Training For Torque Converter & Gear Box System of Wheel Loader

Training for Torque Converter & Gear
Box System of Wheel Loader
April, 2011
Content
Brief Introduction of C&T System
Hydraulic Torque Converter
Planetary Dynamic Shift Gear Box
4
5
Key Points of Dismounting of C&T System
Typical Failure Analysis
RELIABILITY IN ACTION
2
SHANDONG LINGONG CONSTRUCTION MACHINERY CO.,LTD
I Brief Introduction of C&T System

I ) Definition of Drive System
Torque Converter
C&T Assembly
Definition of Drive
System
Gear Box
Main Drive
Drive Axle Assembly
Hub Reduction Gear
Tyre
Drive system includes power plant of wheel loader and drive parts among driving gears.
3

II Classification of C&T 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.
4

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
5

IV Definition of Hydrodynamic Transmission
Hydrodynamic transmission refers to devices that carry out energy transfer and control
based onkinetic 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.
6
Figure1-1 Theory sketch for hydraulic transmission

1water inlet of centrifugal pump
4-- distributor
5water turbine
7turbine draft tube
2centrifugal water pump 3pipeline
6impeller of water turbine
8water leg
7

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.
8

1 Merits
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
9

1 Merits
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 loaders running gear device or
transmission system, and improve service life of loader.
10

1 Merits
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.
11

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)
12

VI Composition of SDLGs C&T Assembly
1 Appearance and Name
Ask trainees to point out all parts of the C&T system based on the serial number. Check
Trainees familiarity with gear box.
13

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
14

VII Basic Parameter of SDLG C&T Assembly
Model of C&T Assembly
A301 gear box
Applicable Models
LG952L LG953L LG956L LG936L Wheel loader
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 Working Pump
LG03-BSB
Oil quantity of No.6 Hydrodynamic Transmission Oil

6
44 L
15
Content
4
5
16
II Hydraulic Torque Converter

I Components of Hydraulic Torque Converter Single Stage four Components)
1. Pump Impeller
2. Idler Pulley
3.Level-one and Level-two Turbine

17

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
18

Attached Figure1. External View of Torque Converter
1
19

Attached Figure2. Breakdown view of Hydraulic Torque Converter
7117 8 9 10 11 12 13
19 20 21 22 23 24 25
31 32 33 34 35 36
Figure2-5 Breakdown view of YJSW315 hydraulic torque converter
YJSW315
1 idler pulley seat 2sealing ring3special-U sealing ring 4shell of torque converter5cover plate 6transfer gear7117bearing 8screw bolt9pump
impeller 10spacer shim 11pressing plate 12 locking plate13idler pulley 14check ring 15level I turbine 16level II turbine 17spline spacer shim 18
heck ring 19bearing 20screw nut 21boult22level I turbine hub 23level I turbine shell cap 24bearing 25spring pin26"O" type sealing ring27cap
wheel28round base plate29spring plate 30pipe joint 31valve deck 32spring 33spool 34base plate 35spring36spool
20

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 315means the diameter of circulating
circle of torque converter is 315mm.
YJSW315 315
315mm
21

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.
22

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
23

3 single stage Torque converter can be divided into single-stage, two-stage and multistage 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 havent been connected by rigidity in the
circulatory circle is called single stage hydraulic torque converter.
24

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.

25

III Route for Transmission of Power and Working Theory
1. Input of Motive Power
Route1 Engine flywheel elastic plate cap wheel pump impeller

1
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
2

SDLG
Construction
Machinery Co. LTD training room
RELIABILITY
IN ACTION
26
26 11/10/15
Shandong Lingong
Volvo Group Member Company

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

27

2. Output of Motive Power
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.
28

IV Sealing of 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;
O
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
29

IV Sealing of Torque Converter
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
.
30
Content
4
5
31
III Planetary Dynamic Shift Gear Box

I Main Structure of Planet Row
Sun gear
Planet gear
Planet row
Planet shelf
Gear ring
Figure 3-1 structure of basic planet row

3-1
1sun gear
2gear ring
3planet shelf 4planet gear
32

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.
RELIABILITY
IN ACTION
33

III Deceleration Form of Planet Row
1. Deceleration Form of Planet Row
1+number of teeth of annular gear/number of teeth of sun gear 1 which means speed
deceleration
1+ / 1
2. Reduction ratio of SDLG 50 planetary gear box 1+60/22=3.727

50 1+60/22=3.727
34

III Deceleration Form of Planet Row
Note
1 SDLG 50planet gear box First gear Reverse gear number of teeth of annular
gear=60 number of teeth of sun gear =22
50 =60 =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.
35

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.
36
First gear
37
Reverse gear

2.Overall Transmission Route of Gear Box
Engine Flywheel
Elastic Plate of Torque Converter
Second gear
Friction Lining of the
First gear
Lateral Shaft
Friction
GearLining
of
of the Planetary
the Lateral Gear
Plunger
Lateral Shaft
Cap Gear
First gear Oil

Friction Lining
Cylinder
First gear
Plunger
Second gear Plunger

General Output Gear of Three
Gears
Level I
Gear Ring
End Cap
Pump Impeller
Level I and Level II turbine
Input Level I and Level II Gear
Overrun Clutch
Middle Input Axis of Clutch
Idler
Pulley
Level I
turbine
Pump
Impeller
Idler
Pulley
Seat
Rotary Oil
Seal
Transfer
Gear
Sun Gear
Gears in Gear Box
38
Middle
Cap
Shell of
Torque
Converter
Sun Gear
Overrun
Clutch
Overflow Valve in Entry
Shell of Gear
Box
Output Shaft
Assembly
3.Transmission Route of Reverse Gear
Engine Flywheel
Machines
Level I Output Gear
second gear Plunger

Friction Lining of Lateral
Gear
Level I I Output Gear
Isolator
Assembly
Annular gear of reverse

Gear
First gear Planet Carrier
Assembly
Middle Out put Gear
Overrun Clutch
Oil cylinder
Of Direct Gear
Inner ring cam
Sun Gear
Planetary Gear of Reverse Gear
Annular Gear of Reverse gear
Gear Pressure Plate
Terminal pad of direct

gear
Middle Input
Shaft
Pressure plate of direct

gear
External ring
Gear
Box
Planetary Shaft of
Reverse Gear
Planet Carrier of
reverse gear
Planet
Gear
Sun
Gear
Gear II Output Gear
Output Shaft Gear

Contents
for Trainees
SDLG Construction Machinery Co. LTD training room Interactive
Volvo
Group
Company
39 Member
SHANDONG
LINGONG
CONSTRUCTION MACHINERY CO.,LTD
Output Shaft
39 11/10/15
Description!
Shandong Lingong
Output assembly
Level I Output
Gear
Isolator
assembly
4.Transmission Route of Machines

with Gear I
First gear
friction linking
First gear
Plunger
First gear oil

cylinder
Lever II Output
Gear
First gear
gear ring
Middle output gear
Engine Flywheel
Oil cylinder
Of Direct Gear
Inner ring
cam
Overrun Clutch
Sun Gear
Terminal pad
Of direct gear
First gear Planet wheel
Pressure plate of
direct gear
Middle Input
Shaft
External
ring gear
Sun Gear
First gear
planet carrier
Planet
Gear
First gear Planet

Shaft
Second gear Pressure Plate
Second gear Output Gear
Output Shaft Gear

Contents
for Trainees
Volvo
Group
Company
40 Member
SHANDONG
CO.,LTD
Output LINGONG
Shaft CONSTRUCTION MACHINERY
Description!
40 11/10/15
Shandong Lingong
Output shaft
assembly
5.Transmission Route of Machines

with Gear II
Level I Output
Gear
Lever II Output
Gear
Middle output
gear
Plunger of direct
gear
Oil cylinder
Engine Flywheel
Inner ring cam
Of Direct gear
disc spring
Pressure plate of
direct Gear
Overrun Clutch
Friction linking
of direct gear
Sun Gear
Shaft of direct Gear
Middle Input Shaft
External
ring gear
Sun Gear
Shaft of
direct Gear
Pressure plate of
direct gear
second gear Pressure plate
second gear output gear
Output Shaft Gear

Contents
for Trainees
Volvo
Group
Company
41 Member
SHANDONG
CONSTRUCTION MACHINERY CO.,LTD
Output LINGONG
Shaft
41 11/10/15
Description!
Shandong Lingong
Output shaft
assembly

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
42

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
1 P 1.08 1.47MPa
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
43

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 14Fuel Feed hole of oil cylinder in reverse gear
10 14
44
Second gear
First gear
neutral position
Reverse gear
Fuel Feed hole of oil cylinder in

reverse gear

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 15Fuel Feed hole of oil cylinder in First gear
45
Second gear
First gear
neutral position
Fuel Feed hole of oil cylinder in First gear
Reverse gear
7 15

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
SDLG Construction Machinery Co. LTD training room
Volvo Group
46 Member Company
SHANDONG
LINGONG CONSTRUCTION MACHINERY CO.,LTD
46 11/10/15
First gear
Second gear
neutral position
Reverse gear
8 9
Fuel Feed hole of oil cylinder in

Shandong Lingong
second gear
Content
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5
47
IV.Key Points of Dismounting of C&T System

I Dismounting Process of C&T System
1.Dismounting devices and instruments
Name of common tools
Specification
Quantity
Gas trigger
LB10 LB16 LB20
1 group
1
Sleeve
10 13 14 15
16 18 21 24
41
Dial test indicator
0.01/0 3
0.01/0 5
Solid wrench
1316 1821 222

4
1 group
1
Choose different specification based on the

diverse size of the assembled bolts
Slightly hit with the part assembled with

interference
Copper bar
1 group
1
48
Parts used


Bounce of the assemble plane of line axle and

pump in variable speed pump

I Dismounting Process of C&T System
1.Dismounting devices and instruments
Name of common tools
Depth vernier gauge
Specification
0.02/0 200
Leveling ruler
Quantity
Parts used
Sub assemble of torque converter; install and input

Level I gear assembly ,assemble friction linking , middle
cap, variable speed pump end cap
Subassembly and variable speed pump of torque

converter
Quantity
The parts used Serial number of the corresponding

network chart or name of assembly
its own dismounting

platform
Increase convenience and security when dismounting

C&T system
Retainer pliers for shaft (hole)
200 300
when check ring is installed
Lifting bolt
M10 M14 M16 M

18
8 29 31
Name of special tools
Specification
Mount support of gear box
49

2.Dismounting Process of Gear Box-1 -1
50
Dismounting Process of Gear Box-2 -2
51

52
53
54
3. Dismounting Process of Torque Converter-1 -1
Interactive question whats the name of the valve in the above red circle? What is
its pressure? What role dose it play?
55

Dismounting Process of Torque Converter -2 -2
Interactive question what is valve in the following circle in red? What is the
pressure? What role does it play?
56
57
58

Interactive question: How many types of the

rotating oil seal on the idler pulley? What
failure will be caused if damaged or frayed?
59
Dismounting process of level I and level II turbine group
60
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?
61

4.Dismounting Process of Overrun Clutch-1 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.
24 20
62
Dismounting Process of Overrun Clutch -2 -2
63

5.Dismounting of Second gear Assembly-1 -1
Interactive question: what role does the disc spring play in the red circle above?
64
Dismounting of Second gear Assembly-2 -2
Interactive question: why are there three locating pins in gear plunger? What failure will be
caused if the pin hole is damaged?
65
6.Dismounting of first gear Assembly-1
66
Dismounting of First gear Assembly-2
67

Dismounting of First gear Assembly-3 -3
68
7.Dismounting of Transmission control Valve -1 -1
Interactive question: How to adjust pressure with the pressure regulating valve and
speed change valve of double spring structure?
69

Dismounting of Transmission control Valve -2 -2
70
Dismounting of Transmission Control Valve -3 -3
71

Dismounting of Transmission Control Valve -4 -4
72

II The Key Moment and Interval in C&T Assembly
1.Moment List for Screw Thread of Parts in Gear Box force
Serial
Parts
Tightening Torque
Bolt and nut which can connect the input shaft and inner ring cam in
overrun clutch
5010 Nm
Terminal pad of direct gear and connecting bolt of gear I planet carrier
7510 Nm
Connecting bolt of variable speed pump
527 Nm
Connecting bolt of middle cap
Connecting bolt of speed change valve
527Nm
Bolt that can connect end cap and box
527Nm
C&T connecting bolt
527Nm
73
14520Nm

2.List for Fit Clearance of the Key Parts in C&T Assemble
Serial
Parts
Fit Clearance
Link
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
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
5111

0.3-0.7mm
Verticality between shaft gear assembly and joint surface of variable speed
pump
Clearance between friction linking of reverse gear and isolator
0.9-2.8mm
Clearance between first gear friction linking and first gearoil cylinder
plunger
1.8-4.6mm
Clearance between first gear oil cylinder plunger and middle cap
0.1-0.3mm
Fit Clearance between bear bore of end cap and Second gear upper
bearing
0.3-1mm
74
Less than0.08 mm
0.08mm

3.Change Standard for Quick-wear Part
Standard for Judgment
Types of Parts
Bearing
Inspection Item
Size(Allowance)
Tolerance Limit
Allowance of Internal Diameter
About 0
0.02
+0.02
Allowance of External Diameter
About 0
0.02
0.04
Measures
for
waterproof
Change
Driven Slice of Direct gear
Thickness
30.05
2.5
Change
Driving Slice of Direct gear
Thickness
3.850.05
3.2 Unilateral Wear

Limit0.4
32 0.4
Change
Driven Slice of Reverse gear with first gear
Thickness
30.05
2.5
Change
Driving Slice of Reverse gear with first gear
Thickness
3.850.05
3.2 Unilateral Wear

Limit0.4
32 0.4
Change
Plunger of Direct gear
External Diameter 248
0.285 0.170
0.40
Internal Diameter 70
0.174 0.10
+0.30
Plunger of Reverse gear
0 0.089
0.20
0.145 0.208
+0.30
0.24 0.15
0.35
0.17 0.242
+0.35
First gear Plunger
75
Change
Change
Change

III Assemble Relationship of Bivariant System in Complete Machine
To oil temperature sensor
To working pump
To engine flywheel
To oil cooler
To oil suction pipe of

variable speed pump
To oil return pipe of

torque converter
To transmission shaft
back and forth
76
To Filter of Torque oil
Content
4
5
77
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.
65 85 95
120
78

2. Analysis on Failure for High Oil Temperature
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 (0.88MPa
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
79
II Failure Related to Variable Speed pressure
All gears are low----Eccentric wear of variable speed pump or failure of pressure
adjusting spring of speed change valve
----
Seal ring of oil supply hole of first gear oil cylinder is damaged
First gear
There is abscess in First gear oil cylinder

Variable speed valve pad in First gear oil duct is damaged
is low
There is abscess in in First gear oil duct
1.Low Pressure for

Speed Change
0.88Mpa
of box
There is abscess in oil cylinder of reverse gear, or which is damaged.
Some gears
Reverse gear is
are low
low
Variable speed valve pad in First gear oil duct is damaged
There is abscess in gear oil duct of box
Seal ring of Second gear oil duct at end cap is damaged
Second gear is
low
80
Variable speed valve pad in Second gear oil duct is damaged
Hole of Second gear plunger guide pin is penetrated in
Failure Related to Variable Speed Pressure (Contd)

(
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
81

III Failure Related to Sealing
Aging of piston packing ring at gears---waiting for gears

---
Aging and losing
Sealing gasket loses its effectiveness----Oil leak outside
effectiveness
----
sealing failure of pump impeller and cap wheel---No running capacity working with
heavy load
---
Failure of
sealing parts
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
----
Neglected loading,
to engine, with black smoke when motor is started
being frayed
---
Neglected loading of input level II gear rotating oil seal ---lagging start
---
Neglected loading of variable speed valve pad---no pressure at each gear
---
82

IV) Failure related to Fit Clearance
Input level II gear and level II turbine check ring---check is broken and the level II turbine is damaged
---
Face of torque converter and mould assembling of gear box---5111thrust bearing is damaged from burn
---5111
Clearance
is too
narrow
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
---
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
---
83
V) Failure Caused by Damaged Drive Elements
Spline shaft of the working pump is broken---swing arm and basket cannot work when the
machine is started ---
Spline shaft of the steering pump is broken- --- there is no steering when the machine is
started
Drive
elements
---
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 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 ---
84

VI Cases about Special Failure
Case I 1
Failure symptom Vehicles can run slowly when the engine isnt gunned and put into gear,
while it doesnt 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 isnt 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.
85

Cases about Special Failure (Contd)
Case 2 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.
86

Case3 3
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 isnt taken away.
RELIABILITY
IN ACTION
87

Case 4 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.
88
The End
89
Chained File
Senor for oil temperature of torque converter

Interactive question what is the normal temperature of torque oil
60-120 degree
90
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?
91
Chained File
water landing
pump
Gear box to oil port of filter
Filter to oil port of gear box

Torque converter to oil port of heat emitter
Heat emitter to pot of torque converter

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.
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?
92
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?
93
Chained File
Oil return pipe of torque converter
1 Why is there oil in this oil pipe
2 What role does the oil pipe play Oil return pipe of torque converter
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?
1/2
94
Chained File
Interactive question Which parts should be checked for failure when the front and back
transmission shafts of gear box are disconnected?
95
Chained File
1
2
3
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?
96
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?
97
Level II turbine
Check
ring
Adjustable gasket
Level II input gear
Bearings
Magnified
98
Chained File
99
Chained File
Bounce from shaft gear to pump body should be not more than 0.08mm.
0.08mm.
100
Chained File
101
Chained File
102
Chained File
103
Chained File
104

Training For Torque Converter & Gear Box System of Wheel Loader

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Training For Torque Converter & Gear Box System of Wheel Loader

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Training for Torque Converter & Gear

Box System of Wheel Loader

Brief Introduction of C&T System

Hydraulic Torque Converter

Planetary Dynamic Shift Gear Box

Key Points of Dismounting of C&T System

Typical Failure Analysis

I Brief Introduction of C&T System

Drive Axle Assembly

Hub Reduction Gear

I Brief Introduction of C&T System

I Brief Introduction of C&T System

4. Differential function Drive axel

I Brief Introduction of C&T System

I Brief Introduction of C&T System

Figure1-1 Theory sketch for hydraulic transmission

7turbine draft tube

2centrifugal water pump 3pipeline

6impeller of water turbine

I Brief Introduction of C&T System

I Brief Introduction of C&T System

I Brief Introduction of C&T System

I Brief Introduction of C&T System

I Brief Introduction of C&T System

I Brief Introduction of C&T System

I Brief Introduction of C&T System

Level-two gear assembly

Input level-two gear

Level-one gear assembly

Drive axle of steering

Reverse gear assembly

I Brief Introduction of C&T System

A301 gear box

LG952L LG953L LG956L LG936L Wheel loader

Type of Hydraulic Torque Converter

Cooling Type of Torque Oil

Cooling through circulating water

Oil Pressure at the Entry of Torque Converter

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

Gear Ratio of Gear-two

Gear Ratio of Reverse Gear

Type of Working Pump

Oil quantity of No.6 Hydrodynamic Transmission Oil

Brief Introduction of C&T System

Hydraulic Torque Converter

Planetary Dynamic Shift Gear Box

Key Points of Dismounting of C&T System

Typical Failure Analysis

II Hydraulic Torque Converter

3.Level-one and Level-two Turbine

II Hydraulic Torque Converter

II Hydraulic Torque Converter

II Hydraulic Torque Converter

Figure2-5 Breakdown view of YJSW315 hydraulic torque converter

II Hydraulic Torque Converter

II Hydraulic Torque Converter