Training course for LG933L

Chapter 3 Torque converter & gearbox

Chapter 3 Torque converter & gearbox

Section 1 Overview of C&T

Section 4 Guidelines for assembly

and operation

Section 2 Torque converter

Overview
Structure
Operating principle
Oil-way

Section 5 Maintenance for gearbox

Section 6 Common faults and
troubleshooting

Section 3 Gearbox

Overview
BYD4208 gearbox
Structure

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Section 1 Overview of C&T

All parts(including torque converter,

gearbox, drive shaft) between power
device(engine) and drive device(axle)
of construction equipment are called
drive system.

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Section 2 Torque converter

1.Overview
LG933L adopts YJ315LGYJ315LG-1 hydraulic
torque converter.

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Section 2 Torque converter

2.Structure
The basic hydraulic torque converter
is mainly composed of pump impeller
1, guide wheel 2 and turbine 3, and
the sealed annular working chamber
formed by said components is the
circulation passage of the working
fluid. The shape of the working
chamber within the cross section cut
by revolving axis (namely, the axial
surface) is called a circulation circle.
The circulation circle of the torque
converter forms to completely
symmetrical part by taking rotating
shaft as centre line. The largest
diameter of the portion passed by the
working fluid in the circulation circle
is called the effective diameter of the
circulation circle.

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Section 2 Torque converter

2.Torque converter operating

principle
During operation of the hydraulic
torque converter, the engine drives
the pump impeller to rotate, and the
torque of the engine is exerted to the
pump impeller. The working fluid in
the pump impeller is driven to rotate
by the blades of the pump impeller
during rotation. The fluid performs
circular motion around the axis of
circular motion (called transport
motion) while executes relative
motion from the inner edge of the
blade to the outer edge thereof along
the passage among the blades, and
combination of the two motions forms
absolute motion; meanwhile, the
pressure on the outer edge of the
pump impeller is higher and on the
inner edge is lower, the difference of
which depends on the radius and
rotation speed of the pump impeller.

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Section 2 Torque converter

The working fluid bears the effect of

blades of pump impeller and gains
certain kinetic energy and pressure
energy when departing the pump
impeller so as to convert the
generated mechanical energy into
fluid energy of working fluid (kinetic
energy and pressure energy).
he high-speed oil flow from the pump
impeller enters the turbine 3 through
a blade-free area from by housing
wheel and impacts the turbine blades
to rotate the turbine and enable the
turbine shaft to obtain certain torque
for overcoming the external
resistance and starting work .

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Section 2 Torque converter

While changing the momentum

moment of the fluid, the guide wheel
further changes the energy form of
the fluid, namely, the transition from
the pressure energy of the fluid into
the kinetic energy thereof, or the
converse transition. Generally
speaking, it changes the pressure
energy of the fluid into kinetic energy.

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Section 2 Torque converter

Power from torque converter is

transmitted to gearbox through drive
shaft.

1-drive shaft

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Section 2 Torque converter

4.Oil
4.Oil
way
oil
oil--way structure of speedspeed-control
pump

1-temperature sensor
2-inlet oil pipe of radiator for drive oil

3-inlet oil pipe of speed

speed--control pump
6
4-oil filter
5-pipe between pump and filter
4
6-speed
speed--control pump
5

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Section 2 Torque converter

4.Oil
4.Oil
way
oil
oil--way structure of working pump

1-inlet oil pipe of torque

converter(belonging to oiloil-way
structure of speedspeed-control pump)
2-working pump
3-inlet oil pipe of working pump
4-outlet oil pipe of working pump

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Section 3 Gearbox

1.Overview
A. Function of gearbox
. reduce the speed and increase
the torque
torque
. Make the loader have a good
self--adaptability
self
adaptability

.realize neutral, make it easy to

start and stop when engine is
working
working

.working with torque converter, and

enlarge the range of output power
and speed
speed
. Enable loader backward
movement .

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Section 3 Gearbox

B. Classification of gearbox
According to Control Mode:
. Power Shifting Gearbox
. Manual Shift Gearbox
.Auto shift gearbox.

Power Shifting Gearbox conclude

conclude
. AxisAxis-fixed Gearbox
. Planetary Gearbox

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Section 3 Gearbox

2.BYD4208 gearbox
AType
BYD4208 is AxisAxis-fixed, constant
mesh, hydraulic or shift fork gearbox.
B.Feature
Simple and compact structure,
Reliable work, convenient operation,
high transmission efficiency and long
serve life.

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Section 3 Gearbox
9
3.Structure
1
Main structure of BYD4208 as
following
following

1-reverse shaft assembly

2-input shaft assembly

8
2

3-middle shaft assembly

4-output shaft assembly
5-shift fork shaft

7
3

6-shift fork
7-clutch of gear II
8-clutch of gear I
4
9-clutch of reverse gear

5
6

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Section 3 Gearbox

Aclutch

15

structure
All clutch of this gearbox are same
basically as shown in right figure:
1-shaft

2-shell

3-piston

4-driving disc

5-driven disc
7-ball

13

6-spring

12

8-oil channel

9-driven gear

10--seal ring
10

11--piston ring 1211

12- valve plate
13--oil port for lubricating oil
13
bearing

1414-

14

15--driving gear
15

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Section 3 Gearbox

working principle

15

When no pressure oil flows into

cylinder, there is a small space
between driven disc and driving disc,
so all disc keep their state of motion;
when pressure oil flows into the

13

cylinder of clutch, the piston is

12

pushed left to make all discs hug

tightly and rotate in the state of
driving disc; when the pressure oil is
cut off, the piston return at the action

14

of the springs, and meanwhile

release all discs.

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Section 3 Gearbox

Clutch assembly of gear I

Clutch assembly of gear I is fixed on
input shaft.

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Section 3 Gearbox

Clutch assembly of gear II

Clutch assembly of gear II is fixed on
the middle shaft.
shaft.

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Section 3 Gearbox

Clutch assembly of reverse gear

Clutch assembly of reverse gear is
fixed in shaft of reverse gear.

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Section 3 Gearbox

B. The arrangement of all shaft

assembly in the gearbox

1-input shaft assembly

2-reverse gear shaft assembly

3-middle shaft assembly

4-output shaft assembly

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Section 3 Gearbox

C. Output shaft assembly

formation
1-rear output flange
2-rear cover of output shaft
3-P bearing
1

4-sliding bearing
5-high
high--speed output gear
6-sliding sleeve
7-output shaft
8-low
low--speed output gear

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Section 3 Gearbox

shifting fork mechanism assembly

1-shifting fork
2-paper spacer
3-shifting fork bracket
4-shifting fork shaft

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Section 3 Gearbox
1

operating principle
The sliding bearings 1 cause gear 2
and 4 move relative to the shaft 3.
Gear 2 and 4 have same modules as
gear in the shaft 3. and they can
mesh tightly with sliding sleeve 5.
Shifting fork 6 gets stuck in the
shifting fork groove in the sliding
sleeve.
There is a highhigh-low speed control rod,
and this rod control the shift fork 6
through the shaft 7 and make it can
move in a certain range.
7

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Section 3 Gearbox
1

When sliding sleeve meshes with

gears in the boss of the gear 2 and
gears in the shaft 3, the wheel loader
drives at high speed. When sliding
sleeve meshes with gears in the boss
of the gear4 and gear in the shaft 3,
the wheel loader drives at low speed.

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Section 3 Gearbox

Dtransmission line
forward gear I

Transmission line as following

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Section 3 Gearbox

forward gear II

Transmission line as following

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Section 3 Gearbox

forward gear III

Transmission line as following

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Section 3 Gearbox

forward gear IV

Transmission line as following

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Section 3 Gearbox

reverse gear I

Transmission line as following

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Section 3 Gearbox

reverse gear II

Transmission line as following

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Section 3 Gearbox

E. SpeedSpeed-control valve
Speed--control valve is the device
Speed
which controls the direction of
pressure oil and control the motion of
the clutch making the vehicle drive at
the speed and in the condition you
choose.

Formation

1-sealant
2-core of the speedspeed-control valve

3-valve body
4-paper washer
3
5-cutting valve
6-bottom plate
7-paper washer

8-gear positioning device

5

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Section 3 Gearbox

Arrangement of oil ports in the

speed--control valve
speed
Cavity A is links with oil inlet(oil inlet is
links with combined valve of torque
converter).
Cavity B links with oil passage of
speed--control valve
speed
Cavity D links to the clutch of gear I

C
F

CC

E
B

Cavity E links to the clutch of gear II

A
Cavity F links t the clutch of reverse
gear

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Section 3 Gearbox
D

C
F

CC

E
B

Cutting valve
valvespare
spare

A
When the brake pedal is pressed
down, brake pressure air presses the
valve core of the cutting valve move,
and cuts the passage between cavity
A and B, so the pressure oil cant
flow into speedspeed-control oil passage,
therefore there is no power output.

C
Clutch of gear I
Clutch of gear II

Clutch of reverse gear

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Section 3 Gearbox

Speed
Speed--control schematic diagram

1-filter
2-speed
speed--control valve
3-speed
speed--control pressure selective
valve
4-pressure limit valve of outlet
5-pressure limit valve of inlet
6-speed
speed--control valve
7-cutting valve

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Section 4 Guidelines for

assembly and operation

1. Notes for assembly

A. End cover of gear II cant change

with it of gear I of reverse gear.

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Section 4 Guidelines for

assembly and operation

B. Adjusting nut of clutch assembly

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Section 4 Guidelines for

assembly and operation

C. When assemble, you should

ensure the input shaft of gearbox and
output shaft of torque converter
coaxial, same as the output shaft of
gearbox and input shaft of front and
rear axle.

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Section 4 Guidelines for

assembly and operation

2. Notes for operation

operation
A. You should pay attention to the
pressure indictor of speedspeed-control oil
1.2
1.2--1.5MPa
1.5MPa
and lubrication oil
0.15
0.15--0.30MPa
0.30MPa at time, no
condition of exceeding the range is
permitted.
permitted

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Section 4 Guidelines for

assembly and operation

B. The speedspeed-control rod and even

the whole speedspeed-control mechanism
should be flexible, no binding is
permitted, position should be precise
when change gear.

Scheme 1
1high
high--low speedspeed-control
mechanism.
Scheme 2
2gear speedspeed-control
mechanism.
C. When the brake pedal is pressed
down, the vehicle mustnt drive even
in condition of strongest power of the
engine.

D. Hand brake mechanism should be

adjusted well to make sure its work
reliably.

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Section 5 Maintenance for gearbox

Change the drive oil at time of the first 50hours use, and change again at 500hours use,
from then on, change every 1000hours.

Clean the filter of drive oil at time of the first 50hours use, and from then on ,clean it every
500hours. Pay attention to that whether there is aluminum swarf,
swarf, copper swarf,
swarf, iron swarf
when change drive oil, so according to the result you can find whether C&T work well. If you
find copper swarf in the oil, you should check the gearbox, and if aluminum swarf,
swarf, check torque
converter.

Check whether the oil level is enough, whether there is abnormal noise in the gearbox,
whether the knots are loose, and whether there is leakage, check whether the temperature and
pressure of drive oil in the normal range.

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Section 6 Common faults and troubleshooting

1Failures
Failures
the oil pressure is low excessively even the pressure is zero.

fault judgment and troubleshooting:

lack for oil, pump sucks air.
air.add oil
oil
blockage in filter.
filter.clean or replace the filter
filter
failure of the pump. (replace the pump)
failure of the main pressure valve in adjuster valve.
valve.repair the speedspeed-control pressure valve
valve
leakage in speedspeed-control valve.
valve.check, repair)
leakage as result of failure of seal of clutch or gasket ring in the end of shaft where there is oil inlet port.
replace gasket ring
ring
miss of the ball of the oneone-way valve in the clutch.

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Section 6 Common faults and troubleshooting

2 Failures
Failures
oil pressure is high excessively

fault judgment and troubleshooting:

failure of main adjuster valve in pressure reducing valve.
valve.check or repair)
something outside enters oiloil-passage to make a blockage.(clean and rip it)
the oil is not fit(
fit(change the oil for standard oil)
oil)
failure of the sensor of the pressure oil

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Section 6 Common faults and troubleshooting

3 Failures
Failures
oil temperature is high excessively

fault judgment and troubleshooting:

blockage in radiator (clean the radiator
radiator
there is some water in oil.
oil.check the pipe and replace the oil)
lack for drive oil in the gearbox
gearboxadd oil
oil
the gear is not suitable when working.
working.choose low gear
gear
hand brake is locked and return bragging seriously.(adjust the brake)
the discs cant part absolutely or they hug together.(replace the discs)

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