The BS305 Transmission

—— Basic training
Description
标题 of power train.
 power
标题 transmission system diagram (BS305)

Transmission
（BS305）

Torque
converter

Rear
axle Front
axle
标题
Outline
1、The brief introductions of transmission
2、Torque converter
3、Transmission
4、Judge and solve fault
1、The brief introduction
of transmission
BS-305
标题 transmission system introduce

Power shift transmission:

 On the go speed and direction changes.
 Hydraulic modulation assures smooth,
cushioned shifting
 Clutch plates and gears continuously oil-
cooled for dependable performance, long
gear life.
BS305
标题 transmission diagram

Torque
converter

Transmission
 标题

 一、product feature：
 The wheel loader is equipped with a double-turbine hydraulic torque
converter installed between the engine and the transmission for
transmitting power, Which has the following advantages.
 The torque converter can automatically change the output torque and
speed of the transmission
 According to load the wheel loader can automatically change speed
 The high torque conversion ratio and the high efficiency over the wide
range of the converter
 Since power is transmitted by hydraulic oil, there is no shock or impact
between engine and transmission.
 Even if the load was increase suddenly of over load, the engine will not
flameout.
 Relieving the driver’s labor intensity and improving the comfortability of
the loader.
2、the brief introduction of converter
The
标题 history of the torque converter

 People begun to research torque converter in the early 20th

century.
 In 1912, torque converter was firstly applied in the power
transmission of the ship and then was widely used in many field,
military vehicle、internal-combustion locomotive、high car、
truck、bus etc.
 Although applying in the construction machine was later than
other machine, torque converter was quickly applied in the
construction machine. Torque converters were widely applied in
the construction, Wheel loader、Grader etc.
 The
标题 feature of the torque converter

Why torque converter was widely applied in the construction

machines?
1、The vehicle has a good performance of the automatic adaptation
The engine cannot be stalled even by sudden increasing of external
load, Thus the oil pumps will work continuously and this ensures safe
and reliable operation of the loader.
2、Improve the service life of vehicles 。
Since power is transmitted by hydraulic oil , there is no shock or
impact between engine and transmission.
3、Improve the passage performance of vehicle
4、Improving the comfortability of the loader
The disadvantage of torque converter
1、Inefficient （75%～83%）；
2、when the wheel loader is hauled and the pump doesn't work, there is
no steering (except installing emergency pump)
The
标题 basic conception of the torque converter

Rations i＝nT／nB （the speed rations of the turbine and pump）

Rations K＝MT／MB （the torque rations of the turbine and pump）
Efficiencyη＝K×i= output power/input power
Nominal moment Mbg＝MB／(nB／1000)2
Three elements （single turbine）converter：pump B、
turbine T、idler pulley D
Four elements （double turbine）converter：pump B、turbine
T1&T2、idler pulley D
 The
标题
basic structure of two common torque converter

一、Four elements double

turbine converter
1 — Diesel engine flywheel
2 — Converter
B — Pump wheel
D — Stator (Reaction member)
T1 —Turbine Ⅰ
T2 —Turbine Ⅱ
3 — Overrunning clutch
Z1 — input first stage gear
Z2 — outer gear
Z3 — input second gear
Z4 — intermediate input shaft
By using overrunning clutch, the
output power of the dual turbine
can be automatically adjusted
 Double
标题 turbine torque converter

Dual Ⅱturbine
Ⅰturbine
turbine

The route of power transmission：

Diesel engine flywheel → plate→sleeve→ pump wheel B→ liquid
→Ⅰturbine→turbine cover→turbine hub→Ⅰstage gear
idler gear →liquid→ Ⅱturbine→bear→ Ⅱstage gear cam clutch
 Joint
标题 of the torque converter

1 — temperature gauge joint

the max outlet pressure of the
converter is 0.45Mpa，oil
temperature is 70～95℃（winter）
and 90～110℃（summer）。
2 — joint （to oil cooler）。
3 — plug
4 — relief valve（0.56MPa）。
adjust the inlet pressure of the
converter
5 — joint （from oil cooler）。
6 — Back Pressure valve （adjust
the pressure of lubrication
0.2MPa）。
Joint
标题 of the torque converter
 Overrunning
标题 clutch

function：according to external load, connection and

disconnection of overrunning clutch is automatically done.

principle：
a. When the loader is in high speed and light load condition, the
speed n2 of gear Z4 (or the cam) is more than the speed n1 of the
turbine driving gear Z2, the roller will rotate along B and the driving
gear Z2 will run freely, and the power from Turbine T1 is cut off. At
this time, only Turbine T2 is running.
b. When the loader is in low speed and heavy load condition, the
external load compels the speed n2 of gear Z4 to reduce to lower than
the speed n1 of the turbine driving gear Z4, the roller will then rotate
along A and be firmly wedged, the two gears Z2 and Z4 will become
one and rotate, aggregating and outputting the power coming from
Turbine T1 and T2. At this moment, the two turbines will work
together.
Such connection and disconnection of overrunning clutch is
automatically done along with the changes of external load, instead
of being controlled by operator.
3、Transmission
 The
标题 type of transmission

●According to gear train

……Fixed Shaft Transmission （ZF
Transmission 、Liugong 30/50 Fixed Shaft
Transmission ）
……Planetary Gearbox （CAT、Liugong
BS305）
● According to shift control
……man power shift （slip gear、sliding
sleeve ）
……Powerful Shift Transmissions
mechanical-hydraulic power shift
electrical-hydraulic power shift
……Automated Shift transmission（semi-
automatic 、automatic shift）
 Planetary
标题 gear system

Features of Planetary gear

system

Zr
k
Zs
The axle of the planetary gear
always change.
Gear-box（Liugong
标题 BS305）

Power path ：2 forward speeds and

1 reverse
Actual Power path：4 forward
speeds and 2 reverse
…….due to automatic breakaway
and connection of overrunning
clutch (according to load）

1st 2nd R remark

Normal Trans 2.696 0.723 1.973 30、40、50

Speed up Trans 2.426 0.651 1.775 30G、50GⅣ、50GⅦ

The
标题 function of gear box

1、change the ratio of the engine and axle

To meet the machine’s requirements ,change the speed and traction of
the machine
2、make machine forward and reverse

3、cut off power drive

4、change wheelbase
solve the problem of engine’s output and axle’s input
5、change the speed of machine
make the best use of engine’s power and increase efficiency
 Planetary
标题 Gearbox

Planetary Gearbox ：
type ：BS305 and CAT950 series。
advantages ：compactness, high
rigidity, high driving efficiency,
simple and reliable controlling,
defect ：complicated construction ，
processing is difficult
The right figure is BS305 that
has two planetary gears and one
direct gear.
Sketch
标题 of the BS305
Take off
Torque
convertor

The first
gear first stage
gear
Direct
gear
Overrunning
clutch

Front
Reverse gear
flange

Rear
flange
Sketch
标题 of the BS305
 The
标题 transmission path of the 1st gear

I turbine
II turbine II gear
torque→1t gear→input
I gear
shaft→sun gear→planet gear
I gear group
ENGINE
[inner gear (Z内）fixed，1st
planet carrier output]→ direct
gear flange
→plate→Intermediate shaft
output gear→output
Intermediate
gear→output shaft→flange input shaft clutch

gear Gear drive ratio

Ⅰgear Z2/Z1→（1+Zinner/Zsun）→Z6/Z5 2.426
The
标题 principle of the 1st gear

the 1st-gear ring gear is

locked by the 1st-gear clutch,
The sun gear drives the planet
gears, the planet gears drive
planet carrier, the route
direction of the planet carrier
is the same as sun gear.

formula of the
drive：1+Zplanet
carrier /Z sun gear
 The
标题 transmission path of the 2nd gear

III turbine
turbine
turbine
II
II turbine
turbine II
II
IIgear
II gear
gear
gear
torque→ the first grade
IIIIgear
gear
gear
gear
gear→ input shaft→sun
gear →direct gear ENGINE
II
II
IIgear
II gear
gear
gear

shaft→direct-gear friction
clutch →direct-gear drive
plate →pin→direct-gear
cylinder →Intermediate 中间输
shaft output gear→output 入轴
clutch
clutch
clutch
clutch
gear→output shaft→flange
gear Gear drive Speed ratio
Ⅱgear Z2/Z1→Z6/Z5 0.651
Direct
标题 gear

Direct
gear
 The
标题 transmission path of the reverse gear

II turbine
turbine
II
II turbine
turbine II
II gear
gear
torque→ first grade gear→ input
shaft →sun gear→ reverse gear II gear
gear

（reverse planet carrier is fixed ， Reverse

Reverse gear
gear
ENGINE
ENGINE
reverse ring gear output）→first
gear planet carrier →direct gear
flange →direct-gear drive
plat→Intermediate shaft output
gear →output gear →output
shaft→flange Input
shaft
clutch
clutch

gear Gear drive Speed ratio

Reverse gear Z2/Z1→Z inner /Z sun→Z6/Z5 1.775
The
标题principle of the reverse gear

the reverse planet carrier is

locked by frictional plate ,
The sun gear drives the
planet gears, the planet
gears drive inner reverse ring
gear , the route direction of
the planet carrier is
different from sun gear.

formula of the drive

Z inner ring gear/Z sun gear
BS305
标题 transmission reverse gear group
 The
标题 hydraulic system of the BS305

1.Oil pan 2.strainer 3.hose

4.pump 5.hose 6.filter
7.hose 8. pressure regulator
9. Clutch cutoff valve
10.control valve 11.Ⅱgear
cylinder 12.Ⅰgear cylinder
13.reverse gear cylinder 14.Air
valve 15.one-way throttle
valve 16.slide valve 17.Inside
oil way 18. overflow valve
19.torque convertor 20.hose
21.oil cooler 22.hose 23. back
pressure valve 24.overrunning
clutch
Control
标题 valve（BF25）

Adjust the Store oil ,to improve the

performance of shift The oil line will be cut
pressure of system
off ,when braking.
there is no output
power

Transmission pressure test

Air intake C Air intake D

1、there is no gas in the point C and D, the

pressure of valve is zero.
2、 there is gas in the point C and D, the
Control pressure of valve is zero.
3、there is pressure gas(0.68～0.7MPa)in the
pressure oil point C.the pressure is 1.1～1.5MPa。
the
标题oil line of control valve

Reverse gear：fuel inlet J；fuel outlet H。

Ⅰgear： fuel inlet M； fuel outlet N。
Ⅱgear： fuel inlet L； fuel outlet K。

Torque convertor oil intake

reverse gear
I gear
II gear
 cut-off
标题 valve of control valve

principle：
1、When the service brakes are released. Right cavity is connected to the atmosphere, and under
the pressure of the air in the left cavity, the air valve stem moves to the right. At the same time,
the pressure of spring (7) acts against the air valve stem(8) and returns the valve to its normal
position. Connects T to F, allowing the pressure oil to flow to the working cylinder. Cavity G
connect to oil tank.

2、When the emergency and parking brake apply, port C(No pressure) , the compressed air in the left
cavity disappear, spring push air valve stem(10) to the left, the channel F blocks, then the
transmission shift to Natural position.
 pump
标题

principle：
The output shaft drives
pump. The sub pressure
was generated. because
of sub pressure the pump
can suck oil in the tank.

1. Pump top 2. gasket 3. pin 4. gear 5. shaft 6. ring 7. gear 8. pin

9.connector 10. O-ring32×3.1 11. pump body 12. boltM10×80-8.8-Zn.D 13.
washer10 14. ring62 15. ring 16. seal PG45×62×12 17. nut M12 18. washer
12 19. bolt AM12×32-8.8-Zn.D 20. bolt M10×55-8.8-Zn.D 21. washer
 4、how to diagnose
and deal with problem
how
标题 to diagnose and deal with problem

No. Trouble Cause Remedy

(Ⅰ) Gear shifting 1.Low oil level of the
pressure of the transmission oil sump.
all gears are low 2.Oil line leakage.
3.Transmission oil strainer
clogged.
4.Defective oil pump.
5.Adjusting spring of the
pressure regulating valve
improperly.
6.Weak or broken Adjusting
spring of pressure regulating
valve.
7.Jamming of pressure
regulating valve or piston.
(Ⅱ) Gear shifting 1.Seal ring in that gear range
pressure of a is damaged.
certain gear 2.Seal ring on that oil line is
range is low. damaged.
3.Oil passage to that gear
range clutch leaking.
1.Replenish oil to specified oil level.
2.Inspect main oil line for leaks.
3.Wash or replace oil strainer.
4.Dismantle and inspect. Replace the oil
pump if necessary.
5.Readjust according to the specified.
6.Replace the spring of pressure
regulating valve.
7.Dismantle and inspect, and eliminate
the jamming.
1.Replace seal ring.
2.Replace seal ring.
3.Find the leakage and repair.
how
标题 to diagnose and deal with problem

(Ⅲ) Converter oil 1.Transmission oil level is too low.
tempe- rature is 2.Transmission oil level is too high.
high. 3.Low gear shifting pressure and
clutch plates slipping.
4.Clogging of the torque converter oil
cooler.
5.Too long continuous operation of the
torque converter under heavy load.
1.Replenish oil to specified oil level.
2.Drain oil to specified oil level.
3.Refer to (Ⅰ) and (Ⅱ).
4.Clean or replace oil cooler.
5.Stop vehicle to cool.

(Ⅳ) Engine running at 1.Air valve spool of transmission 1.Check for failure of the valve parts and
full speed but control valve does not return to normal repair.
loaderfails to position. 2.Again shift to the desired position, or
travel. 2.Gear not engaged. readjust transmission control linkage
3.Regulating spring of pressure 3.Replace the spring.
regulating valve of transmission
control valve is broken..
how
标题 to diagnose and deal with problem

Inadequate driving 1.Gear shifting pressure is too low 1.Refer to (Ⅰ) and (Ⅱ).
(Ⅴ) power . 2.Refer to (III).
2.Converter oil temperature is too 3.Dismantle and inspect the torque
high. converter, replace the impeller.
3.Damage of the torque converter 4.Dismantle and inspect the large over-
impeller. running clutch, replace the damaged
4.Damage of the large parts.
overrunning clutch. 5.Overhaul the engine.
5.Inadequate output power of the
engine.

(Ⅵ) Rising of the 1.Oil leaks on the shaft end of 1.Replace oil seal on the steering
transmission oil steering pump. pump shaft end.
level. 2.Oil leaks on the shaft end of the 2.Replace oil seal on the pump shaft
pump in the working mechanism end.
hydraulic system.