training documents for bivariant system of loader july, 2010 sdlg volvo group member company
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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
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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
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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
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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)
I Brief Introduction of Bivariant System
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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.
I Brief Introduction of Bivariant System
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
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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
I,Brief Introduction of Bivariant System
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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.
I,Brief Introduction of Bivariant System
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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)
I Brief Introduction of Bivariant System
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VI ) Composition of SDLG’s Bivariant Assembly
1 、 Appearance and Name:
I Brief Introduction of Bivariant System
Ask trainees to point out all parts of the bivariant system based on the serial number. Check Trainees’ familiarity with gear box.
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2.Main Parts and their Name inside
I Brief Introduction of Bivariant System
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
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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
I Brief Introduction of Bivariant System
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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 AnalysisSDLG Construction Machinery Co. LTD
Training room
13
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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
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Attached Figure1. External View of Torque Converter
II. Hydraulic Torque
Converter
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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
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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.
II. Hydraulic Torque
Converter
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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
II. Hydraulic Torque
Converter
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III ) Route for Transmission of Power and Working Theory
1.Input of Motive Power
II. Hydraulic Torque Converter
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 )
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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.
II. Hydraulic Torque Converter
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IV ) Sealing of Torque Converter
II. Hydraulic Torque
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.
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Content
II. Hydraulic Torque Converter
22
Brief Introduction of Bivariant System
11
Planetary Dynamic Shift Gear Box
33
44Key Points of Dismounting of Bivariant System
55
22
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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
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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.
III. Planetary Dynamic Shift Gear Box
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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.
III. Planetary Dynamic Shift Gear Box
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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
III. Planetary Dynamic Shift Gear Box
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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
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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
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3.Transmission Route of Reverse Gear
MachinesIII. Planetary Dynamic Shift Gear Box
Annular Gear of Reverse gear
Planetary Gear of Reverse Gear
Sun Gear
Middle Input Axis of Clutch
Gear II Output Gear
First gearPlanet Carrier
Gear Pressure Plate
Output Shaft Gear
Output Shaft
Overrun Clutch
Input Level I and Level II Gear
Hydraulic Torque Converter
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
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4.Transmission Route of Machines
with Gear I
First gearPlanet wheel
Sun Gear
Middle Input Axis of Clutch
Second gearOutput Gear
First gear Planet Carrier
Second gearPressure Plate
Output Shaft Gear
Output Shaft
Overrun Clutch
Input Level I and Level II Gear
Hydraulic Torque Converter
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
Pressure plate 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
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5.Transmission Route of Machines
with Gear II
Shaft of direct Gear
Sun Gear
Middle Input Axis of Clutch
second gear
input gear
second gear
Pressure plate
Output Shaft Gear
Output Shaft
Overrun Clutch
Input Level I and Level II Gear
Hydraulic Torque Converter
Engine Flywheel
III. Planetary Dynamic Shift Gear Box
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
Pressure plate of direct gear
Shaft of direct Gear
Output shaft assembly
Sun GearExternal ring gearMiddle Input Shaft
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V ) planetary gear box-Route for oil supply of torque
converter
III. Planetary Dynamic Shift Gear Box
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).
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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
III. Planetary Dynamic Shift Gear Box
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
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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
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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
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
35
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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
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IV. Key Points of Dismounting of Bivariant System
2.Dismounting Process of Gear Box-1
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IV. Key Points of Dismounting of Bivariant System Dismounting Process of Gear
Box-2
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IV. Key Points of Dismounting of Bivariant System Dismounting Process of Gear
Box-3
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IV. Key Points of Dismounting of Bivariant System Dismounting Process of Gear
Box-4
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IV. Key Points of Dismounting of Bivariant System Dismounting Process of Gear
Box-5
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IV. Key Points of Dismounting of Bivariant System
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?
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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?
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IV. Key Points of Dismounting of Bivariant System
Dismounting Process of Torque Converter -3
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IV. Key Points of Dismounting of Bivariant System
Dismounting Process of Torque Converter -4
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IV. Key Points of Dismounting of Bivariant System
Dismounting Process of Torque Converter -5
Interactive question: How many types of the
rotating oil seal on the idler pulley? What
failure will be caused if damaged or frayed?
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IV. Key Points of Dismounting of Bivariant System
Dismounting Process of Torque Converter -5
Dismounting process of level I and level II turbine group :
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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?
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IV. Key Points of Dismounting of Bivariant System
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.
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IV. Key Points of Dismounting of Bivariant System
Dismounting Process of Overrun Clutch -2
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IV. Key Points of Dismounting of Bivariant System
5.Dismounting of Second gear Assembly-1
Interactive question: what role does the disc spring play in the red circle above?
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IV. Key Points of Dismounting of Bivariant System
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?
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IV. Key Points of Dismounting of Bivariant System
6.Dismounting of first gear Assembly-1
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IV. Key Points of Dismounting of Bivariant System
Dismounting of First gear Assembly-1 -2
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IV. Key Points of Dismounting of Bivariant System
Dismounting of First gear Assembly-3
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IV. Key Points of Dismounting of Bivariant System
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?
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IV. Key Points of Dismounting of Bivariant System
Dismounting of Speed Change Valve -2
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IV. Key Points of Dismounting of Bivariant System
Dismounting of Speed Change Valve -3
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IV. Key Points of Dismounting of Bivariant System
Dismounting of Speed Change Valve -4
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IV. Key Points of Dismounting of Bivariant System
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
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IV. Key Points of Dismounting of Bivariant System
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
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IV. Key Points of Dismounting of Bivariant System
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
ChangeInternal Diameterφ170 0.145 ~ 0.208 +0.30
First gearPlunger
External Diameterφ342 - 0.24~- 0.15 - 0.35
ChangeInternal Diameterφ235 0.17 ~ 0.242 +0.35
3.Change Standard for Quick-wear Part
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IV. Key Points of Dismounting of Bivariant System
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
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Content
Hydraulic Torque Converter
22
Brief Introduction of Bivariant System11
Planetary Dynamic Shift Gear Box
33
44Key Points of Dismounting of Bivariant System
55 Typical Failure Analysis
64
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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.
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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 :
V. Typical Failure Analysis
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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
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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
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V. Typical Failure Analysis
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
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V. Typical Failure Analysis
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
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V. Typical Failure Analysis
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
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V. Typical Failure Analysis
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.
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V. Typical Failure Analysis
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.
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V. Typical Failure Analysis
Cases about Special Failure (Cont’d)
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.
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V. Typical Failure Analysis
Cases about Special Failure (Cont’d)
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.
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The EndThe EndThe EndThe End
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Chained File
Interactive question : what is the normal temperature of torque oil ?
60-120degree
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Senor for oil temperature of torque converter
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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?
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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
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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
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Chained File
Interactive questions :
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?
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Chained File
Interactive questions :
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?
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Oil return pipe of torque converter
Oil return pipe of torque converter
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Chained File
Interactive question : Which parts should be checked for failure
when the front and back transmission shafts of gear box are
disconnected?
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Chained File
Interactive questions :
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
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Chained File
Interactive questions :
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?
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Chained File
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Level II turbine
Level II input gear
Magnified
Bearings
Adjustable gasket
Check ring
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Chained File
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Chained File
Bounce from shaft gear to pump body should be not more than 0.08mm.
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Chained File
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Chained File
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Chained File
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Chained File
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