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BMC www.Broad-Machinery.com BMC Training Presentation.

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Presentation on theme: "BMC www.Broad-Machinery.com BMC Training Presentation."— Presentation transcript:

1

2 BMC BMC Training Presentation

3 BMC BMC Bulldozer Hydraulic System

4 BMC BMC CONTENTS Hydraulic System Principles Hydraulic System Principles Hydraulic System Assembly Hydraulic System Assembly Malfunctions Analysis and Solving Malfunctions Analysis and Solving Pressure Measurement to Diagnose hydraulic system Pressure Measurement to Diagnose hydraulic system

5 BMC BMC Chapter One Hydraulic System Principles

6 BMC BMC Hydraulic Components: Input: Pumps Output: Cylinders, Motors Controls: Valves Ancillary Equipment: Oil tank, Piping, Filters, Oil Cooler Hydraulic System Principles

7 BMC BMC Transmission & Steering Hydraulics SD22 & SD32 Hydraulic System: Transmission and steering control systems are separated to each other, they draw oil from different pumps, but all the oil is from steering clutch case. The oil flows to the torque converter after transmission and steering, then the oil flows back to steering clutch case. So, the transmission and steering are one system called transmission & steering hydraulic system.

8 BMC BMC SD22 Hydraulic System

9 BMC BMC SD16 Hydraulic System: Transmission and Steering control systems draw oil from Transmission case and Steering clutch Case. Oil flows to torque converter after transmission, then to transmission pan again through oil cooler. However steering clutch oil flows back to steering clutch case. So, the transmission and steering are two different systems. Transmission & Steering Hydraulic System

10 BMC BMC SD16 Transmission System

11 BMC BMC SD16 Steering and Brake System

12 BMC BMC Chapter Two Hydraulic System Assembly

13 BMC BMC Gear Pump: Bulldozer Transmission & Steering Pumps are high pressure gear pumps. Their construction is simple and very efficient. Transmission Valve: SD22, SD32 have the same transmission valve unit. It is consists of Relief Valve, Return Valve, Pressure Reduction Valve, Speed Control Valve, Safety Valve and Direction Valve. Relief Valve & Return Valve are for transmission oil pressure, Speed Control Valve is for shift change, Direction Valve is for Forward and Reverse, Pressure Reduction Valve is for First Shift, Safety Valve is for protection of starting machine. Assembly & Operation

14 BMC BMC SD22, SD32 Transmission Valve

15 BMC BMC SD16 transmission valve has no Safety valve, but other 5 valves structure and principle are same as SD22 and SD32.

16 BMC BMC SD16 Transmission Valve From Pump To Torque Converter

17 BMC BMC Modulating Relief Valve: The modulating relief valve controls the buildup of oil pressure when the gear shift lever is operated and the clutch engaged, so as to avoid shock during start and off and improves the service life of power shift transmission. Modulating Time

18 BMC BMC Steering Valve SD32, SD23, SD22 and SD16 steering valves structure and principle are the same. Steering & brake hydraulic system includes relief valve, steering control valve, brake booster valve. they have a bypass/relief valve, to avoid abnormal oil pressure if the filter is clogged.

19 BMC BMC Steering Valve Steering Relief Valve

20 BMC BMC Work equipment control system

21 BMC BMC Relief Valve

22 BMC BMC

23 BMC Chapter Three Troubleshooting & Problem Solving

24 BMC BMC Hydraulic system problems are caused by many factors. The Process of identifying a problem: Watch Test Machine Check Pressure Resolving the problem: a. Refer to Operation or Shop Manual b. Carry out adjustments/fit replacement parts Methods of Troubleshooting

25 BMC BMC Transmission Problems Solving

26 BMC BMC Reason: a. Inner Transmission Box: 1. the gearshifts cylinder seal damaged or installed wrong 2. Oil path leak 3. if First Shift is inoperative: 1) Ball of anti return valve is broken 2) Oil path rotating seal ring is damaged b. Hydraulic system: 1. the 5 O-rings of clutch oil entrance in the seat of transmission valve are damaged 2. the factors of the pressure reduction valve: If the pressure reduction valve is blocked at closed position, 1st gearshift is inoperative; if the pressure reduction valve piston hole is blocked, the oil pressure will increase, leading to worn seals, the 1st gearshift is inoperative. 1. Gearshift inoperative 1. Gearshift inoperative

27 BMC BMC Reason: 1.Incorrect adjustment of the direction valve position 2.Forward and reverse clutch disc distorted or broken, it locked, the clutch cant separate completely. 2. The machine drives on Neutral Gearshift 2. The machine drives on Neutral Gearshift

28 BMC BMC Reason: The machine will not drive on any gearshift position, its because the clutch cant get oil. 1.Transmission pump damaged, it cant draw oil. 2.Transmission pump seal leak. 3.Transmission case oil level is down. 4.Oil piping leak, problem with pump. 5.Relief valve is blocked, 5 clutches have no oil pressure. 3. The machine will not drive 3. The machine will not drive

29 BMC BMC Reason: 1.the clutch cant get oil, suction piping leak. 2.Relief valves relief spring is broken, it delays the pressure increase in time. 4. Gearshift Lag 4. Gearshift Lag

30 BMC BMC 5. Hot machine no drive, but cold machine is normal. 5. Hot machine no drive, but cold machine is normal.Reason: The suction pipe is aging or worn or distorted, and the suction ability is not good. The oil is thin, clutch cant engage properly, so the hot machine has low power.

31 BMC BMC Reason: Relief valves blocked, the valve cant move correctly, the oil pressure is low and the clutch cant engage. 6. Transmission Torque Reduced 6. Transmission Torque Reduced

32 BMC BMC Reason: a.Torque converter problem: 1. return oil pump filter is blocked 2. the seal leaking b.Hydraulic system problem: 1. oil quality is not good 2. oil quantity is low, or oil leak 3. insufficient cooling. 7. Torque converter over heating 7. Torque converter over heating

33 BMC BMC Reason: Relief valves blocked or inlet blocked, the high pressure bulges the cover. Must clean the relief valve. 8. Steering filter cover bulged 8. Steering filter cover bulged

34 BMC BMC Reason: Pulling the steering lever to the end and the pressure normal, the reason is that steering lever is adjusted incorrectly. 9. Poor Steering Control 9. Poor Steering Control

35 BMC BMC Reason: 1.S tube o-ring is damaged 2.Clutch intake oil rotation seal is damaged 3.Clutch piston seal is damaged 10. One side no steering, another side is normal 10. One side no steering, another side is normal

36 BMC BMC Reason: 1.The tube between steering pump and filter is damaged, so oil cant pass through. 2.The oil becomes thin as the machine warms up, or the seal is worn, oil leak, oil pressure decrease. 11. Cold machine has steering, 11. Cold machine has steering, but hot machine has not steering but hot machine has not steering

37 BMC BMC Reason: This phenomenon shows that another side cant transfer power, maybe another side steering direction valve block at open position. 12. Pulling one steering lever, the machine will stop 12. Pulling one steering lever, the machine will stop

38 BMC BMC Reason: Steering suction oil system seal is damaged and steering pump cant get enough oil, the pressure is down. Due to steering pump drawing air, the oil filter has not oil, it leads transmission pump to draw air too. So sometimes transmission failure is caused by steering system damage. When the pump draws air, there are sharp whistle, and there are many air bubbles in oil. 13. Sometimes steering is intermittent 13. Sometimes steering is intermittent

39 BMC BMC Reason: a.Brake band is worn out, need adjustment or replacement b.Brake linkage are adjusted incorrectly c.Brake booster valve dont seal well 14. Braking is poor 14. Braking is poor

40 BMC BMC 15. Pushing force is poor Reason: a.Engine b.Torque Converter c.Transmission d.Steering Clutch

41 BMC BMC Check for the position of problem: a.If the universal joint rotates, the malfunction is after engine or torque converter. b.If the universal joint does not rotate, then the malfunction is before transmission or steering clutch. c.If bevel gear rotates, the problem is at steering clutch; if bevel gear does not rotate, the problem is at transmission. 15. Pushing force is poor 15. Pushing force is poor

42 BMC BMC Check for the Pressure: a.If the pressure is right, it must be that there is mechanical malfunction or inner failure. b.If the pressure isnt normal, we must diagnose, by referring to the manual. 15. Pushing force is poor

43 BMC BMC Chapter Four Pressure Measure for Diagnosis

44 BMC BMC 1. Important Measurements a. Oil brand, quality and grade are correct, steering case oil level correct b. Warm-up engine, ensure coolant and oil temperature are in o C c. Engine is at operating speed 2. Measurement Method Measure the oil pressure at engine full speed and idle speed. 3. Measure Points, Standard Pressure (theoretic data in manual) Pressure Measurement to Diagnose hydraulic problems

45 BMC BMC Examples for Diagnosing Pressure Measurements

46 BMC BMC 1.Machine will not move on selecting a gear Measure relief valve pressure: low is 0.1, full speed is 0.3MPa. Due to this low pressure, gear clutch cant get enough force, the machine cant move. Discharge the air in steering filter, the pressure raised, but once engine stops 10 minutes later start again, the pressure is low again. This means that air is in the pump, replace the O-ring, and the problem is solved.

47 BMC BMC 2. Speed is low in any gear Measure transmission relief valve pressure: low is 0.4MPa, full speed is 0.7MPa Due to this low pressure, discharge the air from filter, it is not helpful. Then check the return valve, then find the valve piston is blocked, the oil is leaking from output. Clean the valve piston, reset it again, the problem is solved.

48 BMC BMC 3. Power is down on the mid rpm Measure transmission relief valve pressure: low is 1.0MPa, full speed is 3.5MPa, the pressure changed too much with increased engine speed, it means that the relief valve need to be adjusted. After checking, finding the valve piston is blocked with many carbon and corrupted hollows. After cleaning valve piston, reset it again, the problem is solved.

49 BMC BMC 4. Torque converter power decrease Measure transmission and steering relief valve pressure: both are normal. Measure the entrance of torque converter, the oil pressure is 0.4MPa Check torque converter safety valve, if spring is broken, replace it, the problem is solved.

50 BMC BMC 5. If hydraulic oil temperature high, long term working, then the valve will block easily Measure transmission valve, the pressure is normal. Measure the entrance of torque converter, low speed pressure is 0.1MPa, full speed oil pressure is 0.5MPa. Due to the entrance pressure being low, the oil flow is low and cooling poor, so the temperature is high. Check torque converter, check the seal of inner oil path for damage, replace it, the problem is solved.

51 BMC BMC 6. No steering at low speed, but at increased engine rpm, the steering is ok. Measure steering relief valve pressure: low speed pressure is 0.4MPa, full speed oil pressure is 1.1MPa; And steering clutch oil pressure is low. At the same time the valve is faulty. It means that steering relief valve is the problem, check it, if the spring is broken, replace it, the problem is solved.

52 BMC BMC 7. Cold machine steering is normal, but after working, the steering is very heavy Measure steering relief valve pressure: low speed oil pressure is 0.5MPa, full speed oil pressure is 1.1MPa; Steering relief valve oil pressure is low, it is caused by a blockage of relief valve. Disassemble and clean it, the problem is solved.

53 BMC BMC 8. One side steering is not serviceable Steering relief valve pressure is normal, other side steering brake pressure is normal too, but this side steering brake pressure is low. It show this booster or its piping has a leak. Disassemble booster, check the piping entrance o-ring is damaged, replaced it, the problem is solved.

54 BMC BMC The End of This Training Module Thanks Your Cooperation !!! The End of This Training Module Thanks Your Cooperation !!!


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