training for torque converter & gear box system of wheel loader

Training for Torque Converter & Gear

Box System of Wheel Loader

April, 2011

装载双变系统培训资料

2RELIABILITY IN ACTIONSHANDONG LINGONG CONSTRUCTION MACHINERY CO.,LTD

Content 目录

Hydraulic Torque Converter液力变矩器22

Brief Introduction of C&T System 双变系统概述11

Planetary Dynamic Shift Gear Box行星式动力换挡变速箱33

44Key Points of Dismounting of C&T System双变系统的拆装要点

55Typical Failure Analysis典型故障分析


I ) Definition of Drive System 传动系统的定义

I 、 Brief Introduction of C&T System 双变系统概述

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

C&T Assembly

双变总成

Definition of Drive System

传动系统

Drive Axle Assembly

驱动桥总成

Torque Converter 变矩器

Gear Box 变速箱

……

Main Drive 主传动

Hub Reduction Gear 轮边减速器

Tyre 轮胎

轮式装载机动力装置和行走装置之间的传动部件总称为传动系统。


II ） Classification of C&T System 双变系统的分类

1.Classification based on structure and drive medium

按结构和传动介质的不同可分为：Four types: mechanical, hydraulic mechanical, static hydraulic (volume hydraulic) and

electric. Hydraulic mechanical drive is widely used on wheel loader

机械式、液力机械式、静液式（容积液压式）和电力式四种型式。轮式装载机广泛采用液力机械式传动。

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

按操纵方式的不同可分为：人力换挡和动力换挡变速箱；

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

按轮系型式的不同可分为：行星式变速箱和定轴式变速箱。



III) Function of Bivariant System 双变系统的作用

1. Reduce rev.rate and increase torque 降低转速，增大转矩 .

2. Make loader drive backwards 实现装载机倒退行驶

3. Break off drive when necessary （ Neutral position of gear box ）必要时中断传动（变速箱空挡）

4. Differential function （ Drive axel ）差速作用（驱动桥）



IV ） Definition of Hydrodynamic Transmission 液力传动的概念

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.

凡是依靠工作液体的动能进行能量传递与控制的装置，称为液力传动。将液压能转换为机械能。

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.

如液力变矩器里面高速旋转的油液冲击涡轮叶片旋转，带动一二级输出齿轮旋转，将液压动能转换为机械能。



Figure1-1 Theory sketch for hydraulic transmission 液力传动的原理简图

1—water inlet of centrifugal pump 离心泵进水管 2—centrifugal water pump 离心水泵 3—pipeline 管路

4-- distributor 导水机构 5—water turbine 水轮机 6—impeller of water turbine 水轮机叶轮

7—turbine draft tube 水轮机尾水管 8—water leg 集水槽



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

液力传动（装载机）的优缺点

1 、 Merits 优点

1 ） Make the loader have a good automatic adaptability 使装载机具有良好的自动适应性

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.

装载机在额定工况下，液力变矩器能使车辆根据外界的阻力大小，自动变换（降低）行驶

速度与（增大）牵引力，避免因外界负荷突然增大而熄火。





1 、 Merits 优点

2 ） Improve mobility of loader 提高装载机的通过性

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

配备液力传动装置的装载机具有良好的低速稳定性，通过性好，可在泥泞地、沙地、雪地

等软路面以及非硬质土路面行驶或作业。





1 、 Merits 优点

3) Improve Service Life of Loader 提高装载机的使用寿命

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.

液力传动的工作介质是液体，各叶轮之间可以相对滑转，能吸收和衰减来自装载机行走装

置或传动系统的振动和冲击，提高发动机的使用寿命。





1 、 Merits 优点

4 ） Simplify Operation and Improve Operation Comfortableness 简化操作和提高操作舒适性

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.

在行驶过程中液力元件又可以吸收和减小振动、冲击，从而提高了装载机的驾驶舒适性。

起步平稳，加速迅速、在较大范围内实现无级变速，能减少换档次数 , 简化操作，减轻驾驶员

的疲劳强度。



2. Demerits 缺点：

1) Inefficiency and poor economy of Hydrodynamic transmission system

液力传动系统的效率低，经济性差；

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

equipments), high manufacturing costs.

结构复杂（系统必须增加一些供油、冷却等附加设备），制造成本高。

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)

液力传动元件的输入和输出构件之间没有刚性连接，不能用牵引（即不能反向传递动力来启

动发动机）的方法来起动发动机。



VI ） Composition of SDLG’s C&T Assembly 山东临工双变总成的组成 1 、 Appearance and Name 外观及名称

Ask trainees to point out all parts of the C&T system based on the serial number. Check

Trainees’ familiarity with gear box.

请学员对照序号，说出双变各部位的名称。检验学员对变速箱的熟悉程度。



2.Main Parts and their Name inside 内部主要部件及名称

Level-two gear assembly

二档总成

Input level-two gear

输入二级齿轮

Level-one gear assembly

一档总成

Shaft gear

轴齿轮

Drive axle of steering

pump 转向泵驱动轴

Input level-one gear

输入一级齿轮

Reverse gear assembly

倒档总成

Overrun clutch

超越离合器



VII ） Basic Parameter of SDLG C&T Assembly 山东临工双变总成的基本参数 Model of C&T Assembly 双变总成型号 A301 gear box 变速箱

Applicable Models 适用机型 LG952L 、 LG953L 、 LG956L 、 LG936L Wheel loader 装载机

Type of Hydraulic Torque Converter液力变矩器型式

Single stage two-phase centripetal Twin turbo hydraulic torque converter with four components 单级两相向心式四元件双涡轮液力变矩器

Torque Ratio 变矩系数 4.14

Cooling Type of Torque Oil 变矩油冷却方式 Cooling through circulating water 循环水冷却

Oil Pressure at the Entry of Torque Converter 变矩器进口油压

0.549 MPa

Oil Pressure at the Exit of Torque Converter 变矩器出口油压

0.275 ～ 0.343 MPa

Type of Gear Box 变速箱型式 Planetary dynamic shift 行星式动力换挡

Gears for Speed Change 变速档位 Two forward gears and one reverse gear 前二后一

Gear Ratio of Gear-one 一档变速比 2.155

Gear Ratio of Gear-two 二档变速比 0.578

Gear Ratio of Reverse Gear 倒档变速比 1.577

Type of Working Pump 变速泵型号 LG03-BSB

Oil quantity of No.6 Hydrodynamic Transmission Oil 6号液压传动油油量

44 L



Content 目录







1. Pump Impeller 泵轮 2. Idler Pulley 导轮

3.Level-one and Level-two Turbine 一、二级涡轮

I ） Components of Hydraulic Torque Converter （ Single Stage four Components)

液力变矩器的组成（单级四元件）

II 、 Hydraulic Torque Converter 液力变矩器


1.Input Parts 输入部分：

composed of pump impeller ,cap wheel and elastic plate, co-rotating at the same

speed with the engine. 由泵轮、罩轮和弹性板组成，并与发动机的同速同向旋转。

2 、 Output Parts 输出部分：

composed of level-one and level-two turbine, connected through spline and output

gear 由一级涡轮、二级涡轮组成，通过花键与输出齿轮相连。

3 、 Fixed Parts 固定部分：

composed of shell , idler pulley and idler pulley seat 由壳体、导轮、导轮座等组成。



Attached Figure1. External View of Torque Converter

附图 1 ：变矩器外观



Figure2-5 Breakdown view of YJSW315 hydraulic torque converter YJSW315 液力变矩器分解图

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 Figure2. Breakdown view of Hydraulic Torque Converter

附图 2 ：变矩器分解图


1一导轮座 2—密封环 3—

特U密封环 4—变矩器壳体 5—盖板 6—分动齿轮

7—117轴承 8—螺栓

9—泵轮

10—调整垫片 11—压板 12－锁片 13—导轮

14—挡圈 15—一级涡轮 16—二级涡轮 17—花键调整垫片 18—挡圈 19—轴承 20—螺母 21—螺钉

22—一级涡轮毂 23—一级涡轮壳罩

24—轴承 25—弹

性销 26—"O" 型密封圈 27—罩轮

28—圆垫板 29—弹性板 30—管接头 31—阀盖

32—弹簧 33—阀芯

34—垫板

35—弹簧

36—阀芯


II ） Basic Definitions 基本概念

1. circulating circle 循环圆：

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.

液力变矩器密闭的工作腔在通过回转轴线切割的截面（即轴面）内所表示出的形状，称为

循环圆。 YJSW315 型液力变矩器，数字 “ 315” 即代表该变矩器的循环圆直径为 Ф315mm 。




2. torque ratio 变矩比：

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.

涡轮转矩与泵轮转矩之比，称为变矩比 (也称变矩系数 )值愈大 , 说明变矩器所扩大的动力

范围也就愈大。

3. rotate speed ratio 转速比：

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

涡轮的转速和泵轮转速之比，称为液力变矩器的转速比。




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

双涡轮、四元件、单级、两相、向心式液力变矩器

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

双涡轮：一二级涡轮，能相对转动，铆接在一起

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

四元件：泵轮、导轮、一、二级涡轮；




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.

单级：根据掖力变矩器循环圆内涡轮叶片的列数或刚性连接在一起的涡轮数目，可将变矩器分为单级、两级和多级。循环圆内只有一个或没有刚性连接的两个涡轮的变矩器称为单级液力变矩器。




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

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

两相：变矩器内工作元件的功用变化数，即为相；两个功能即两相。

5 ） centripetal type ： a torque converter, whose work flow in turbine flows from the

periphery

to the center, is called centrifugal torque converter.

向心式：变矩器涡轮中的工作液流，从周边流向中心的为向心式变矩器。


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III ） Route for Transmission of Power and Working Theory 动力传动路线及工作原理

1. Input of Motive Power 动力输入部分

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

路线 1 ：发动机飞轮→弹性板 → 罩轮→ 泵轮

Engine flywheel

发动机飞轮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 ）

路线 2 ：发动机飞轮→弹性板 → 罩轮→ 泵轮→ 分动齿轮

→主齿轮轴（工作泵）和转向泵驱动轴（转向泵）

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2. Output of Motive Power 动力输出部分

1 ） Transmission route for level I turbine 一级涡轮的传动路线为：

level I turbine →hub of level II turbine → output shaft of level I turbine

→ Overrun clutch of gear box.

一级涡轮 →一级涡轮轮毂→一级涡轮输出轴→变速箱超越离合器。

2 ） Output route for level II turbine 二级涡轮输出路线则为：

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

二级涡轮 → 二级涡轮输出轴 → 变速箱超越离合器



2. Output of Motive Power 动力输出部分

3 ） Theory description 原理描述 :

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.

当装载机在低速、重载工况下运行时，二级涡轮的转速较低，超越离合器的内环凸轮与外环齿轮处于楔紧状态。这时，一、二级涡轮实际上就像一个整体涡轮，一起作用，以增大变矩器克服外界阻力的能力。当装载机在高速轻载时，一级涡轮空转，只有二级涡轮输出动力。



IV ） Sealing of Torque Converter 变矩器的密封

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” 型圈密封：没有相对运动的两连接件间，如罩轮和泵轮的连接处；

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

合金铸铁密封环密封：有相对运动的连接件间，如在分动齿轮与导轮座之间；



IV ） Sealing of Torque Converter 变矩器的密封

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.

唇口式密封 ( 旋转油封 ) ：属接触式密封，如二级输出轴与导轮座之间、一级输出轴与二级输

出轴之间。

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

注意：唇式密封圈的唇口应对着来油的方向。 .



Content 目录







I ） Main Structure of Planet Row 行星排的主要结构

Figure 3-1 structure of basic planet row

图 3-1 基本行星排的结构

1—sun gear 太阳轮 2—gear ring 齿圈

3—planet shelf 行星架 4—planet gear 行星轮

Sun gear 太阳轮

Planet row

行星排

Planet gear 行星轮

Planet shelf 行星架

Gear ring 齿圈

III 、 Planetary Dynamic Shift Gear Box 行星式变速箱


II ） Feature and merits of Planetary Gear Box 行星式变速箱的特点和优点：

1.Feature 特点：

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

通过合适的传动比实现降速，提供不同的档位速度 .

2.Merits 优点：

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

relatively

small force carried by themselves;

受力分散：多对行星轮共同传递动力，各自受力较小；

2) Radial size is relatively compact: only one ring gear, and planetary gear module is smaller.

径向尺寸较紧凑：齿圈只有一个，行星轮模数较小 .



III ） Deceleration Form of Planet Row 行星排的减速公式

1. Deceleration Form of Planet Row 行星排减速公式：

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

deceleration ；

1+ 内齿圈齿数 /太阳轮齿数＞ 1 为减速；

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

临工 50 行星式变速箱的减速比是： 1+60/22=3.727



III ） Deceleration Form of Planet Row 行星排的减速公式

Note 注：

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

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

临工 50 行星变速箱，一档（倒档）内齿圈齿数 =60 ；太阳轮齿数 =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.

变矩器主要作用是增加扭矩，发动机功率一定，增扭就必须降速。因此，变矩器是按负荷大

小在不断的改变力矩和转速，实际上也是在减速。



IV ） Mechanical transmission Route for each Gear of Gear Box 变速箱各档机械传动路线

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

各档行星排相对运动关系：

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

一档：太阳轮输入，一档架输出，齿圈被固定；

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

倒档：太阳轮输入，齿圈输出，倒档架被固定

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

gear.

二档：Ⅱ档离合器将太阳轮传来的动力，直接传至输出齿轮。



First gear Reverse gear



2.Overall Transmission Route of Gear Box 变速箱总体传动路线

→→→

→→→→→→

Level I and Level II turbine一、二级涡轮

Pump Impeller 泵轮

Cap Gear 罩轮

Elastic Plate of Torque Converter

变矩器弹性板

Middle Input Axis of Clutch离合器中间输出轴

Input Level I and Level II Gear输入一二级齿轮

Overrun Clutch 超越离合器

Sun Gear太阳轮

Gears in Gear Box 变速箱各档

Engine Flywheel 发动机飞轮

Friction Lining of the Lateral Shaft

Second gear

Friction Lining First gear Oil Cylinder Second gear PlungerFirst gear

Friction Lining Planetary Gear of the Lateral Gear

Plunger of the Lateral Shaft

First gear Plunger

Level I Gear Ring

General Output Gear of Three Gears

Idler Pulley

End Cap

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 Machines倒档机械传递路线

Annular Gear of Reverse gear倒档内齿圈

Planetary Gear of Reverse Gear倒档行星轮

Sun Gear太阳轮

Middle Input Axis of Clutch离合器中间输出轴

Gear II Output Gear二档输出齿轮

First gear Planet Carrier

一档行星架Gear Pressure Plate二档受压盘

Output Shaft Gear 输出轴齿轮

Output Shaft 输出轴

Overrun Clutch超越离合器


Hydraulic Torque Converter

液力变矩器


Interactive Contents for Trainees’ Description!互动内容，学员叙述！

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一档机械传递路线

First gear Planet wheel 一档行星轮

Sun Gear太阳轮

Middle Input Axis of Clutch离合器中间输入轴

Second gear Output Gear二档输出齿轮

First gear Planet Carrier 一档行星架

Second gear Pressure Plate二档受压盘






液力变矩器


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



41 23/4/22

5.Transmission Route of Machines

with Gear II二档机械传递路线

Shaft of direct Gear直接档轴

Sun Gear太阳轮

Middle Input Axis of Clutch离合器中间输入轴

second gear output gear

二档输出齿轮

second gear Pressure plate

二档受压盘




Input Level I and Level II Gear 输入一二级齿轮


液力变矩器


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



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

行星式变速箱 - 变矩器供油路线

1. Overall route for oil supply 总供油路线：

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

发动机飞轮→变矩器泵轮→泵轮上分动齿轮和变速泵轴齿轮→驱动变速泵从油底壳吸油

→泵出压力油→滤油器（滤清器滤芯阻塞时，旁通阀打开）→进入变速操纵阀



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.

路线 1 ：经减压阀（ P ＝ 1.08 ～ 1.47MPa ）进入变速操纵油路，并根据

变速阀杆的不同位置进人各档油缸，完成不同档位的工作。variable operational

Valve

变速操纵阀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).

路线 2 ：进入变矩器的工作腔（变速箱档位供满油后，才开始向变

矩器供油）。



2.Oil Supply Route for Reverse Gear 倒档供油路线

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

变速阀的调压阀 → 切断阀 → 调速阀倒档位置油口 10 和 14 → 倒档油缸进油孔

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 一档供油路线

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

变速阀的调压阀 → 切断阀 → 调速阀一档位置油口 7 和 15 → 一档油缸进油孔

Fuel Feed hole of oil cylinder in First gear

Re v

erse

gea

r ne

u tra

l pos

itio

n

Fir

st g

e ar

Sec

ond

gea

r



46 23/4/22

4. Second gear Oil Supply Route 二档供油路线

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

变速阀的调压阀 → 切断阀 → 调速阀二档位置油口 8 和 9 → 二档油缸进油孔

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



Content 目录







Name of common tools通用工具名称

Specification规格

Quantity数量

Parts used所用部位

Gas trigger 气扳机 LB10 、 LB16 、 LB20

1 group1组

Choose different specification based on the diverse size of the assembled bolts根据装配螺栓大小的不同选取不同规格

Sleeve套筒

10 、 13 、 14 、 15 、 16 、 18 、 21 、 24 、 41

1 group1组


Dial test indicator 百分表

0.01/0 ～ 30.01/0 ～ 5

2Bounce of the assemble plane of line axle and pump in variable speed pump变速泵驱动轴与泵装配平面的跳动

Solid wrench 呆扳手

13×16 、 18×21 、 22×24

1 group1组


Copper bar 铜棒 1

Slightly hit with the part assembled with interference装配有过盈量零部件时，用其轻击即可

I ） Dismounting Process of C&T System 双变的拆卸过程 1.Dismounting devices and instruments 拆装工具及仪表

IV.Key Points of Dismounting of C&T System 双变系统的拆装要点


Name of common tools通用工具名称

Specification规格

Quantity数量

Parts used所用部位

Depth vernier gauge深度游标卡尺 0.02/0 ～ 200 1

Sub assemble of torque converter; install and input Level I gear assembly ,assemble friction linking , middle cap, variable speed pump end cap变矩器部装、装输入一级齿轮总成、装摩擦片、中盖、变速泵、端盖

Leveling ruler平尺 1

Subassembly and variable speed pump of torque converter变矩器部装、变速泵

Name of special tools专用工具名称

Specification规格

Quantity数量

The parts used Serial number of the corresponding network chart or name of assembly

所用部位（对应网络图序号或总成件名）

Mount support of gear box变速箱装配支架

its own dismounting platform

自备拆卸平台1

Increase convenience and security when dismounting C&T system双变拆装时增加便利性和安全性

Retainer pliers for shaft (hole)轴用（孔用）挡圈钳 200 、 300 1

when check ring is installed装挡圈时

Lifting bolt 吊装螺栓 M10 、 M14 、 M16 、 M18

1 8 、 29 、 31

I ） Dismounting Process of C&T System 双变的拆卸过程 1.Dismounting devices and instruments 拆装工具及仪表



2.Dismounting Process of Gear Box-1 变速箱拆装过程 -1



Dismounting Process of Gear Box-2 变速箱拆装过程 -2



3. Dismounting Process of Torque Converter-1 变矩器的拆卸过程 -1

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

互动问题：上图红圈内是什么阀？压力多少？起什么作用？



Dismounting Process of Torque Converter -2 变矩器的拆卸过程 -2

Interactive question ： what is valve in the following circle in red? What is the pressure? What role does it play? 互动问题：下图红圈内是什么阀？压力多少？起什么作用？




Interactive question: How many types of the

rotating oil seal on the idler pulley? What

failure will be caused if damaged or frayed?

互动问题：导轮座上的旋转油封有哪几种形式？如果磨损或损坏出现什么故障？




Dismounting process of level I and level II turbine group 一二级涡轮拆装过程




Dismounting process of level I and level II turbine group 一二级涡轮拆卸过程：

Interactive question: What failure will be caused respectively if

bearings behind cap of level II and level I turbine are damaged?

互动问题：二级涡轮和一级涡轮罩后面的轴承如果损坏，分别会

出现什么故障？



4.Dismounting Process of Overrun Clutch-1 超越离合器的拆卸过程 -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.

新结构的超越取消了隔离环、滚柱由 24 变为 20粒，上部加挡板。



Dismounting Process of Overrun Clutch -2 超越离合器的拆卸过程 -2



5.Dismounting of Second gear Assembly-1 二档总成的拆卸过程 -1

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

互动问题：上图红圈内的蝶形弹簧起什么作用？



Dismounting of Second gear Assembly-2 二档总成的拆卸过程 -2

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

互动问题：二档活塞为什么有三个定位销？销孔透了出现什么故障？



6.Dismounting of first gear Assembly-1 一档总成的拆卸过程



Dismounting of First gear Assembly-2 一档总成的拆卸



Dismounting of First gear Assembly-3 一档总成的拆卸 -3



7.Dismounting of Transmission control Valve -1 变速阀的拆卸过程 -1

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

互动问题：双弹簧结构的变速阀调压阀，如何调整压力？



Dismounting of Transmission control Valve -2 变速阀的拆卸过程 -2



Dismounting of Transmission Control Valve -3 变速阀的拆卸过程 -3



Dismounting of Transmission Control Valve -4 变速阀的拆卸过程 -4



Serial序号

Parts部位

Tightening Torque拧紧力矩

1Bolt and nut which can connect the input shaft and inner ring cam in overrun clutch超越离合器内连接输入轴与内环凸轮螺栓螺母

50±10 Nm

2Terminal pad of direct gear and connecting bolt of gear I planet carrier直接档连接盘与一档行星架连接螺栓 75±10 Nm

3 Connecting bolt of variable speed pump 变速泵连接螺栓 52±7 Nm

4 Connecting bolt of middle cap 中盖连接螺栓 145±20Nm

5 Connecting bolt of speed change valve 变速阀连接螺栓 52±7Nm

6 Bolt that can connect end cap and box 连接端盖与箱体的螺栓 52±7Nm

7 C&T connecting bolt 双变连接螺栓 52±7Nm

II ） The Key Moment and Interval in C&T Assembly 双变装配中的重要力矩和间隙

1.Moment List for Screw Thread of Parts in Gear Box force 变速箱部位螺纹紧固力矩表



2.List for Fit Clearance of the Key Parts in C&T Assemble 双变重要部位配合间隙一览表

Serial 序号

Parts部位

Fit Clearance配合间隙

Link链接

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)输入二级齿轮轴端与变矩器二级涡轮挡圈（导轮座孔内）之间的间隙

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？）变速箱输入一二级齿轮之间的 5111 轴承轴向间隙（互动问题：何处加调整垫？）　

0.3-0.7mm 　

3　 Verticality between shaft gear assembly and joint surface of variable speed pump 　轴齿轮总成对变速泵结合面的垂直度

Less than0.08 mm

小于 0.08mm　

4　 Clearance between friction linking of reverse gear and isolator　倒档摩擦片到隔离架的间隙　 0.9-2.8mm 　

5　 Clearance between first gear friction linking and first gearoil cylinder plunger 一档摩擦片与一档油缸活塞间隙 1.8-4.6mm 　

6　 Clearance between first gear oil cylinder plunger and middle cap一档油缸总成与中盖之间的间隙 0.1-0.3mm 　

7 　Fit Clearance between bear bore of end cap and Second gear upper bearing 端盖轴承孔与二档上部轴承的配合间隙

0.3-1mm 　



Types of Parts零部件种类

Inspection Item

检验项目

Standard for Judgment 判断标准Measures

for waterproof超差措施

Size(Allowance)

尺寸（公差）Tolerance Limit

允许极限

Bearing 轴承

Allowance of Internal Diameter内径公差

About 约 0 ～－0.02

+0.02Change更换Allowance of External Diameter

外径公差About 约 0 ～－

0.02－ 0.04

Driven Slice of Direct gear 直接档从动片 Thickness 厚度 3±0.05 2.5Change更换

Driving Slice of Direct gear 直接档主动片 Thickness 厚度 3.85±0.053.2 （ Unilateral Wear Limit0.

4 ）32 （单边磨损极限 0.4 ）

Change更换

Driven Slice of Reverse gear with first gear倒档一档从动片 Thickness 厚度 3±0.05 2.5

Change更换

Driving Slice of Reverse gear with first gear倒档一档主动片 Thickness 厚度 3.85±0.05

3.2 （ Unilateral Wear Limit0.4 ）

32 （单边磨损极限 0.4 ）Change更换

Plunger of Direct gear 直接档活塞

External Diameter 外径 φ248 － 0.285 ～－ 0.170 － 0.40 Change更换Internal Diameter 内径 φ70 0.174 ～ 0.10 +0.30

Plunger of Reverse gear 倒档活塞

External Diameter 外径 φ342 0 ～－ 0.089 － 0.20 Change更换Internal Diameter 内径 φ170 0.145 ～ 0.208 +0.30

First gear Plunger一档活塞

External Diameter 外径 φ342 － 0.24 ～－ 0.15 － 0.35 Change更换Internal Diameter 内径 φ235 0.17 ～ 0.242 +0.35

3.Change Standard for Quick-wear Part 易损件更换标准



To oil suction pipe of variable speed pump至变速泵吸油管

To oil cooler至油冷却器

To transmission shaft back and forth

至变速箱前后传动轴

To engine flywheel至发动机飞轮

To oil temperature sensor至油温传感器

To oil return pipe of torque converter至变矩器回油管

To working pump至工作泵

To Filter of Torque oil至变矩油滤清器

III ） Assemble Relationship of Bivariant System in Complete Machine 双变在整机中的装配关系



Content 目录







I) Failure Related to Oil Temperature of torque 和变矩油温有关的故障：

1.Identification Standard for High Oil Temperature 油温高的鉴别标准 :

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.℃

若发动机工作正常，变矩器油温在 65℃以上才允许工作，最佳温度为 85 － 95℃，当变矩

器的油温超过 120℃，视为变矩器油温过高。

V. Typical Failure Analysis 典型故障分析


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

检查变速箱油位是否过低或过高

Check whether the quality of hydrodynamic transmission is poor or deteriorated

检查液力传动油质量差或变质

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

检查变速箱内的吸油滤网是否堵塞

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 检查变速压力是否过低 (0.88MPa 以下），导致摩擦片打滑发热。

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

水箱散热片叶片之间油泥过多导致散热不良

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

变矩器油冷却器散热不良（堵塞或水垢过多）

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

检查变速箱大超越离合器是否损坏

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

检查变矩器涡轮组是否损坏

2. Analysis on Failure for High Oil Temperature 油温高的故障分析：



II ） Failure Related to Variable Speed pressure 和变速压力有关的故

障

1.Low Pressure for Speed Change

变速压力低

≤0.88Mpa

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

adjusting spring of speed change valve

各档均低 ---- 变速泵偏磨或变速阀调压弹簧失效

Some gears

are low

某个档低

First gear

is low

一档低

Seal ring of oil supply hole of first gear oil cylinder is damaged

一档油缸进油孔密封圈损坏

There is abscess in First gear oil cylinder 一档油缸有砂眼

Variable speed valve pad in First gear oil duct is damaged

一档油道处的变速阀垫损坏

There is abscess in in First gear oil duct of box

箱体上一档油道处有砂眼

Reverse gear is

low

倒档低

There is abscess in oil cylinder of reverse gear, or which is damaged. 倒档油缸砂眼或破裂Variable speed valve pad in First gear oil duct is damaged

一档油道处的变速阀垫损坏There is abscess in gear oil duct of box

箱体上倒档油道处有砂眼

Second gear is

low

二档低

Seal ring of Second gear oil duct at end cap is damaged

端盖处二档油道密封圈损坏Variable speed valve pad in Second gear oil duct is damaged

二档油道处的变速阀垫损坏Hole of Second gear plunger guide pin is penetrated in

二档活塞导向销孔钻透



Failure Related to Variable Speed Pressure (Cont’d) 和变速压力有关的故障

(续）2.High variable speed

pressure 变速压力高

＞ 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.

各档均高且越加油越高 ---- 变矩器主进油道堵塞

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

(spring) or the valve spool is stuck

各档均高 ---- 变速阀调压过高（弹簧）或调压阀芯卡死

main oil taking duct 主进油道 spring for pressure adjustment 调压弹簧



III ） Failure Related to Sealing 和密封有关的故障

Failure of

sealing parts

密封件故障

Aging and losing

effectiveness

老化、失效

Aging of piston packing ring at gears---waiting for gears

档位活塞密封环老化 --- 等档

Sealing gasket loses its effectiveness----Oil leak outside

密封垫片失效 ---- 外漏油

sealing failure of pump impeller and cap wheel---No running capacity working with heavy load

泵轮与罩轮密封失效 ---重负荷作业行走无力

Neglected loading,

being frayed

漏装、磨损

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

档位油道密封圈 ---- 各档无压力或压力低

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

to engine, with black smoke when motor is started

分动齿轮旋转油封 --- 变矩器向发动机窜油；启动马达冒黑烟

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

输入二级齿轮旋转油封漏装 --- 起步滞后

Neglected loading of variable speed valve pad---no pressure at each gear

变速阀阀垫漏装 --- 各档无压力



IV) Failure related to Fit Clearance 和配合间隙有关的故障

Clearance

is too

narrow

间隙过小

Face of torque converter and mould assembling of gear box---5111thrust bearing is damaged from burn

变矩器与变速箱合箱面 ---5111止推轴承烧死损坏

Friction lining of reverse gear and isolator----the process of plunger is to short ， which cannot be isolated clearly

by reverse gear

倒档摩擦片与隔离架 ----活塞行程过短，倒档分离不清

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

一档摩擦片与一档油缸活塞 ---活塞行程过短，一档分离不清

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

输入二级齿轮与二级涡轮挡圈 ---顶断挡圈，二级涡轮轴向窜动损坏

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

一档油缸与中盖 --- 中盖压不紧，压力油外泄，一倒档压力低

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

端盖与箱体端面 ---烧坏二档上面的轴承



V) Failure Caused by Damaged Drive Elements 驱动元件损坏的故障

Drive

elements

驱动元件

Spline shaft of the steering pump is broken- --- there is no steering when the machine is started

转向泵花键轴断 ---启动机器后，无转向Overrun middle input shaft is broken- ---The machine cannot work at each gear when the

machine is started 超越中间输入轴端 ----启动机器后，各档不能行走

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

直接档联接盘固定螺栓断 --- 压力正常，无一倒档，只有二档

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

machine is started 工作泵花键轴断 ---启动机器后，动臂、铲斗不能动作

Spline out of the sun gear is damaged---there is pressure for speed change ， but the machine

cannot work at each gear 太阳轮外花键损坏 --- 有变速压力，各档不能行走

The elastic plate is torn--- there is no pressure for speed change ， and the machine cannot

work at each gear 弹性板撕裂 --- 无变速压力，各档不能行走



VI ） Cases about Special Failure 特殊故障案例

Case I 案例 1

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.

故障现象：不加油挂档后车辆缓慢行走，一加油反而不走。

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;

变矩油滤清器管路或变速泵吸油管老化，内部起皮，不加油时自然状态，管路堵塞较轻，加油时被吸起来堵住管路；

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

gunned. 管路内掉入硬币，加油时吸起来堵住管路。



Cases about Special Failure (Cont’d) 特殊故障案例（续）

Case 2 案例 2

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

故障现象：热车时，重负荷作业行走无力。

Analysis 分析：

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;

超越离合器的滚柱磨损，热车时打滑，锲合不住，内外环齿轮不能同时同向旋转；

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.

变矩器泵轮有细小的裂纹或砂眼，热车时变矩油泄露，造成驱动力不足。




Case3 案例 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.

故障现象：启动机器后变速压力正常，但加油门时各档位压力激增，大大超过正常压力。

Analysis 分析：

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.

变矩器主进油道堵塞（溢流阀附近），造成变矩油供满各档位后，进不到变矩器内。以前变矩器进厂时，该主油道有一个白色的塑料堵头，在装配时如果忘记拿下，就回出现上述故障。




Case 4 案例 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.

故障现象：严寒地区，司机忘记防水，将变矩油冷却器冻坏。更换损坏件及防冻液后，第二天司机启动机器时，变速泵异响严重，无变速压力。

Analysis 分析：

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.

冻坏变矩油冷却器后，水随着油进入变速箱。经过一夜的停放，水沉淀到变速箱油底壳（水的比重大于变矩油），连同变速泵吸油管一起被冻结。因此，早上启动机器时，吸不上油。



The EndThe EndThe EndThe End


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

互动问题：变矩油正常温度范围是多少？

60-120 degree

Senor for oil temperature of torque converter

Chained File 链接文件


Interactive questions互动问题：

1 ） Please describe the common skills and methods for connecting elastic plate of torque converter and engine flywheel 请描述一下变矩器弹性板与发动机飞轮联接时常用的技巧方法 ;

2 ） How to efficiently pick up foreign matters which fall down from the peep door of the engine flywheel? 如果从发动机飞轮观察孔掉入异物，你有什么好办法取出来？



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.

散热原理：进油口温度高于出口，水泵将高温的水吸到水箱进行散热。Interactive questions互动问题：1 ） What kind of failure will be caused if intake and output oil pipes of torque oil cooler are blocked?

变矩油冷却器的进出油管堵塞会出现什么故障？2 ） What kind of failure will be caused if torque oil cooler is frozen or has abscess?

变矩油冷却器冻坏或有砂眼会出现哪些故障？

water landing pump 接水泵

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



Interactive questions 互动问题：

1 ） What kind of failure will be caused if

oil sucking screen of gear box is blocked?

变速箱吸油滤网堵塞，会出现哪些故障？

2 ） What is the standard to check the oil

in gear box?

检查变速箱油的标准是什么？


：

1 ）

2 ）


Interactive questions互动问题：

1 ） Why is there oil in this oil pipe？该油管内为何有油？

2 ） What role does the oil pipe play？该油管起什么作用？

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?

发动机运转时，变矩器回油管的油过多（超过油管的 1/2 ），会出现什么故障？

Oil return pipe of torque converter

Oil return pipe of torque converter



Interactive question ： Which parts should be checked for failure when the front and back

transmission shafts of gear box are disconnected?

互动问题：断开变速箱的前后传动轴，通常是检查哪个部件的故障？



Interactive questions互动问题：1 ） Please describe the trend of torque oil when flowing through filter.

描述一下变矩油经滤清器的走向 .

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

filter and pipeline are blocked?

变矩油滤清器滤芯堵塞和管路堵塞时，分别会出现什么故障？

1

2

3



Interactive questions互动问题：1 ） How to check working pump or steering pump if oil in the hydraulic oil tank is

sucked into gear box?

液压油箱的油串到变速箱，如何检查工作泵或转向泵？2 ） How to determine whether the working pump is damaged or not?

如果判断工作泵是否损坏？3 ） What kind of failure will be if the spline shaft of working pump is broken?

如果工作泵花键轴断了，会出现什么故障？



Level II turbine

Level II input gear

Magnified

Bearings

Adjustable gasket

Check ring


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

轴齿轮对泵体面的跳动应小于 0.08mm.


training for torque converter & gear box system of wheel loader

Documents