Training Presentation

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Training Presentation
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BMC
UNDERCARRIAGE SYSTEM
Component Assembly
Operation Principles
Bulldozer Assembly
BMC
Power Take-off
Torque Converter
Universal Joint
Transmission Unit
Main Drive
Steering Clutch
Steering Brake
Final Drive
Track Equipment
Control System
Working Equipment
Cabin
Floor & Fender
Track Frame
Power Train
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Engine
Torque Converter
Universal Joint
Gear Box
Main Drive
Steering Clutch
Final Drive
Track System
Power Take-off
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Function:
PTO power
Equipment:
Work system pump
Transmission pump
Steering Pump
Torque Converter Assembly

Type:
3-element
1 stage
1 phase
Assembly: Pump,
Turbine and Stator
There are many
vanes on these
components for
using oil to transfer
power
BMC
These 3 components
combined with oil, give us
as smooth power
transmission.
Safety valve: fitted to oil
input, ensures the input
oil pressure is no more
than 0.87MPa.
Relief Valve: fitted on oil
output, ensures the oil
pressure inside the torque
converter is maintained
below 0.45MPa.
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Principles of Torque Converter
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Oil Flow: Pump Turbine

Stator pump
There is 2 mm clearance
between pump and
Turbine, and transfers
power by Oil. There is no
mechanical impact, they
protect each other
Assist hydraulic system: to
resist loss of oil; to
maintain the normal oil
temperature.
Operation of Torque Converter

When the load increases,
the dozer ground speed
is reduced, causing
turbine speed to slow
down. But at this time the
energy from the pump
transfer to torque
converter is not reduced.
This energy is still
transferring to the stator
through the slowing
turbine. Then the energy
to stator from turbine,
results in the turbine
gaining torque, then the
turbine output torque is
increasing.
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Torque Converter Operation
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1.Change torque
automatically
2.Absorb vibration,
prolong working life
3.Good power
transmission capability,
driving at slow speed
4.Simple operation
5. Start smoothly,
eliminates any shocks
in power train
6.Easy maintenance
BMC
High Torque Converter Oil Temperature
Normally, SD22 Torque Converter Temperature of

output oil is 115-120oC. For a short time, a higher
temperature of 130-135oC is allowed, but long term
high temperature shows there is something wrong,
for the following reasons:
1.Shortage of Oil
Torque converter, transmission, main drive, steering
and final drive will take 30% of engine rated power.
This power will transfer to heat energy, and increase
the oil temperature. Therefore it requires enough oil
to absorb this heat.
If the oil quantity is not sufficient, the oil temperature
will be too high.
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2.Oil Pressure of input and output are incorrect
If torque converter input oil pressure is not correct
(Standard: 0.87MPa) or the oil is dirty, the piston of
valve will stay at relief position, so the oil pressure to
the torque converter is low. This leads to a loss of
efficiency and excessive oil temperature.
If torque converter output oil pressure is not correct
(Standard: 0.45MPa) or the oil supply is blocked,
return oil temperature will be too high. The flow of oil
to oil cooler is reduced, and the oil temperature too
high
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3. Incorrect Operation
Excessive use of low engine speed for extended
time, torque converter will work at low efficiency.
Torque converter will lose power, and transfer heat
energy leading to high oil temperature.
Power Transmission Case
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The types of Transmission Case:

Base Operation type:
1.Manual Gearshift 2.Hydraulic booster 3.Powershift
Base Transmission type:
1.mechanical type; 2.Planetary Gear
Planetary type powershift transmission case type:
Planetary Gear, Multi-disc clutch, Hydraulic control, forced
lubrication.
Function:
1.Enable forward and reverse
2.Select different gear ratio
3.Matched with the torque converter, enables a wide
range of power output and ground speed
Planetary Gear System
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C
The system consists of:

A: Sun Gear
B: Planetary Gears
C: Ring Gear
D: Carrier
The planetary gears are

installed on the carrier being
in constant mesh with the
sun gear and the ring gear
Planetary Gear system
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Principle of Planetary Gear system

If the carrier is fixed, the
torque is transmitted from
sun gear to planetary
gear, and is transmitted
from planetary gear to
ring gear to make the ring
gear rotate. Rotation
direction of ring gear is
opposite from sun gear.
A: Sun Gear
B: Planetary Gear
C: Ring Gear
D: Carrier
Principle of Planetary Gear system
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If the ring gear is fixed, the

torque is transmitted from
sun gear to planetary gear.
The planetary gear rotates
by itself, at the same time
rotates around sun gear.
Rotation direction of the
planetary gear shaft is
opposite from sun gear.
It is a slowdown outfit that
power input from sun gear,
output from carrier
A: Sun Gear
B: Planetary Gear
C: Ring Gear
D: Carrier
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The above principles are structure principle of No.1,3,4

planetary gear system.
The sun gear is active in No.1 Planetary Gear system
The carrier is active in No.3 & 4 Planetary Gear system
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This is structure
and principle of
No.2 planetary
gear system.
The rotate
direction is
contrary with No.1
planetary gear
system.
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SD22 powershift transmission system
Consists of 4 planetary gear systems with 4

clutches, and 1 locking clutch (no planetary gear
system) and housing, input shaft, end gear and
output bevel gear.
No.1 clutch is for Forward Gear
No.2 clutch is for Reverse Gear
No.3 clutch is for 3rd Gear Shift
No.4 clutch is for 2nd Gear Shift
No.5 lock clutch is for 1st Gear Shift
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BMC
SD22 powershift transmission

system
The 4 planetary gear system clutchs washers and disc are the
same, but the disc quantity is different. Its design is based on
transmission torque.
The No. of Clutch
No.1
No.2
No.3
No.4
No.5
Washer Qty
3
2
1
1
2
Disc Qty
4
3
2
2
3
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No.1- 4 planetary gear
systems structure are
same, clutches washer and
disc are same, but the disc
quantity and piston is
different.
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Method of fixing of each planetary
gear is as this figure, it is actuated
by the clutch.
Engagement of clutch is actuated
by oil pressure from control valve
pushing piston 3.
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Disengagement of clutch is
actuated by return spring 33
which pushes piston 3 to
original position after oil
pressure is cut off.
The function of disc spring 42 is
to improve operating speed of
piston 3 and improve release
the discs.
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This figure is a drawing of No.5
locking clutch. When the clutch
disengages, oil in the cylinder
body 16 by the action of
centrifugal force. Disks cant
disengage quickly, only by disk
spring 29. This can make the
clutch half disengage. This will
cause difficulty for next gearshift.
In order to eliminate this problem,
the ball check valve 17 is
incorporated in the piston after
the rotary clutch.
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No.5 Clutch is a lock
clutch.
When this clutch engages,
pressure oil from
controlling valve enters
into oil cavity and pushes
piston 26, at the same
time, the oil pushes check
valve ball 17 to plug the
hole of valve. The clutch is
engaged quickly.
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No.5 Clutch is a lock
clutch.
When the pressure oil from
controlling valve is cut off,
by the action of centrifugal
force, ball 17 can move to
the direction of arrow in this
figure. At this time, the hole
of valve cage is opened
and the oil is drained off.
Forward 1st Speed
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Forward 2nd Speed
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Forward 3rd Speed
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Transmission Lubrication and

Cooling:
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Its a forced lubrication system, from above

and below, two ways divided through a
valve.
Transmission Case lubrication pressure is
0.124Mpa. Upper way lubricates the
second half bearing and cools the second
half discs; lower way lubricates the first
half bearing and cools first half discs.
Main Drive (SD22)

Assembly:
Bevel gears
Horizontal Shaft
Bearings
Sprocket Hub
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Functions:
Power train gear
reduction to
increase the final
drive torque
Steering Clutch
Function:
To disengage the shaft
drive and control
steering
Type:
Wet, multi-disc, spring
loaded, hydraulic
separated, normally
engaged.
Spring force
F=3.2 tons
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Steering Clutch Operation
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Steering Brake
Function:
The brake on the
outside of steering
clutchs outside drum,
reduced the rpm of the
final drive on that side.
Type:
Wet band, hydraulic
boosted control
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Steering Brake Operation
Forward
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Reverse
Steering Brake Control
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Linkage through valves
Steering Case Lubrication and

Breather
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There are 3 associated components, Main drive,

Steering Clutch and Steering Brake. They are
lubricated and cooled by the oil in steering case.
The oil level can be checked with oil dipstick
Steering case has a breather to balance inside
and outside pressures.
Final Drive
Final Drive: One Set
Final Drive on each
side.
2 stage spur gears
reduction. Floating
Seal and O-ring to
contain oil, then
connected outside
with breather.
Assembling
Sprocket hub and
gear requires 60
tons force with
special tools.
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Track System --- Walking Gear

Assembly:
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Track Frames
Track Rollers
Carrier Rollers
Recoil system
Track Shoes
Equalizer
Recoil system for Track
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Function:
1. Maintain track
tension
2 absorb the
vibration of idler
Note:
the fixed pressure
is 20.38 tons, it
requires special
fitting tools
Measurement of Track Tension
BMC
use a ruler placed on

the track grousers
between carrier roller
and idler, the measure
distance is C C=2030mm
SD32 track has more
wide, the distance is
bigger between carrier
roller and idler, the
measured distance is
C=30-40mm
Idler
Carrier roller
Idler
Function:
Gives guidance for
track chain and
maintains track tension
Lubrication
There are lub oil in the
cage that is sealed by
floating seal, between
idler and support
housing. The oil
capacity is 70%.
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To Adjust Idler Clearance
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If the clearance is over limit ,

the idler will swing, and track
links off centre and will wear
the sprocket.
If Clearance in one side
A 4mm,
it must be adjusted into
A=0.5-1mm
If Clearance of up and down
(B+C)5mm
it must be adjusted into
(B+C)=2mm
Track Roller
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First it carries dozer

weight, secondly it
prevent track chain
moving off centre of
track frame
Bushing and float seal
is similar to idler
Track Shoe
Assembly
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Supports all of the

dozer weight, and
determines the
ground pressure
Four high strength
bolts fix track shoe
onto track link,
bolt torque:
SD16:70kg.m
SD22:76kg.m
SD32:100kg.m
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Use and Maintenance of Track Shoe
Track supports 30 tons bulldozer weight, and if the working

conditions are bad, it will wear more quickly, so use and
maintain it correctly.
1. Often check the tension of track shoe. use a ruler put the track
grousers between carrier roller and idler, the measure is
C C=20-30mm; SD32 track is more weight, the distance is
more large between carrier roller and idler, the measure is
C=30-40mm
When the work is hard, the track shoe assy will need to be
adjust tighter; if the work is moderate , the track shoe assy
tension can be adjusted back.
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Use and Maintenance of Track Shoe
2. The sprocket segments need be replaced when the sprocket

segments wear under the limit.
3. Dont drive dozer hard and avoid track damage and excessive wear.
4. If there is excessive track play and noise, you must stop and check
tracks and machine.
5. When the dozer across the railway line, you must drive it across the
railway at right angle, and dont change speed, dont stop and
reverse, avoid track shoes locking in railway line.
7. After working, you must check tracks, and if there is something
wrong. If there is something wrong, must repair or replace.
End of this Training

Module
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Thanks Your Cooperation !!!

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BMC

Torque Converter Assembly

Principles of Torque Converter

Oil Flow: Pump Turbine

Operation of Torque Converter

Torque Converter Operation

High Torque Converter Oil Temperature

Normally, SD22 Torque Converter Temperature of

Power Transmission Case

The types of Transmission Case:

Planetary Gear System

The system consists of:

The planetary gears are

Planetary Gear system

Principle of Planetary Gear system

Principle of Planetary Gear system

If the ring gear is fixed, the

The above principles are structure principle of No.1,3,4

SD22 powershift transmission system

Consists of 4 planetary gear systems with 4

SD22 powershift transmission

Forward 1st Speed

Forward 2nd Speed

Forward 3rd Speed

Transmission Lubrication and

Its a forced lubrication system, from above

Main Drive (SD22)

Steering Clutch Operation

Steering Brake Operation

Steering Brake Control

Linkage through valves

Steering Case Lubrication and

There are 3 associated components, Main drive,

Track System --- Walking Gear

Recoil system for Track

Measurement of Track Tension

use a ruler placed on

To Adjust Idler Clearance

If the clearance is over limit ,

First it carries dozer

Supports all of the

Use and Maintenance of Track Shoe

Track supports 30 tons bulldozer weight, and if the working

Use and Maintenance of Track Shoe

2. The sprocket segments need be replaced when the sprocket

End of this Training

Thanks Your Cooperation !!!

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