Training Documents for Bivariant System of Loader July, 2010 SDLG Volvo Group Member Company.

Training Documents for Bivariant System

of Loader

July, 2010 SDLG

Volvo Group Member Company

23/4/22

Content

Hydraulic Torque Converter

22

Brief Introduction of Bivariant System

11

Planetary Dynamic Shift Gear Box

33

44Key Points of Dismounting of Bivariant System

55 Typical Failure Analysis

2

SDLG Construction Machinery Co. LTD training room Shandong LingongVolvo Group Member Company

SDLG Construction Machinery Co. LTD training room

3 23/4/22

I ) Definition of Drive System

I,Brief Introduction of Bivariant System

Drive system includes power plant of wheel loader and drive parts among driving gears.

Bivariant

Assembly

Definition of Drive System

Drive Axle

Assembly

Torque

Converter

Gear Box

……

Main Drive

Hub Reduction Gear

Tyre

Shandong LingongVolvo Group Member Company


4 23/4/22

II ） Classification of Bivariant System

1.Classification based on structure and drive medium:

Four types: mechanical, hydraulic mechanical, static hydraulic (volume hydraulic) and electric.

Hydraulic mechanical drive is widely used on wheel loader.

2. Classification based on means of operation: man power gear and dynamic gear box;

3.Classification based on gear train types : planetary gear box and dead axle gear box.

I Brief Introduction of Bivariant System



5 23/4/22

III) Function of Bivariant System

1. Reduce rev.rate and increase torque

2.Make loader drive backwards

3.Break off drive when necessary （ Neutral position of gear box ）

4.Differential function （ Drive axel）




6 23/4/22

IV ） Definition of Hydrodynamic

Transmission

Hydrodynamic transmission refers to

devices that carry out energy

transfer and control based on

kinetic energy of the liquid in

operation . Transfer hydrodynamic

energy into mechanical energy.

Hydraulic kinetic energy will be

transferred into mechanical energy

if high speed rotary oil in hydraulic

torque converter strikes turbine

blade for rotating, which drives level

one and two output gears to rotate.


Figure1-1 Theory sketch for hydraulic transmission

1—water inlet of centrifugal pump 2—centrifugal

water pump 3—pipeline

4-- distributor 5—water turbine 6—impeller of

water turbine

7—turbine draft tube 8—water leg



7 23/4/22

V) Merits and Demerits of Hydrodynamic Transmission (Shovel Loader)

1.Merits:

1 ） Make the loader have a good automatic adaptability

At the rated condition, hydraulic torque converter of loader can make vehicles automatically

change (lower) driving speed and (magnify) tractive force in line with the external resistance

to avoid shutting down due to sudden increase of external load.

2 ） Improve mobility of loader

Loader with hydrodynamic transmission device has good low-speed stability and mobility,

which can run or work on muddy site, sand, snowfield and other soft soil surface as well as

non-rigid road




8 23/4/22

Merits (Cont’d)

3)Improve Service Life of Loader

The working medium of hydraulic transmission is a liquid, and impellers can slip face to face,

which can absorb and reduce vibration and shock from loader’s running gear device or

transmission system, and improve service life of loader.

4 ） Simplify Operation and Improve Operation Comfortableness

It can be started smoothly with rapid acceleration, and can achieve infinitely variable speed in a

wide range, so that the gear times can be reduced and operation can be simplified, which can

reduce drivers’ fatigue strength.

During operation, hydraulic components can absorb and reduce vibration and shock, thereby

improving the driving comfortableness of loader.




9 23/4/22

2. Demerits:

1) Inefficiency and poor economy of Hydrodynamic transmission system;

2) complex structure (the system must be added some oil supply, cooling and other auxiliary

equipments), high manufacturing costs.

3) There is no rigid connection between input and output parts of the hydraulic transmission

components, so that it is feasible to start the engine with traction (i.e. reverse transmission

power cannot be used to start the engine)




10 23/4/22

VI ） Composition of SDLG’s Bivariant Assembly

1 、 Appearance and Name:


Ask trainees to point out all parts of the bivariant system based on the serial number. Check Trainees’ familiarity with gear box.



11 23/4/22

2.Main Parts and their Name inside


Level-two gear assembly

Input level-two gear

Level-one gear assembly

Shaft gear

Drive axle of steering pump

Input level-one gear

Reverse gear assembly

Overrun clutch



12 23/4/22

VII ） Basic Parameter of SDLG Bivariant AssemblyModel of Bivariant Assembly A301gear box

Applicable Models LG952L 、 LG953L 、 LG956L 、 LG936Lloader

Type of Hydraulic Torque Converter Single stage two-phase centripetal Twin turbo hydraulic torque converter with four components

Torque Ratio 4.14

Cooling Type of Torque Oil Cooling through circulating water

Oil Pressure at the Entry of Torque Converter

0.549 MPa

Oil Pressure at the Exit of Torque Converter

0.275 ～ 0.343 MPa

Type of Gear Box Planetary dynamic shift

Gears for Speed Change Two forward gears and one reverse gear

Gear Ratio of Gear-one 2.155

Gear Ratio of Gear-two 0.578

Gear Ratio of Reverse Gear 1.577

Type of Variable Speed Pump LG03-BSB

Oil quantity of No.6 Hydrodynamic Transmission Oil

44 L



23/4/22

Content


22


11


33


55 Typical Failure AnalysisSDLG Construction Machinery Co. LTD

Training room

13



14 23/4/22

1.Pump Impeller 2. Idler Pulley 3.Level-one and Level-two Turbine

I ） Components of Hydraulic Torque Converter （ Single Stage four

Components)

II. Hydraulic Torque Converter

1.Input Parts ： composed of pump impeller ,cap wheel and elastic plate, co-rotating at the same

speed with the engine.

2 、 Output Parts ： composed of level-one and level-two turbine, connected through spline and

output gear

3 、 Fixed Parts ： composed of shell , idler pulley and idler pulley seat



15 23/4/22

Attached Figure1. External View of Torque Converter

II. Hydraulic Torque

Converter



16 23/4/22

Figure2-5 Breakdown view of YJSW315 hydraulic torque converter

1 一 idler pulley seat 2—sealing ring3—special-U sealing ring 4—shell of torque converter5—cover plate 6—transfer gear7—117bearing 8—screw bolt9—pump

impeller 10—spacer shim 11—pressing plate 12 － locking plate13—idler pulley 14—check ring 15—level I turbine 16—level II turbine 17—spline spacer shim 18

—heck ring 19—bearing 20—screw nut 21—boult22—level I turbine hub 23—level I turbine shell cap 24—bearing 25—spring pin26—"O" type sealing ring27—cap

wheel28—round base plate29—spring plate 30—pipe joint 31—valve deck 32—spring 33—spool 34—base plate 35—spring36—spool

Attached Figure1. Breakdown view of Hydraulic Torque Converter



17 23/4/22

II ） Basic Definitions

1. circulating circle ： It refers to shape shown by a closed working cavity of torque converter when it is within the cross section cut through the axis of rotation (i.e., axial plane).

YJSW315 hydraulic torque converter ,the number “315”means the diameter of circulating circle of torque converter is Ф315mm.

2.torque ratio ： It refers to the ratio between turbine torque and pump impeller torque (also

named torque ratio). The more the value is, the dynamic range extended by torque converter

will be.

3.rotate speed ratio ： It refers to the ratio between turbine speed and pump impeller speed.


Converter



18 23/4/22

Basic Definition (Cont’d)

4. twin turbo , four components, single stage, two-phase, centripetal hydraulic torque converter:

1 ） twin turbo ： level I and level II turbine ， which can rotate face to face ， riveted ；

2 ） four components ： pump impeller ,idle pulley, level I and level II turbine ；

3 ） single stage ： Torque converter can be divided into single-stage, two-stage and multi-stage according to number of turbines connected based on the column number or rigidity of turbine blade in the circulatory circle of hydraulic torque converter. The torque converter with only one turbine or two turbines that haven’t been connected by rigidity in the circulatory circle is called single stage hydraulic torque converter.

4 ） two-phase : the number of function change of working components in torque converter,

namely, phase; two functions, i.e. two-phase.

5 ） centripetal type ： a torque converter, whose work flow in turbine flows from the periphery to the center, is called centrifugal torque converter


Converter


SDLG Construction Machinery Co. LTD training room19 23/4/22

III ） Route for Transmission of Power and Working Theory

1.Input of Motive Power


Route1 ： Engine flywheel→ elastic plate→ cap wheel→ pump impeller

Engine flywheel

Route 2 ： Engine flywheel→ elastic plate→ cap wheel→ pump impeller → transfer gear

→main gear shaft （ working pump ） and drive shaft of steering pump （ steering pump ）



20 23/4/22

2. Output of Motive Power

1 ） Transmission route for level I turbine ：

level I turbine →hub of level II turbine → output shaft of level I turbine → Overrun clutch of gear

box.

2 ） Output route for level II turbine ：

level II turbine → output shaft of level II turbine → Overrun clutch of gear box

3 ） Theory description:

When the loader works in the low-speed and heavy running conditions, rotating speed of level II

turbine is lower, and inner ring cam and outer ring gear of overrun clutch are connected tightly.

At this time, like a overall turbine, level I and level II turbines will work together to increase

ability of the torque converter to overcome the resistance from the outside world. When the

loader is in the high-speed with light load, level I turbine is idling, and only level II turbine

outputs power.


SDLG Construction Machinery Co. LTD

Training room Shandong LingongVolvo Group Member Company


21 23/4/22

IV ） Sealing of Torque Converter


Converter

1.Sealing of “O” type circle ： between two connecting parts without relative motion, such as the

connection point between cap wheel and pump impeller;

2.Sealing of sealing ring made of alloy cast iron : between two connecting parts with relative

motion, such as between transfer gear and idler pulley seat

3. Lip-mouth type sealing (rotating oil sealing ）： It is connect seal, such as between level

output shaft and idler pulley seat, between level I output shaft and level II output shaft.

Note ： The mouth of the lip-mouth type seal ring should face the direction of oil entering.


23/4/22

Content


22


11


33


55

22



I ） Main Structure of Planet Row

III. Planetary Dynamic Shift Gear Box

Figure 3-1 structure of basic planet

row

1—sun gear

2—gear ring

3—planet shelf 4—planet gear

Sun gear

Planet rowPlanet gear

Planet shelf

Gear ring



24 23/4/22

II ） Feature and merits of Planetary Gear Box ：

1.Feature ：

Achieve deceleration through appropriate transmission ratio, to provide different gear speeds.

2.Merits ：

1) Force is in dispersion: many planetary gears transfer motive power together,

with relatively small force carried by themselves;

2) radial size is relatively compact: only one ring gear, and planetary gear module

is smaller.




25 23/4/22

III ） Deceleration Form of Planet Row1. Deceleration Form of Planet Row ：

1+number of teeth of annular gear/number of teeth of sun gear ＞ 1 which means speed

deceleration ；

2.reduction ratio of Lingong 50 planetary gear box ： 1+60/22=3.727

Note ：

1 ） Lingong 50planet gear box ， First gear （ Reverse gear ） number of teeth of annular

gear=60 ； number of teeth of sun gear =22 ；

2 ） Main role of torque converter is to increase torque, and speed is reduced at the same time

when engine power is fixed. Therefore, torque converter constantly changes moment and

rotating speed based on the size of load, which is actually to make the speed slow down.




26 23/4/22

IV ） Mechanical transmission Route for each Gear of Gear Box

1.The relationship for relevant motion of each gear lined in planet shape ：

1 ） First gear ： input in sun gear, output in First gear shelf and gear ring is fixed;

2 ） Reverse Gear ： input in sun gear, output in gear ring and reverse gear shelf is

fixed;

3 ） Second gear ： Second gear clutch directly transfers the motive power from sun

gear to output gear.

First gear Reverse gear




27 23/4/22

2.Overall Transmission Route of Gear Box

→→→

→→→→→→

Level I and Level II turbine

Pump Impeller

Cap Gear

Elastic Plate of Torque Converter

Middle Input Axis of Clutch

Input Level I and Level II Gear

Overrun Clutch

Sun Gear

Gears in Gear Box

Engine Flywheel


Friction Lining of the Lateral Shaft

Second gear

Friction Lining First gear Oil Cylinder Second gear Plunger

First gear

Friction Lining

Planetary Gear of the Lateral Gear

Plunger of the Lateral Shaft

First gear Plunger Level I

Gear RingGeneral Output Gear of Three Gears

End Cap

Idler Pulley

Middle Cap

Sun Gear

Idler Pulley Seat

Level I turbine

Pump Impeller

Rotary Oil Seal

Transfer Gear

Shell of Torque Converter

Overrun Clutch

Overflow Valve in Entry

Shell of Gear Box

Output Shaft Assembly

SDLG Construction Machinery Co. LTD training room Volvo Group Member Company Shandong Lingong28 23/4/22

3.Transmission Route of Reverse Gear

MachinesIII. Planetary Dynamic Shift Gear Box

Annular Gear of Reverse gear

Planetary Gear of Reverse Gear

Sun Gear


Gear II Output Gear

First gearPlanet Carrier

Gear Pressure Plate

Output Shaft Gear

Output Shaft

Overrun Clutch



Engine Flywheel

Interactive Contents for Trainees’ Description!

Level I Output Gear

Level I I Output Gear

second gear Plunger

Friction Lining of Lateral Gear

Isolator Assembly

Annular gear of reverse Gear

Middle Out put Gear

Oil cylinder

Of Direct Gear

Terminal pad of direct gear

First gear Planet Carrier Assembly

Inner ring cam

Middle Input Shaft

Box

External ring Gear

Pressure plate of direct gear

Output assemblyPlanetary Shaft of Reverse Gear

Planet Carrier of　 reverse gear

Planet Gear

Sun Gear


4.Transmission Route of Machines

with Gear I

First gearPlanet wheel

Sun Gear


Second gearOutput Gear

First gear Planet Carrier

Second gearPressure Plate

Output Shaft Gear

Output Shaft

Overrun Clutch



Engine Flywheel

Interactive Contents for Trainees’ Description!

Level I Output Gear

Lever II Output Gear

Inner ring cam

First gear Plunger

First gear friction linking

Isolator assembly

First gear oil cylinder

First gear gear ring

Middle output gear

Oil cylinder

Of Direct Gear


Terminal pad

Of direct gear

First gear Planet Shaft

Output shaft assembly

Planet Gear

First gear planet carrier

Sun GearMiddle Input Shaft

External ring gear


5.Transmission Route of Machines

with Gear II

Shaft of direct Gear

Sun Gear


second gear

input gear

second gear

Pressure plate

Output Shaft Gear

Output Shaft

Overrun Clutch



Engine Flywheel


Interactive Contents for Trainees’ Description ！

Level I Output Gear

Lever II Output Gear

Oil cylinder

Of Direct gear

Middle output gear

Inner ring cam

Pressure plate of direct Gear

disc spring

Plunger of direct gear

Friction linking of direct gear


Shaft of direct Gear

Output shaft assembly

Sun GearExternal ring gearMiddle Input Shaft


31 23/4/22

V ） planetary gear box-Route for oil supply of torque

converter


1.Overall route for oil supply ：

engine flywheel→pump impeller of torque converter→transfer gear on pump impeller and gear of

variable pump shaft→drive variable pump sucks oil from the oil pan→pumping out pressure

oil →oil filter （ bypass-valve is open when the filter element is blocked ）→ entering into

variable operational valve

Route1 ： Enter into variable speed operation oil way through （ P ＝ 1.08 ～ 1.47MPa ） , and enter into oil cylinder with each gear based on the different position of variable valve rod to complete work at diverse gears.

variable operational valve

Route2 ： Enter into the working cavity of torque converter (oil cannot

be supplied for toque converter until oil in gears of gear box is full).



2.Oil Supply Route for Reverse Gear

pressure regulating valve of speed change valve → stop valve → oil ports at reverse gear of

speed control valve 10 and 14

→Fuel Feed hole of oil cylinder in reverse gear


Fuel Feed hole of oil cylinder in reverse gear

Re v

erse

gea

r ne

u tra

l pos

itio

n

Fir

st g

e ar

Sec

ond

gea

r


3. Gear I Oil Supply Route

pressure regulating valve of speed change valve → stop valve →oil ports at First gear of speed control valve

7and 15

→Fuel Feed hole of oil cylinder in First gear

III. Planetary Dynamic gear Box

Fuel Feed hole of oil cylinder in First gear Reverse gear

Neutral position

First gear

Second gear

Re v

erse

gea

r ne

u tra

l pos

itio

n

Fir

st g

e ar

Sec

ond

gea

r


4. Second gear Oil Supply Route

pressure regulating valve of speed change valve → stop valve →oil ports at Second gear of speed control valve

8and 9

→Fuel Feed hole of oil cylinder in Second gear

III. Planetary Dynamic gear Box

Fuel Feed hole of oil cylinder in

second gearR

e ver

se g

ear

neu t

ral p

osit

ion

Fir

st g

e ar

Sec

ond

gea

r

23/4/22

Content


22


11


33



35

SDLG Construction Machinery Co. LTD training room Shandong Lingong



36 23/4/22

IV. Key Points of Dismounting of Bivariant System

Name of common tools SpecificationQuantit

yParts used

Gas trigger LB10 、 LB16 、 LB20 1groupChoose different specification based on the diverse size of the assembled bolts

Sleeve10 、 13 、 14 、 15 、 16 、18 、 21 、 24 、 41

1groupChoose different specification based on the diverse size of the assembled bolts

Dial test indicator0.01/0 ～ 30.01/0 ～ 5

2Bounce of the assemble plane of line axle and pump in variable speed pump

Solid wrench 13×16 、 18×21 、 22×24 1groupChoose different specification based on the diverse size of the assembled bolts

Copper bar 1 Slightly hit with the part assembled with interference

Depth vernier gauge 0.02/0 ～ 200 1Sub assemble of torque converter; install and input Level I gear assembly ,assemble friction linking , middle cap, variable speed pump end cap

Leveling ruler 1 Subassembly and variable speed pump of torque converter

Name of special toolsSpecification Quantit

yThe parts used Serial number of the corresponding

network chart or name of assembly

Mount support of gear box its own dismounting platform 1Increase convenience and security when dismounting bivariant system

Retainer pliers for shaft (hole) 200 、 300 1 when check ring is installed

Lifting bolt M10 、 M14 、 M16 、 M18 1 8 、 29 、 31

I ） Dismounting Process of Bivariant System

1.Dismounting devices and instruments

Shandong Lingong



37 23/4/22


2.Dismounting Process of Gear Box-1

Shandong Lingong



38 23/4/22

IV. Key Points of Dismounting of Bivariant System Dismounting Process of Gear

Box-2

Shandong Lingong



39 23/4/22


Box-3

Shandong Lingong



40 23/4/22


Box-4

Shandong Lingong



41 23/4/22


Box-5

Shandong Lingong



42 23/4/22


3.Dismounting Process of Torque Converter-1

Interactive question ： what’s the name of the valve in the above red circle? What is its pressure? What role dose it play?

Shandong Lingong



43 23/4/22

IV. Key Points of Dismounting of Bivariant System Dismounting Process of Torque Converter -2

Interactive question ： what is valve in the following circle in red? What is the pressure? What role does it play?

Shandong Lingong



44 23/4/22


Dismounting Process of Torque Converter -3

Shandong Lingong



45 23/4/22



Shandong Lingong



46 23/4/22



Interactive question: How many types of the

rotating oil seal on the idler pulley? What

failure will be caused if damaged or frayed?

Shandong Lingong



47 23/4/22



Dismounting process of level I and level II turbine group ：

Shandong Lingong



48 23/4/22

IV. Key Points of Dismounting of Bivariant System .Dismounting Process of Torque

Converter -6

Dismounting process of level I and level II turbine group ：

Interactive question: What failure will be caused

respectively if bearings behind cap of level II and

level I turbine are damaged?

Shandong Lingong



49 23/4/22


4.Dismounting Process of Overrun Clutch-1

The surpass of new structure can cancel the isolating ring, and the number of pin roller changes from 24 to 20, with dam-board on the upper part.

Shandong Lingong



50 23/4/22


Dismounting Process of Overrun Clutch -2

Shandong Lingong



51 23/4/22


5.Dismounting of Second gear Assembly-1

Interactive question: what role does the disc spring play in the red circle above?

Shandong Lingong



52 23/4/22


Dismounting of Second gear Assembly-2

Interactive question: why are there three locating pins in gear plunger? What failure will be caused if the pin hole is damaged?

Shandong Lingong



53 23/4/22


6.Dismounting of first gear Assembly-1

Shandong Lingong



54 23/4/22


Dismounting of First gear Assembly-1 -2

Shandong Lingong



55 23/4/22


Dismounting of First gear Assembly-3

Shandong Lingong



56 23/4/22


7.Dismounting of Speed Change Valve -1

Interactive question: How to adjust pressure with the pressure regulating valve and speed change valve of double spring structure?

Shandong Lingong



57 23/4/22


Dismounting of Speed Change Valve -2

Shandong Lingong



58 23/4/22



Shandong Lingong



59 23/4/22



Shandong Lingong



60 23/4/22


Serial Parts Tightening Torque

1Bolt and nut which can connect the input shaft and inner ring cam in overrun clutch 50±10 Nm

2Terminal pad of direct gear and connecting bolt of gear I planet carrier 75±10 Nm

3 Connecting bolt of variable speed pump 52±7 Nm

4 Connecting bolt of middle cap 145±20Nm

5 Connecting bolt of speed change valve 52±7Nm

6 Bolt that can connect end cap and box 52±7Nm

7 Bivariant connecting bolt 52±7Nm

II ） The Key Moment and Interval in Bivariant Assembly 1.Moment List for Screw Thread of Parts in Gear Box force

Shandong Lingong



61 23/4/22


2.List for Fit Clearance of the Key Parts in Bivariant Assemble

Serial Numbe

rParts Fit Clearance Link

1 　 Clearance between shaft end of input level II gear and level II turbine check ring of torque converter (In the hole of idler pulley)

0.3-0.6mm 　

2 　End clearance of 5111 bearings between input level I and level II gear of gear box （ Interactive question ： where should the adjust ring be placed ？）　

0.3-0.7mm 　

3 　 Verticality between shaft gear assembly and joint surface of variable speed pump 　 Less than0.08 mm 　

4 　 Clearance between friction linking of reverse gear and isolator 　 0.9-2.8mm 　

5 　 Clearance between first gear friction linking and first gearoil cylinder plunger 1.8-4.6mm 　

6 　 Clearance between first gear oil cylinder plunger and middle cap 0.1-0.3mm 　

7 　 Fit Clearance between bear bore of end cap and Second gear upper bearing 0.3-1mm 　

Shandong Lingong



62 23/4/22


Types of Parts Inspection Item

Standard for JudgmentMeasures

for waterproo

fSize （ Allowance） Tolerance Limit

Bearing

Allowance of Internal Diameter

About 0～－ 0.02 +0.02

ChangeAllowance of External

DiameterAbout 0～－ 0.02 － 0.04

Driven Slice of Direct gear Thickness 3±0.05 2.5 Change

Driving Slice of Direct gear Thickness 3.85±0.05 3.2 （ Unilateral Wear Limit0.4） Change

Driven Slice of Reverse gear with first gear

Thickness 3±0.05 2.5 Change

Driving Slice of Reverse gear with first gear

Thickness 3.85±0.05 3.2 （ Unilateral Wear Limit0.4） Change

Plunger of Direct gearExternal Diameterφ248 － 0.285～－ 0.170 － 0.40

ChangeInternal Diameterφ70 0.174 ～ 0.10 +0.30

Plunger of Reverse gearExternal Diameterφ342 0～－ 0.089 － 0.20


First gearPlunger

External Diameterφ342 － 0.24～－ 0.15 － 0.35


3.Change Standard for Quick-wear Part

Shandong Lingong



63 23/4/22


To oil suction pipe of variable speed pump

To oil cooler

To transmission shaft back and forth

To engine flywheel

To oil temperature sensor

To oil return pipe of torque converter

To working pump

To Filter of Torque oil

III ） Assemble Relationship of Bivariant System in Complete Machine

Shandong Lingong


23/4/22

Content


22

Brief Introduction of Bivariant System11


33



64

SDLG Construction Machinery Co. LTD training room Shandong Lingong



65 23/4/22

V. Typical Failure Analysis

I) Failure Related to Oil Temperature of torque ：

1.Identification Standard for High Oil Temperature:

If the engine is in normal operation, work can be allowed when

the oil temperature of torque converter is above 65 with 85-95 ℃

for the best temperature; the oil temperature of torque ℃

converter which is more than 120 , can be regarded as being ℃

over high.

Shandong Lingong



66 23/4/22

Check whether the oil level of gear box is too low or too high

Check whether the quality of hydrodynamic transmission is poor or deteriorated

Check whether the oil suction screen of gear box is blocked or not

Check whether the variable speed pressure is too low (lower than 0.88MPa ), which can lead the friction linking to slipping or giving out heat

Poor heat dissipation is caused by lots of oil loam between blades of cooling fin in water tank

Poor hear dissipation of oil cooler in torque converter (blocked or too much scale deposit)

Check whether the big overrun clutch in gear box is damaged or not

Check whether the turbine group of torque converter is damaged or not

2. Analysis on Failure for High Oil

Temperature ：


Shandong Lingong



67 23/4/22

V. Typical Failure AnalysisII ） Failure Related to Variable Speed pressure

1.Low Pressure for Speed Change

≤0.88Mpa

All gears are low----Eccentric wear of variable speed pump or failure of pressure

adjusting spring of speed change valve

Some gears are low

First gear

is low

Seal ring of oil supply hole of first gear

oil cylinder is damaged

There is abscess in First gear oil cylinder

Variable speed valve pad in First gear oil duct is

damaged

There is abscess in in First gear oil duct of box

Reverse gear

is low

There is abscess in oil cylinder of reverse gear, or

which is damaged. Variable speed valve pad in First gear oil duct is

damaged

There is abscess in gear oil duct of box

Second gear

is low

Seal ring of Second gear oil duct at end cap is

damaged

Variable speed valve pad in Second gear oil duct

is damaged

Hole of Second gear plunger guide pin is

penetrated in

Shandong Lingong



68 23/4/22

V. Typical Failure AnalysisFailure Related to Variable Speed (Cont’d)

2.High variable speed pressure ＞ 1.5Mpa

Each gear is high, and the more oil, is added, the higher the speed

will be ----The main oil-taking duct of torque converter is blocked.

Each gear is high ----The pressure adjusted by variable valve is over high

(spring) or the valve spool is stuck

main oil taking duct spring for pressure adjustment

Shandong Lingong



69 23/4/22


III ） Failure Related to Sealing

Failure of sealing

parts

Aging and losing

effectiveness

Aging of piston packing ring at gears---

waiting for gears

Sealing gasket loses its effectiveness----

Oil leak outside

sealing failure of pump impeller and cap wheel---No running

capacity working with heavy load

Neglected

loading, 、 being frayed

Seal ring of oil duct of each gear---- no pressure or low

pressure at each gear

Rotating oil seal of transfer gear--- oil pumped from torque

converter to engine, with black smoke when motor is

started

Neglected loading of input level II gear rotating oil seal ---

lagging start

Neglected loading of variable speed valve

pad---no pressure at each gear

Shandong Lingong



70 23/4/22


IV) Failure related to Fit Clearance

Clearance is too

narrow

Face of torque converter and mould assembling of gear box---5111thrust

bearing is damaged from burn

Friction lining of reverse gear and isolator----the process of plunger is to

short ， which cannot be isolated clearly by reverse gear

First gear friction lining and gear I oil cylinder plunger --- the process of plunger is to

short ， which cannot be isolated clearly by First gear

Input level II gear and level II turbine check ring---check is broken ， and the level II turbine is

damaged

First gear oil cylinder and middle cap---middle cap cannot be tightened, so that pressure oil is

leaked, with low pressure of reverse First gear

End cap and end face of box ---bearing on Second gear is burnt

Shandong Lingong



71 23/4/22


V) Failure Caused by Damaged Drive Elements

Drive elements

Spline shaft of the steering pump is broken- --- there is no steering

when the machine is started

Overrun middle input shaft is broken- ---The machine cannot work at each

gear when the machine is started

Fixed bolt of connection plate in the direct gear is broken---The pressure is normal, while

there is no reverse First gear, but only second gear

Spline shaft of the working pump is broken---swing arm and basket cannot

work when the machine is started

Spline out of the sun gear is damaged---there is pressure for

speed change ， but the machine cannot work at each gear

The elastic plate is torn--- there is no pressure for speed change ，

and the machine cannot work at each gear

Shandong Lingong



72 23/4/22


VI ） Cases about Special Failure

Case I

Failure symptom ： Vehicles can run slowly when the engine isn’t gunned and put into

gear, while it doesn’t work when engine is gunned.

Analysis ： 1 ） Pipe line of variable torque oil filter or oil sucking pipe of variable

speed pump is aging with peeling inside, so it is in the natural state when the engine

isn’t gunned, with lighter block in pipe; it will be sucked up to block the pipe line when

the engine is gunned;

2 ） There is a coin in the pipeline, which is sucked up to make the pipeline blocked

when it is gunned.

Shandong Lingong



73 23/4/22


Cases about Special Failure (Cont’d)

Case 2

Failure symptom ： The vehicle runs slowly with heavy load when it is hot.

Analysis ：

1 ） Pin roller of overrun clutch is frayed, and it is slipping when the vehicle is

hot, and cannot be connected, so that internal and external gears cannot rotate

simultaneously at the same direction;

2 ） There are small cracks or abscess in the pump impeller of torque converter,

and torque oil is leaked when the vehicle is hot, resulting in lack of driving force.

Shandong Lingong





Case3

Failure symptom :After starting the machine, variable speed pressure is normal, but pressure of each gear surges when the engine is gunned, much higher than normal pressure.

Analysis ：

The main oil taking duct of torque converter is blocked (near to relief valve),

so that the torque oil reached all gears, but cannot enter into the torque

converter. In the past, when torque converter came into the factory, the main

oil duct has a white plastic plug; the above failure will occur when the plug

isn’t taken away.

Shandong Lingong



75 23/4/22



Case 4

Failure symptom ： The oil cooler is frozen if drivers forget to take measures for waterproof in colder areas. After replacement of the damaged parts and antifreeze, the abnormal noise from the variable speed pump is serious without variable speed pressure when drivers start the machine the next day.

Analysis ：

After the oil cooler of torque oil is frozen, water enters into gear box with oil. One night later, water deposits to the oil pan of gear box (the proportion of water is greater than the torque oil), and is frozen together with the oil suction pipe of variable speed pump. Therefore, oil cannot be sucked up when starting the machine in the morning.

Shandong Lingong



76 23/4/22

The EndThe EndThe EndThe End

Shandong Lingong



77 23/4/22

Chained File

Interactive question ： what is the normal temperature of torque oil ？

60-120degree

Shandong Lingong


Senor for oil temperature of torque converter


78 23/4/22

Chained File

Interactive questions ：1 ） Please describe the common skills and methods for connecting elastic plate of torque converter and engine flywheel;

2 ） How to efficiently pick up foreign matters which fall down from the peep door of the engine flywheel?

Shandong Lingong



79 23/4/22

Chained File

Theory for heat dissipation ： The temperature of oil inlet is higher than oil-out, and water with high temperature is sucked by water to water tank for dissipation.

Interactive questions ：

1 ） What kind of failure will be caused if intake and output oil pipes of torque oil cooler are blocked?

2 ） What kind of failure will be caused if torque oil cooler is frozen or has abscess?

water landing pump

Shandong Lingong


Filter to oil port of gear box

Gear box to oil port of filter

Torque converter to oil port of heat emitter

Heat emitter to pot of torque converter


80 23/4/22

Chained File


1 ） What kind of failure will be

caused if oil sucking screen of

gear box is blocked?

2 ） What is the standard to

check the oil in gear box?

Shandong Lingong



81 23/4/22

Chained File


1 ） Why is there oil in this oil pipe ？

2 ） What role does the oil pipe play ？

3 ） What kind of failure will be caused if there is too much oil(1/2 more than the

oil pipe) in the oil return pipe of torque converter when the engine is started?

Shandong Lingong


Oil return pipe of torque converter

Oil return pipe of torque converter


82 23/4/22

Chained File

Interactive question ： Which parts should be checked for failure

when the front and back transmission shafts of gear box are

disconnected?

Shandong Lingong



83 23/4/22

Chained File


1 ） Please describe the trend of torque oil when flowing through filter 。

2 ） What kind of failure will be caused respectively when filter element of torque oil

filter and pipeline are blocked?

1

2

3

Shandong Lingong



84 23/4/22

Chained File


1 ） How to check working pump or steering pump if oil in the hydraulic oil tank is

sucked into gear box?

2 ） How to determine whether the working pump is damaged or not?

3 ） What kind of failure will be if the spline shaft of working pump is broken?

Shandong Lingong



85 23/4/22

Chained File

Shandong Lingong


Level II turbine

Level II input gear

Magnified

Bearings

Adjustable gasket

Check ring


86 23/4/22

Chained File

Shandong Lingong



87 23/4/22

Chained File

Bounce from shaft gear to pump body should be not more than 0.08mm.

Shandong Lingong



88 23/4/22

Chained File

Shandong Lingong



89 23/4/22

Chained File

Shandong Lingong



90 23/4/22

Chained File

Shandong Lingong



91 23/4/22

Chained File

Shandong Lingong


Date post:	29-Jan-2016
Category:	Documents
Upload:	hugh-bryan
View:	220 times
Download:	2 times