the same operation procedure in advance to avoid accident due to out of step conditions.
9. Make sure to keep all tools properly and get familiar with their operating methods.
10. To align one hole with another, do not get your hand or finger into the holes. As regards to parts
requiring direct assembly with hand, always pay attention to the holding position and check it for
risk of crushing.
11. Make sure to perform inspection on the removed parts. The part of which the defect has already
affected the performance must be replaced.
12. After assembling all parts, no interference is allowed.
13. When assembling the oil seal and seal ring, if they have to pass key groove, screw hole and step,
then corresponding protective measures shall be taken so as to avoid damaging them.
14. In the process of refitting parts, the tools used shall match corresponding threaded fasteners so
as to prevent the fasteners from being damaged.
15. To tighten joint body and plug screw, do not use pneumatic wrench. Be sure to rotate them to
some extent with hand, and then tighten them with torque wrench of corresponding specification to
the required torque value.
16. When draining oil from transmission, be sure to unscrew the drain plug slowly so as to prevent
oil from spurting out.
1.2 Description of signs

To make this manual fully play its roles, the signs in Table 1-1 are used in respect of critical safety
and quality requirements.

Table 1-1
Sign
Item
Remarks
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 & refitting modes.
Weight
Pay attention to the selection of sling and the postures during

operation.
Tightening
torque
Pay special attention to the tightening torque of component

during assembly.
Application
Points requiring the application of adhesive and grease.
Oil and water Add a certain amount of oil, water and fuel.
Draining
Position for draining oil or water, as well as draining amount.
1.3 Tightening torque table for plain bolts

Table 1-2
Nominal diameter of bolt (mm)
Yield
Strength
strength
class
(N/mm2)
10
12
14
Tightening torque (Nm)
8.8
640
9~12
22~30
45~59
78~104
124~165
10.9
900
13~16
30~36
65~78
110~130
180~210
12.9
1080
16~21
38~51
75~100
131~175
209~278
Yield
Strength
strength
16
18
20
class
(N/
22
24

mm2)
8.8
640
193~257
264~354
376~502
521~683
651~868
10.9
900
280~330
380~450
540~650
740~880
940~1120
12.9
1080
326~434
448~597
635~847
864~1152
1098~1464
Yield
Strength
strength
class
(N/

27
30
33
36
39
mm2)
8.8
640
952~1269
1293~1723
1759~2345
2259~3012
2923~3898
10.9
900
1400~1650
1700~2000
2473~3298
2800~3350
4111~5481
12.9
1080
1606~2142
2181~2908
2968~3958
3812~5082
4933~6577
2 Transmission system
2.1 Description of transmission
BS428 transmission is a fixed shaft, constant mesh and power gearshift transmission, which is
mainly used for LG933L and LG936L loader. In the transmission system of LG933L and LG936L,
the engine is directly connected to the torque converter via an elastic plate so as to realize output
power, and torque converter is connected via the propeller shaft to front input flange of the
transmission where speed change and torque increase happens such that the power can be
transmitted to front and rear drive axles via front and rear propeller shafts respectively.
BS428 transmission mainly consists of input shaft assembly, countershaft assembly, and reverse
gear shaft assembly, high-low gear sliding sleeve as well as its control mechanism and many pairs
of constant mesh gear, etc.
Fig. 2-1
1.Breather 2.Transmission control valve 3.Reverse gear shaft 4. Input shaft 5.Countershaft
6.Oil drain plug 7.High-low gearshift fork 8.Output shaft 9.Filter 10.Oil filler pipe
11.Parking brake
2.2 Basic parameters of transmission & torque converter assembly

Table 2-1
Item
Parameters/description
Single-stage three-element turbine hydraulic
Type
torque converter
Torque ratio
Torque
converter
3.25
Oil pressure at torque converter inlet

0.5~0.6
(MPa)
Oil pressure at torque converter
0.2~0.3
outlet (MPa)
Transmission
Type
Fixed-shaft power shift
Gears
4 gears in front and 2 in the rear
Transmission working pressure

1.1~1.5
(MPa)
2.3 Structure and principle of transmission

2.3.1 Structure of transmission
BS428 transmission includes three sets of normally opened clutches, which are closed by hydraulic
fluid, and they control the 1st gear, 2nd gear, 1st reverse gear respectively, or the 3rd gear, 4th gear
and 2nd reverse gear when the shift fork is set to a higher gear. The one installed on the input shaft
is the 1st gear clutch; the power from torque converter is transmitted to input shaft via a connecting
flange and the input shaft is the total input of transmission. The one installed on the countershaft is
the 2nd gear clutch, and the countershaft can transmit the power from the 1st gear and the reverse
gear to the output gear. The one installed on the reverse gear shaft is the reverse gear clutch which
can make the loader drive backwards when it is engaged.
View from input terminal
Input shaft
Reverse gear shaft

Countershaft
Output shaft
Fig. 2-2
1. Reverse gear shaft clutch
2. Input shaft clutch 3. Intermediate gear shaft clutch
2.3.2 Shifting principle of transmission

The transmissions gearshift mechanism is a mechanically-operated one, with the gear controller of
BS428 transmission shown in Fig.2-3. This gear controller includes two gearshift levers: 1.
direction control handle (see Fig. on the left), which connects to the gearshift control valve stem on
the transmission via a flexible shaft; 2. high/low speed control handle (see Fig. on the right), which
connects to the shift fork on the transmission via a flexible shaft. The gear controller operates the
clutches of different gears by controlling the speed change valve. The working conditions of
clutches are shown in table 2-2.
Fig. 2-3 Gear selector

7

Table 2-2 Working conditions of clutches
Shift fork
2.3.3 Gear transmission lines

The power of the hydraulic torque converter is transmitted to the transmission via the input shaft
flange installed on the part of the right end of the input shaft that extends outside the transmission
box. The input shaft assembly, reserve gear shaft assembly and immediate shaft assembly connects
with the transmission box in the same way. Both ends of them are supported on the transmission
box and big end cap by conical bearings. Adjust the clearance of conical bearing during assembly,
to avoid damage to the bearing. The gears on the output shaft assembly, reverse gear shaft assembly,
countershaft assembly and output shaft are constantly meshed with each other. There are three stop
positions (HI, N, LO) in the high-low gear sliding sleeve which is refitted on the output shaft. The
high gear position corresponds to a high speed; the low gear position corresponds to a low speed.
When the sliding sleeve stays at the neutral position, no power will be output by the transmission.
Caution: Never shift the high-low gear sliding sleeve before the transmission is in the
neutral gear after the loader is stationary, otherwise, impacting and crashing of the gears may
occur.

1. 1st (3rd) gear transmission line
3rd gear (when the shift fork is set to the right
Reverse gear shaft
high speed gear):

inputZ3Z4Z7Z9output
Input shaft
Input
1st gear (when the shift fork is set to the left

shaft
Countershaft
low speed gear):

inputZ3Z4Z7Z5Z8Output
Output shaft
Fig. 2-4
2. 2nd (4th) gear transmission line
4th gear (when the shift fork is set to the right
Reverse gear shaft
high speed gear): inputZ3Z6Z7Z9

Input shaft
output
2nd gear (when the shift fork is set to the left
Countershaft
low speed gear): inputZ3Z6Z5Z8

output
Output shaft
Fig. 2-5
3. 1st 2nd reverse gear transmission line
1nd reverse gear (when the fork is set to the left
Reverse gear shaft
low speed gear): inputZ3Z1Z2Z7

Z5Z8output
Input shaft
2nd reverse gear (when the fork is set to the
right high speed gear): inputZ3Z1Z2
Countershaft
Z4Z7Z9output
Output shaft

Fig. 2-6
2.3.4 Structure and principle of shifting clutch

1. Structure
The housing and gear of the hydraulic clutch is fixed together with bolts, and the gear connects to
the external spline of the propeller shaft via the internal spline, all of which consist of the driving or
driven part of the clutch. The inner part of the clutch consists of piston, outer friction lining, inner
friction lining, oil seal ring, return spring, outer end cover, retaining ring, etc. The driving friction
lining of the clutch connects to the clutch housing via the external spline, and the driven friction
lining of the clutch connects to the external spline of the gear via the internal friction lining.
Another gear is supported on the propeller shaft by the bearing and can rotate with respect to the
propeller shaft.
The outer friction linings in three sets of clutches are copper based powder metallurgy friction
linings (6 PCS for each). The internal friction linings are made of 65Mn (5 PCS for each), with 0.5
mm concavity. When assembling, the convex surface shall face the piston end and make sure to
rotate the friction linings manually after assembly for inspection.
10
Fig. 2-7
1. Constant mesh gear 2. Centrifugal emptying valve 3. Clutch housing 4. Piston
5. Driving friction lining 6. Driven friction lining 7. Driven gear 8. Spring 9. Piston ring
10. Cylinder oil inlet passage 11. Lubricating oil passage 12. Seal ring
2. Working principle
When working: the transmission oil from the transmission control valve flows through the oil
passage in the transmission box and the big end cap and to the cylinder via the inlet end cover and
clutch shaft that will make the piston move forward, compress the driving and driven clutch plates,
and output the power via the driven gear that has been integrated with the clutch housing.
When stop working: The pressure oil will be cut off; the transmission oil in the cylinder returns via
the oil port; the piston returns via the return spring; the driving and driven clutch plates separates
and the gear idles.
2.3.5 Structure and principle of automatic emptying valve (oil drain valve)
After the clutch cylinder cut off the oil supply, the clutch housing will continue to rotate with the
shaft under the action of inertia force, and the transmission oil in the cylinder will move from the
11

inside to the outside under the action of centrifugal force which will generate pressure at the
circumferential edge of the cylinder and a thrust for the poison return, therefore hindering the rapid
separation of the clutch. In order to remove the centrifugal pressure from the oil inside the rotating
cylinder, an automatic emptying valve shall be set on the clutch housing.
When the clutch is engaged
When the clutch is released
Fig. 2-8
1 Piston 2 Clutch cylinder 3 Steel ball
When the clutch is engaged:
The pressure oil flows into the cylinder and flows out from the oil drainage hole via the pore
passage between the steel ball and the pore. At this point, pressure difference will be formed at the
front and the back of the steel ball. Under the action of this pressure difference, the steel ball will be
pushed to the oil drainage hole to cover it. When the oil drainage stops, the oil pressure in the
cylinder will rise.
When the clutch is released:
The cylinder connects with the return oil passage to release the pressure. At this point, the steel ball
will no longer be pushed by the pressure oil and will move outward under the action of the
centrifugal force, then, the oil drainage hole will open. The oil in the cylinder flows out from the oil
drainage hole via the pore passage between the steel ball and the pore, which will help the quick
return of the cylinder piston.
12
2.4 Oil supply system

2.4.1 Structure and working principle of transmission & torque converter
oil supply system
1. Structure of oil supply system
The oil supply system is an important component of the hydro-mechanical transmission system,
which generally consists of transmission pump, transmission control valve, oil filter, radiator, oil
pan and pipeline, etc.
Fig. 2-9 Composition of oil supply system

1. Relief valve 2. Secondary filter 3. Transmission pump 4. Torque converter
5. Radiator 6. Speed change valve 7. Oil pan 8. Primary filter
2. Working principle of oil supply line
When the pump impeller of the torque converter is running, the driving gear will drive the operation
of the oil pump to suck oil from the tank and output the pressure oil, which will flow into the torque
converter combination valve. The torque converter combination valve consists of transmission
pressure valve, inlet pressure valve and constrictor. The working oil to the combination valve
ensures sufficient oil for operation first and then is transmitted to the torque converter via the
transmission pressure valve under the action of the transmission pressure valve. The oil pressure for
13

transmission control and the oil pressure at torque converter inlet are controlled by the transmission
pressure valve and inlet pressure valve, with oil pressure of 1.1~1.5 MPa and 0.5~0.6 MPa
respectively. If the oil pressure at torque converter inlet exceeds the setting value of the inlet
pressure valve, the valve port will open and the oil will spill out for oil spray of the transmission
and the torque converter. Torque converter outlet pressure valve will keep the pressure at torque
converter outlet within 0.05~0.15 MPa. The oil from the outlet pressure valve will flow through the
radiator to the transmission lubrication system.
Inlet pressure valve
Torque
converter
combination valve
Transmissi
on pressure
valve
Torque converter
Reverse gear
Neutral gear
1st and 3rd gear
2nd and 4th gear
Cooler
Lubrication
Shower
1st and 3rd gear clutch
2nd and 4th gear

clutch
Reverse gear clutch
Fig. 2-10 Schematic diagram for the oil supply of transmission & torque converter system
2.4.2 Introduction to oil supply system main components

1. Structure and working principle of hydraulic torque converter
YJ315LG-1 hydraulic torque converter is a single-stage single-phase three-element hydraulic torque
converter. This series of torque converter as shown in Fig. 2-11 consist of energy conversion
elements (impeller, turbine, guide pulley), power input/output elements (elastic platewheel cover,
turbine shaft, output flange), fixed supporting element (housing), hydraulic parts and other
accessories, etc.
14
Fig. 2-11 Structure and schematic diagram of torque converter

1. Elastic plate 2. Turbine 3. Impeller 4. Guide pulley
5. Guide pulley seat 6. Turbine shaft 7. Output flange.
(1) Power input part
The drive plate, wheel cover and impeller constitute the power input part of the torque converter.
The wheel cover connects with the drive plate via rubber damping block or elastic plate, and the
drive plate connects with the engine flywheel housing via screws.
When the engine is running, the flywheel will drive the rotation of wheel cover via the drive plate.
The wheel cover is firmly connected to the impeller with bolts and sealed at the joint surface with
O-rings. One end of the input part is supported on the center hole of the diesel engine flywheel
housing by the shaft end of the wheel cover, and the other end is supported on the guide pulley seat
by the bearing of impeller.
YJ315LG-1 torque converter has also been equipped with PTO port. A part of power from the diesel
engine is directly transmitted to the pump shaft gear via the transfer gear refitted on the impeller
and drives the operation of gear pump by the pump shaft, etc.
(2) Power output part
The turbine, driving shaft, driving gear, output gear and output shaft together constitute the power
output part of the torque converter. The turbine output shaft is supported at two points. Thats, the
left end is supported on the torque converter wheel cover by needle roller bearing, and the right end
is supported on the torque converter housing by ball bearing. The power from turbine output shaft is
15

transmitted via driving gear to the output gear with which the driving gear is meshed, and then to
the output shaft by the output gear.
(3) Fixed supporting part of guide pulley
Guide pulley is fixed on the guide pulley seat via the splined joint, and the guide pulley seat is fixed
on the torque converter housing with screws.
(4) Sealing part of circulating circle
YJ315LG-1 hydraulic torque converter uses three kinds of seals:
O-ring is used at the joint of wheel cover and impeller to prevent the leakage of liquid in the
circulating circle along the joint.
Alloy cast iron seal ring is used between the impeller hub and the guide pulley seat to prevent
the leakage of oil at the bearing seat.
Skeleton oil seal is used at the middle part of flywheel housing and the impeller hub. Note that
the lips of the skeleton oil seal shall face to the incoming flow when assembling.
2. Transmission control valve
The transmission control valve is mainly composed of speed change valve and power shut-off valve,
etc. When pulling the speed change valve lever outwards to the limit, the reverse gear will be
engaged, and when pushing it inwards, neutral gear, 1st gear and 2nd gear will be engaged
successively. The valve body has also been equipped with power shut-off valve, which will shut off
the power oil to the transmission during braking to ensure more reliable braking performance.
Fig. 2-12 Transmission control valve

16

1. Power shut-off valve 2. Main pressure measuring port 3. Speed change valve oil inlet
4. Speed change valve lever 5. 1st and 3rd gear lubricating oil passage 6. 1st and 3rd gear
pressure oil passage 7. 2nd and 4th gear pressure oil passage 8. 2rd and 4th gear lubricating oil
passages 9. Reverse gear lubricating oil passage 10. Reverse gear pressure oil passage
11. Oil sprayer port 12. Cooling oil port
(2) Relief valve
The relief valve is mainly composed of transmission pressure valve and torque converter inlet
pressure valve, etc. The speed change valve controls the transmission control pressure (1.1~1.5
MPa); the torque converter inlet pressure valve controls the torque converter inlet oil pressure
(0.5~0.6 MPa). The relief valve is equipped with an oil passage which can be used to lubricate the
torque converter internal gear. When the oil supply pressure in the system is too high, the overflow
valve in the relief valve will open and release pressure via the pressure relief vent.
Fig. 2-13 Relief valve

1. Pressure adjusting bolt 2. Pressure relief vent 3. Lubricating oil port of torque converter
internal gear 4. Torque converter oil inlet 5. Overflow valve 6. Transmission control valve oil
inlet 7. Relief valve oil inlet 8. Torque converter inlet oil pressure adjusting bolt
17
2.5 Transmission Operation and Maintenance

2.5.1 Installation and Application Notices for Transmission
(1) When installing transmission, ensure the input share the same axis with the torque converter
output and the transmission output share the same axis with the input of front/rear axle.
(2) Transmission, after installed to the vehicle, shall be filled with about 45L of 6# hydraulic
transmission oil from oil filler, and the oil level shall be checked 5 min after starting the engine,
which shall reach to the level of oil dipstick. Before and after working every shift, always check the
oil level in the transmission carefully.
(3) The gear change in transmission from forward gear to reverse
gear or vice versa as well as between high and low gears must be
carried out after parking, but the change between 1st and 2nd gear or
between 3rd and 4th gear can be done while driving.
(4) Attention shall be paid to maintain the operating oil pressure at
1.1~1.5MPa during transmission operation, and the outlet oil
temperature of torque converter shall be generally not more than
105C and will not exceed 115C in the short run, together with the
Fig. 2-14
oil temperature at the transmission oil sump not larger than 100C.
(5) Each control handle and mechanism shall be flexible without
seizure, and gearshift must be accurate with obvious tactility.
(6) When depressing the brake pedal with engine throttle full open,
the vehicle shall not move.
(7) Appropriate adjustment must be done to parking brake to make
sure it will work reliably.
2.5.2 Maintenance of Transmission

(1) Change oil in the transmission of new vehicle for the first time after the vehicle travels for 100 h
and thereafter perform this operation every 500 h. The oil to be filled shall be 6# (8#) hydraulic
transmission oil with filling amount of about 38L; the oil level shall be checked within 5 min after
18

the engine is started and then runs at idling, and the level of oil dipstick shall apply. Before and after
working every shift, always check the oil level in the transmission carefully.
(2) Attention shall be paid to maintain the operating oil pressure at 1.1~1.5MPa during transmission
operation, and the outlet oil temperature of torque converter shall be generally not more than 105C
and will not exceed 115C in the short run.
(3) New transmission, after installed to the vehicle, shall experience 12 h running-in, 2 h for each
gear, and the load during which shall not exceed 70 of rated load. Meanwhile, note the oil
temperature, oil level and the fastening of bolts. After the period of running-in, wash transmission
oil sump and the oil filter screen.
(4) The gear change in transmission from forward gear to reverse gear or vice versa as well as
between high and low gears must be carried out after the vehicle is stopped, but the gear change
between 1st and 2nd gear or between 3rd and 4th gear can be done while the vehicle is running.
19
3 Removal of Transmission
3.1 Removal of assembly components
Preparation for removal:
(1) Fully clean the mud and dirt on the transmission.
(2) Remove drain plug to drain transmission oil.
Hydraulic transmission oil: about 45L.
(3) Prepare a stable transmission mounting bracket.
Transmission: about 200Kg
3.1.1 Removal of oil filler pipe and filter
1.
Remove oil dipstick and the bolts fastening oil

filler pipe and transmission body, and then
disassemble oil filler pipe and O-ring.
NOTE:
Protect O-ring.
Fig. 3-1
1 Oil dipstick 2 Oil filler pipe
3 Bolt
20

2.
Disassemble filter housing, and remove O-ring,

6 bolts, filter cover and shim.
Fig. 3-2
1 Filter
3.
Take filter element out.
Fig. 3-3
1 Filter element
3.1.2
Removal
of
parking
brake
assembly
1.
Disassemble the bolts connecting parking

brake and transmission body to take down the
parking brake.
Fig. 3-4
1 Parking brake
2 Fixing bolt
21

2.
Disassemble the lock plate and fixing bolts

from rear front output flange; remove pressure
plate and O-ring.
Fig. 3-5
1 Lock plate
2 Bolt
3.
Remove output shaft flange, brake caliper &

disc and dust cover with hands. Disassemble
the bolts connecting oil seal cover and
transmission body, remove oil seal cover and
adjusting shim and take out oil seal from oil
seal cover.
Fig. 3-6
1 Oil seal cover 2 Oil seal
3 Output shaft flange 4 Dust cover
5 Brake caliper & disc
3.1.3 Removal of transmission control

valve
1.
Disassemble the bolts connecting transmission

control valve and transmission, and then
remove upper paper washer, bottom plate and
lower paper washer in turn.
Fig. 3-7
1 Bolt
2 Transmission control valve
NOTE:
Ensure
cleanness
and
protection
removing the transmission control valve.

22
after

Protect sealing surface and gasket.
3.1.4 Removal of breather and cover

plate
1.
Disassemble breather and take out flap, copper

pipe and 5 Labyrinth gaskets.
Disassemble connecting bolts from the cover plate

to remove paper washer.
Fig. 3-8
1 Bolt 2 Cover plate
3 Breather
3.1.5 Removal of input flange

1.
Disassemble round nuts from input shaft with a
special socket to remove round nut washer, washer,

input flange and dust cover.
Fig. 3-9
1 Round nut 2 Round nut washer
3 Washer
3.1.6 Removal of oil sump

1.
Lay
transmission
body
sideways,
and
disassemble the bolts connecting oil sump and

transmission body to remove the oil sump.
Fig. 3-10
1 Bolt
2 Oil sump
23
3.1.7 Removal of high/low gearshift

fork mechanism
1.
Disassemble the iron wire on high/low

gearshift fork mechanism, unscrew fastening
screws and remove fork shaft and the fork.
Fig. 3-11
1 Iron wire 2 Fastening screw
3 Fork shaft
2.
Unscrew screw plug and washer, remove steel

balls and spring and then disassemble oil seal.
Fig. 3-12
1 Bolt
3.1.8 Removal of output shaft

1.
Disassemble lock plate, unscrew the fixing

bolts of rear output flange, remove pressure
plate and O-ring and then take out the output
shaft flange, dust cover and oil seal by hand.
NOTE:
Fig. 3-13
1 Lock plate 2 Bolt
3 Pressure plate 4 Output shaft flange
Protect O-ring.
24

2.
Unscrew the bolts connecting output rear end

cover to transmission body, disassemble output
rear end cover and take it out together with the
whole output shaft backwards.
Fig. 3-14
1 Bolt
2 Output rear end cover
3.
Remove bearing, gear, high/low gear sliding

sleeve, spacer ring and thrust ring from the
shaft.
NOTE:
Gear wheel can be taken out from the bottom

hole of the transmission body.
Fig. 3-15
1 Output shaft 2 Thrust ring
3 Gear (output shaft high gear) 4 High/low
gear sliding sleeve
5 Gear (output shaft low gear)
25
3.1.9 Removal of three sets of clutch

gear shafts
1.
Lay transmission body flat with the big end cap

surface up, disassemble 3 oil inlet end covers
and remove washers. Remove all seal rings on
the three sets of clutch gear shafts.
NOTE:
Fig. 3-16
1 Input shaft end cover 2 Reverse shaft end
Safekeep the seal rings.
cover
3 Intermediate gear shaft end cover
2.
Remove all external oil seal sleeves inside each

cover.
Fig. 3-17
1 External oil seal sleeve
3.
Firstly use jackscrew to jack up big end cap,

secondly screw two hoisting bolts into the
mounting holes of the end cover, and finally
operate the crane and disassemble the big end
cap to remove 3 bearing cups wherein.
About 15kg.
NOTE:
Fig. 3-18
1 End cover 2 Hoisting bolt
3 Bearing cup
The hoisting operation shall be done slowly.
26

4.
Take out input shaft assembly vertically.

NOTE:
Tap lightly on the rear end when it is hard to

take the shaft out.
Fig. 3-19
1 Input shaft assembly
5.
Take out countershaft assembly and reverse

shaft assembly in turn.
Fig. 3-20
1 Reverse shaft assembly
2 Countershaft assembly
6.
Erect transmission body, disassemble hexagon

bolts and stop plates on 3 small end covers at
the front and unscrew adjusting screws.
Fig. 3-21
1 Stop plate 2 bolt
3 Adjusting screw
27

7.
Disassemble fixing bolts of the end cover to

remove the end cover.
8.
Remove 3 paper washers, 2 adjusting rings,

one oil seal (input shaft) and 3 bearing cups
separately.
Fig. 3-22
1 Bolt 2 End cover
3 Adjusting ring 4 Paper washer
3.2 Removal of assembly

3.2.1 Removal of transmission control
valve
1.
Unscrew the plug and shim from valve stem

locating lock pin and take out spring and steel
ball.
Fig. 3-23
1 Plug
28

2.
Disassemble snap rings at the front and rear of

the valve stem, push forward valve stem, and
squeeze out 2 oil seals and adjusting washers at
the front of the valve holes.
Fig. 3-24
1 Snap ring
3.
Then push backward the valve stem, squeeze

out 2 oil seals and adjusting washers at the rear
end of the valve hole and take out the valve
stem.
Fig. 3-25
1 Oil seal 2 Adjusting washer
3 Valve stem
4.
Disassemble the screw plug at the front end of

brake valve stem and take out spring seat,
O-ring and spring.
Fig. 3-26
1 Screw plug
29

5.
Disassemble screw plug from the rear end of

valve hole, remove O-ring, and push out brake
valve stem and leather cup.
Fig. 3-27
1 Screw plug 2 O-ring
3 Leather cup 4 Brake sliding valve
3.2.2 Removal of three sets of clutch

gear shaft assemblies
NOTE:
The removal of input shaft assembly shall be
carried out from the front end of shaft to the
rear end. The removal of reverse gear shaft and
countershaft assemblies shall be carried out
from the rear end of shaft to the front end.
The method of disassembling countershaft and
reverse gear shaft assemblies is similar to that of
input shaft assembly, and the only difference lies
in the direction of clutch. Moreover coMPared
with the input shaft assembly, the countershaft
assembly has one more gear and the reverse gear
shaft assembly one more shaft sleeve. Take input
shaft assembly as example to introduce the
disassembling procedure, and the others will not
be repeated here.
30

1.
Disassemble connecting bolts and stop pad

from shaft end to remove shaft end baffle.
Fig. 3-28
1 Bolt 2 Stop pad
3 Shaft end baffle
2.
Remove internal oil seal sleeve and 2 piston

rings on it.
Fig. 3-29
1 Piston ring
2 Internal oil seal sleeve
3.
Remove bearings from both ends of the shaft

and shaft sleeve from the front end of the shaft.
Fig. 3-30
1 Shaft sleeve
2 Bearing
31

4.
Remove clutch external drum from the shaft

and disassemble 8 bolts and 4 stop pads as well
as a gear wheel.
Fig. 3-31
1 Clutch external drum 2 Bolt
3 Stop pad 4 Gear wheel
5.
Disassemble automatic emptying valve (oil

drain valve) base and steel ball on the clutch
housing.
Fig. 3-32
1 Emptying valve
6.
Disassemble retainer ring and take out external

end cover from the clutch. Take out friction
lining: steel disc and wafer.
Fig. 3-33
1 Retainer ring
2 External end cover
32

7.
Remove retainer ring from housing internal

hub with special tools.
8.
Disassemble spring seat, spring and piston.
9.
Disassemble oil seal ring from the piston.
Fig. 3-34
1 Special tools 2 Shaft elastic retainer ring
3 Spring 4 Piston
10. Remove O-ring from the housing internal hub.
Fig. 3-35
1 Oil seal ring
11. Press
pinion
out
from
the
shaft
and
disassemble the snap rings at both ends and 2

bearings.
Fig. 3-36
1 Pinion
33
4 Refitting of Transmission
4.1 Refitting of assembly
NOTE:
Wash all parts before refitting.
4.1.1 Refitting of clutch shaft assembly

NOTE:
Three sets of clutch assemblies are of similar structure. Take input shaft assembly as example
to introduce refitting procedure and the others will not be repeated here.
1.
Assemble steel ball and automatic emptying

valve (oil drain valve) base.
Fig. 4-1
1 Automatic emptying valve
2.
Assemble O-ring on the housing internal hub.
3.
Assemble oil seal ring on piston, apply clean oil

and put the piston into the housing.
NOTE:
When installing oil seal ring, the sealing surface

shall be placed toward pressure oil surface.
The oil seal ring is made of rubber and shall be
Fig. 4-2
free of damages caused by crush during assembly.
1 Oil seal ring
The opening width of piston ring shall be within

0.05~0.1mm.
34

4.
Put lower spring seat, spring and upper spring

seat in the internal hub in turn and use special
tools to compress the spring in order to assemble
retainer ring.
Fig. 4-3
1 Special tools 2 Retainer ring
3 Spring seat 4 Spring
5.
There are 6 clutch driving plates in all, which are

friction linings made of copper based powder
metallurgy, and 5 driven plates made of steel
with 0.5 mm concavity; make sure to put the
concave surface towards piston end while
refitting.
Fig. 4-4
NOTE:
1 Outer friction lining

2 Internal friction lining
The number of outer friction linings for the

three sets of clutches is 6.
The number of internal friction linings for the
three sets of clutches is 5.
6.
Assemble 11 friction linings to the housing in the

sequence of outer gear, inner gear and outer gear
Outer friction lining
as shown in Fig. 4-5.

NOTE:
If abrasion that occurs during the usage of outer
Internal friction lining
friction lining is more than 2/3 in the depth of

Fig. 4-5
pattern
groove,
replacement
is
required
immediately.
Replace the corresponding friction lining only
35

and make sure its number and refitting order is
correct.
7.
Assemble external end cover and snap ring.
8.
Assemble the pinion with snap ring and 2
Fig. 4-6
1 Retainer ring
2 External end cover
bearings to the shaft in place.
Fig. 4-7
1 Bearing
2 Retainer ring
9.
Align gear wheel with the cylindrical pin on the

clutch housing, fasten them with bolts and
meanwhile assemble 4 stop pads to avoid
looseness.
Fig. 4-8
1 Gear wheel 2 Bolt
3 Stop pad
36

10. Lay clutch flat and insert the pinion after
aligning the teeth of internal gear friction linings
with a screwdriver.
Fig. 4-9
1 Pinion
11. Turn left and right the pinion continuously until
the spline of the pinion is inserted into the
internal tooth of driven plate, insert input shaft to
ensure the clutch is installed in place and
assemble 2 bearings on both ends of the shaft.
NOTE:
When the length of the extending gear on the
Fig. 4-10
1 Shaft sleeve
2 Bearing
spline shaft is equals to the width of shaft sleeve, it

shows that the clutch is installed in place;
otherwise, it means that the internal teeth of some
driven plates deviate and are not engaged with the
pinion.
12. Assemble 2 piston rings to internal oil seal
sleeve.
NOTE:
Piston ring is made of cast iron with greater
brittleness, so it needs to be installed with even
force to avoid damage.
The openings of two seal rings need to be
Fig. 4-11
1 Piston ring
2 Oil inlet passage
staggered, and also have a distance from oil inlet
37

passage.
13. Assemble internal oil seal sleeve to shaft.
NOTE:
Internal oil seal sleeve shall be installed to shaft
by heating evenly in oil at the temperature of
100~150C.
Wear heat insulation gloves while refitting, and
the picture is only for reference.
Fig. 4-12
14. Install shaft end baffle, stop pad and bolts.
Fig. 4-13
1 Shaft end baffle 2 Stop pad
3 Bolt
4.2 Refitting of assembly components

4.2.1 Assembly of three sets of gear
shafts
1.
Lay transmission body flat, put the assembled

reverse gear shaft assembly to the mounting
position in the transmission body and then put in
countershaft assembly.
NOTE:
Fig. 4-14
1 Reverse gear shaft assembly
When refitting, clutch shall be installed by
2 Countershaft assembly
38

rotating.
2.
Put the assembled input shaft assembly to the

mounting position in the transmission body.
NOTE:
Make sure all sets of gears are correctly engaged.
Fig. 4-15
1 Input shaft assembly
3.
Install big end cap to the transmission body, and

fasten the bolts connecting end cover and
transmission body.
About 41.5kg.
NOTE:
Check and replace with new gasket.
Fig. 4-16
1 Big end cap
4.
Install external oil seal sleeves to each cover.
Fig. 4-17
1 External oil seal sleeve
39

5.
Install three sets of oil inlet end covers, and

fasten the bolts connecting end cover and
transmission body.
NOTE:
Check and replace with new gasket.
Fig. 4-18
1 Input shaft end cover 2 Reverse shaft
end cover
3 Countershaft end cover
Three oil inlet end covers have the same
appearance but different inside oil passages. The
oil passage of 1st and reverse gears are identical
but different from that of neutral gear.
Fig. 4-19
1 1st/reverse gear end cover
2 Neutral gear end cover
4.2.2 Refitting of input flange and rear

end cover
1.
Install oil seal into input shaft oil seal seat, install
the bearing of input shaft in place by tapping,
and measure and adjust the axial clearance of
input shaft.
Fig. 4-20
Adjusting method:
Use depthometer to measure the depth H from
bearing (cone and cup) to the surface of the
transmission body as well as the height h of oil
seal seat step; select and add adjusting shim
40

(=0.1mm) to ensure H-h-=0.1~0.15mm.
2.
Assemble input flange as well as washer, round

nut and washer in turn and fasten round nuts
using special tools.
Fig. 4-21
1 Round nut washer 2 Washer
3 Round nut
4.2.3 Assembly of countershaft and

reverse gear shaft rear end cover
1.
Install bearing mounting paper washer, bearing

cup and adjusting ring to the rear ends of reverse
gear shaft and countershaft. Install the rear end
covers of reverse hear shaft and countershaft and
fasten them with bolts. Tap adjusting ring in
place through the hole on the rear end cover.
Fig. 4-22
1 Adjusting screw
2 Adjusting ring
2.
Adjust the clearance of taper roller bearing

supporting at both ends of the shaft through
rotating the screw in the center of rear end cover.
Install stop pad to fasten the adjusting screw.
Adjusting methods:
Turn the adjusting screw to the limit and then

return by about 15(the screw pitch is 1mm and
Fig. 4-23
1 Stop pad
the clearance required shall be 0.25~0.5mm).
41

3.
Input flange shall be rotated freely.
4.2.4 Assembly of output shaft

1.
Assemble bearing, gear, high/low gear sliding

sleeve, spacer ring and thrust ring of the output
shaft, and put them into transmission body.
NOTE:
Low-speed gear can be put into transmission body

Fig. 4-24
1 Output shaft assembly
2 Low-speed gear
from its bottom hole.
2.
Tighten the bolts connecting output rear end

cover and transmission body and install 2 oil
seals and dust covers.
3.
Install O-ring, pressure plate and fixing bolts that

used to fix rear output flange, and fit lock plate.
Fig. 4-25
1 Bolt 2 Output rear end cover
3 Pressure plate 4 Bolt
4.2.5 Assembly of high/low gearshift

fork mechanism
1.
Insert fork shaft, install fork, put fork shaft in the

neutral position, set sliding sleeve to the spline
tooth in the middle of output shaft, align fork
shaft with the thread hole on the fork, then fasten
Fig. 4-26
1 Iron wire
2 Fixing bolt
screws and tighten with iron wire.

NOTE:
The high/low speed lever includes high, neutral
42

and low gears, and the travel between two
adjacent positions is 15mm.
2.
Install spring and steel ball, fasten screw plug

and washer and install gearshift shaft oil seal.
Fig. 4-27
1 High/low gearshift fork 2 Screw plug
3 Steel ball 4 Spring
5 Oil seal
4.2.6 Assembly of oil sump

1.
Install gasket and fasten the bolts connecting oil

sump and transmission body.
NOTE:
Check and replace gasket.

The bolts shall be fastened diagonally in several
steps.
Fig. 4-28
1 Bolt
4.2.7 Assembly of transmission control

valve
1.
Install upper paper washer, bottom plate and

lower paper washer to transmission control
valve.
2.
Erect transmission body and install transmission

control valve to the transmission body.
Fig. 4-29
1 Bolt
NOTE:
43

steps.
4.2.8 Assembly of breather and cover

plate
1.
Install cover plate and paper washer, fasten the

bolts on them and screw on the breather.
NOTE:

Fig. 4-30
1 Cover plate
2 Breather
steps.
4.2.9
Assembly
of
parking
brake
assembly
1.
Install oil seal cover to transmission body.
2.
Install O-ring and pressure plate.
Fig. 4-31
1 Oil seal cover 2 Oil seal
3 Output shaft flange 4 Dust cover
5 Brake caliper disc
Fig. 4-32
1 Pressure plate
2 O-ring
44

3.
Screw up the fixing bolts on the output flange

and assemble upper lock plate.
Fig. 4-33
1 Lock plate
2 Bolt
4.
Install parking brake and fasten connecting bolts.
Fig. 4-34
4.2.10 Assembly of oil filler pipe and

filter
1.
Install filter with O-ring and fix them to

transmission body.
Fig. 4-35
1 Filter
2 Oil filler pipe
2.
Install oil filler pipe and O-ring, and fasten

connecting bolts.
45
5 Service Tools for Transmission

Table 5-1
Special tools
Tool name
Location to be used
Remarks
If
not
available,
Transmission mounting To support and tilt

disassembly and assembly
bracket
transmission
platform can be set up.
Hoisting tools
End cover
M10
Round nut on the

Socket
input shaft
Disassembly
and
Three sets of clutch
assembly tool of clutch

springs
spring
Spec: 0.02/0~200
Depth meter
Input shaft
Transmission pressure Pressure
joint
of
6410006223
joint
relief valve
Use
with
pressure
joint
and
pressure
Pressure testing hose
4030000368
gauge.
Pressure gauge with a

6430000943
gauge of 25 bar
46
6 Common Fault Diagnosis and

Troubleshooting
Table 6-1
Symptoms
Probable causes
Solution
Low oil level, and empty pump
Check if the oil level is below

oil dipstick and add oil
Oil suction filter element falls Check, wash and replace after
off or is blocked up
removal
The inner layer of oil suction Check

pipe is peeling off
removal
Air enters oil suction pipe
Check
and
replace
after
Relief valve is adjusted to a too Check, adjust and replace valve

low pressure
Pump abrasion and oil leakage
Replace pump
1. Weak traveling and gear The oil drain pipe of torque Check, wash and replace
shift seizure
converter is blocked up
The
opening
pressure
of Raise the opening pressure
overflow valve is too low

Transmission clutch slipping
Check
transmission
after
removal
Piston oil seal ring has abrasion Replace
or damage
Oil passage from relief valve to Check pipeline
pilot valve is blocked up
Transmission shaft end ring or Replace seal ring and sleeve
sleeve shows abrasion
2. High oil temperature
47
Check oil level and add oil

Symptoms
Probable causes
Solution
Oil suction filter element falls Check, wash and replace after
removal
The inner layer of oil suction Check
and
pipe is peeling off
removal
Air enters oil suction pipe
Check
Replace pump
replace
after
Low transmission pressure and Raise pressure or find out

clutch slipping
causes
Torque converter has large Check torque converter after

inside leakage
removal
Oil temperature gauge and Replace

sensing plug are broken
Check oil level and add oil
Oil suction filter element falls Check, wash and replace

Air enters oil suction pipe or its Check and replace
inner layer is peeling
Transmission
shaft ring or Replace seal ring and sleeve
sleeve shows abrasion

3. Low oil pressure
Piston oil seal ring has abrasion Replace

or damage
The spring of relief valve is Check and replace valve
broken
Replace pump
Pressure valve is adjusted to a Adjust again

too low pressure
Oil passage from relief valve to Check pipeline
48

Symptoms
Probable causes
Solution
pilot valve is blocked up

Propeller shaft is installed in a Follow the direction of arrow
wrong direction
Vortex appears when opening Replace relief valve
4. Abnormal sound
relief valve
Internal parts are damaged or Check after removal
gears have poor accuracy
The positioning steel ball of Check and replace
fork is abraded flat causing the
ball unable to work normally
Steel
ball
shows
serious Check and replace
abrasion
5. High/low gear is out of
Spring is damaged
Check and replace
mesh
The depth of positioning hole Check and replace
for locking screw is insufficient
causing the fork cannot be
locked by screw securely
Locking screw is sliding, etc.
Check and replace
Oil inlet end cover is installed Exchange

6. Only one gear is normal
in a wrong way
and
others
have
low
The oil seal ring or piston ring Check and replace
pressure
of other two gears are damaged
7.
Only
one
gear
is The clutch of one gear is burnt Check and repair
available, and the vehicle out and friction lining is unable

can run even in the neutral to separate
gear
49
50

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BS428 Transmission Service Manual

BS428 Transmission Service Manual

BS428 Transmission Service Manual

3.1.6 Removal of oil sump ................................................................................ 23

BS428 Transmission Service Manual

as safety sign. With

BS428 Transmission Service Manual

1.2 Description of signs

BS428 Transmission Service Manual

During operation, pay special attention to safety because of

Pay attention to the selection of sling and the postures during

Pay special attention to the tightening torque of component

Points requiring the application of adhesive and grease.

Position for draining oil or water, as well as draining amount.

1.3 Tightening torque table for plain bolts

Tightening torque (Nm)

Nominal diameter of bolt (mm)

Tightening torque (Nm)

BS428 Transmission Service Manual

Nominal diameter of bolt (mm)

Tightening torque (Nm)

BS428 Transmission Service Manual

BS428 Transmission Service Manual

2.2 Basic parameters of transmission & torque converter assembly

Oil pressure at torque converter inlet

Fixed-shaft power shift

4 gears in front and 2 in the rear

Transmission working pressure

2.3 Structure and principle of transmission

BS428 Transmission Service Manual

View from input terminal

Reverse gear shaft

2. Input shaft clutch 3. Intermediate gear shaft clutch

2.3.2 Shifting principle of transmission

Fig. 2-3 Gear selector

BS428 Transmission Service Manual

2.3.3 Gear transmission lines

BS428 Transmission Service Manual

Reverse gear shaft

high speed gear):

1st gear (when the shift fork is set to the left

low speed gear):

Reverse gear shaft

high speed gear): inputZ3Z6Z7Z9

low speed gear): inputZ3Z6Z5Z8

low speed gear): inputZ3Z1Z2Z7

BS428 Transmission Service Manual

2.3.4 Structure and principle of shifting clutch

BS428 Transmission Service Manual

BS428 Transmission Service Manual

When the clutch is released

BS428 Transmission Service Manual

2.4 Oil supply system

Fig. 2-9 Composition of oil supply system

BS428 Transmission Service Manual

2nd and 4th gear

Reverse gear clutch

2.4.2 Introduction to oil supply system main components

BS428 Transmission Service Manual

Fig. 2-11 Structure and schematic diagram of torque converter

BS428 Transmission Service Manual

circulating circle along the joint.

the leakage of oil at the bearing seat.