Transmission Basic

SD310 Wheel loader

June, 2014
Product Support
Doosan Infracore
1. Basic knowledge
Classfication of drive systems

According to operating principles, the drive system is classified into mechanical

drive, fluid drive, electric drive.
Mechanical drive: mainly belt drive, friction drive and gear drive.
Fluid drive: hydraulic drive, pneumatic drive.
Electric drive: generator and starter, etc. Capable of converting electric energy into
mechanical
energy, or mechanical energy into electric energy.

Lay stress on the gear drive of mechanical drive in this lecture.

1
1. Basic knowledge
Gear drive

Gear is a mechanical toothed component, which

can continually engage with another toothed
component through its teeth, and transmit the
movement to the latter, or receive the movement
from the latter.

The gear drive consists of driving gear, driven

gear and frame. The gear drive is a device
capable of transmitting the movement and power
through the direct tooth engagement of driving
gear and driven gear. As shown in the figure,
when a pair of gears engage with each other for
work, Tooth 1, 2 or 3.. of driving gear O1 pushes
Tooth 1, 2 or 3.. of driven gear one by one due to
the action of engaging force Fn to make the driven
gear rotate, thus the driving gear transmits its
power and movement to the driven gear.
1. Basic knowledge
Drive ratio

The drive ratio of gear drive is the ratio of angular speeds (or rotation speeds)for
driving gear and driven gear, which is also equal to inverse ratio of their tooth
numbers, i.e.
n1 z2
i   z1  n1  z 2  n2
n2 z1

Where n1-angular speed or rotation speed of driving gear

n2-angular speed or rotation speed of driven gear
z1-number of driving gear teeth
z2-number of driven gear teeth

The drive ratio of gear drive shall not be too high, otherwise it will cause the excessive
structural size, which is not good for manufacture and installation.
Generally, drive ratio of cylindrical gear≤8, and drive ratior of conical gear≤5.
1. Basic knowledge
Features for application of gear drive

In comparison with other drive modes, the gear drive has the following features:
1. Constant instantaneous drive ratio, higher stability, correct and reliable movement transmission.
2. Wide application scope, capable of realizing the transmission between the parallel shaft,
intersecting shaft and alternating shaft.
3.Larger power and speed range of transmission, high transmission efficiency, long service life.
4.Compact structure, reliable operation, capable of realizing the higher drive ratio.

Disadvantages of gear drive

1.High precision of manufacture and installation, production of noises during the operation.
2.The number of gear teeth is an integral number, able to achieve the limited drive ratio, and
unable to realize steppless speed control.
3.Overlage center distance will lead to large or heavy exposed drive structure, so it’s not applicable
for any case with larger center distance.

Basic requirements for gear drive

1.Stable transmission, any instantaneous drive ratio shall keep constant during the tranmission of
gear to keep the stability of transmission, and avoid or reduce the noises, impact and vibration of
transmission.
2. Its strong loading capacity is ensured by small size, light weight and high load bearing ability of
gear, i.e. high strength, good adrasive resistance and long service life.
1. Basic knowledge
Classification of gear

1.As per different relative positions of both drive shafts for gear pair
Parallel shaft gear
Intersecting shaft gear
Alternating shaft gear
2.As per different tooth traces
Straight tooth gear drive
Oblique tooth gear drive
Curved tooth gear drive
3.As per different gear reference surfaces
Cylindrical gear drive
Bevel gear drive
4.As per different working conditions of gear drive
Closed gear drive
Open gear drive
1. Basic knowledge
Parallel shaft gear

Parallel straight gear pair Parallel helical gear pair

1. Basic knowledge
Intersecting shaft gear

Straight bevel gear pair Helical bevel gear pair

1. Basic knowledge
Alternating shaft gear

Hypoid gear pair Worm gear pair

1. Basic knowledge

Increase of helical angle, increase of driving pinion diameter, increase of gear

overlap coefficient, high strength, large drive torque, stable movement, increase of
min. ground clearance
Note: high sliding coefficient on tooth surface, and the special hypoid gear oil must
be applied.
1. Basic knowledge
Rotation direction of gear

Right hand teeth Left hand teeth

1. Basic knowledge
Gear train

In order to achieve higher drive ratio sometimes in the mechanical drive, convert one rotation
speed of driving shaft into several rotation speeds of driven shaft, or change the turning direction
of driven shaft, usually adopt a series of gears engaging with each other, and connect the driving
shaft and driven shaft together for driving, thus it’s called as gear train.

Features for application of gear train

1.Achieve the higher drive ratio.
2.Realize the long-distance transmission.
3.Realize the speed change.
4.Realize the change of turning direction of driven shaft.
5.Realize the combination and decomposition of movement.

Classification of gear trains

1. Ordinary gear train
2. Epicyclical gear train
1. Basic knowledge
Ordinary gear train

During the operation of gear train, the geometrical axis positions of all the gears (including the
worm and worm gear) hold still, so this gear train is called as ordinary gear train.
1. Basic knowledge
Epicyclic gear train

During the rotation of gear train, the geometrical axis of at least one gear of gear train rotates
around that of another gear, so this gear train is called as epicyclic gear train and also called as
planet gear train.
Components of planet gear train: planet gear, planet carrier, sun gear
1. Basic knowledge
1. Basic knowledge
Shafting

The shaft is a key part of machine, which is used to carry the rotating parts and transmit the movement and
power; the part to fix the shaft and parts on it in circumferential direction and transmit the torque is a key; the
bearing is used to carry the shaft and parts on it, keep its rotation precision, and reduce the frictions and wears
between the shaft and bearing; the coupling and clutch are two shafts to connect different mechanisms, make
them turning and transmit the torque.
1. Basic knowledge
Classification of shafting

1.As per the functions and loading conditions of shaft

Core shaft a shaft to bear the bending moment but transmit no torque, e.g. front
wheel shaft of bicycle.
Drive shaft a shaft to mainly transmit the torque but bear no bending moment or
bear very low bending
moment.
Front wheel Front
Rotation shaft a shaft
fork to not only transmit the torque but also bear the bending
shaft
moment, e.g. output shaft of
gear reducer.
Universal drive
shaft
Front hub

Front wheel shaft of Drive shaft Reducer output

bicycle shaft
1. Basic knowledge
Classification of shafting

2.As per the shape of shaft axis

Straight shaft Used in common machines. Divided into optical shaft and stepped shaft.
Crankshaft A speical part of reciprocating machinery.
Flexible shaft, i.e. soft shaft Transmit the turning movement and power freely to different
positions.

Driven device
Joint

Straight shaft Steel wire soft shaft

(its outer layer is a jacket)
Joint

Power source

Crankshaft Flexible shaft

1. Basic knowledge

Basic components of speed reducer

Ventilator

Peephole cover

Box cover Bolt, nut, washer

Cover opening screw

Gear

Adjusting gasket Oil dipstick

Gear shaft Shaft

Pin Bearing
Bearing end
Box seat cover
Oil seal

Oil plug Screw washer

2. Main technical parameters of ZF 4WG-208

• Max. input power：200 kW

• Weight（No containing oil）：about 470
kg
• Torque converter’s start transform torque
rate：2.25
• Transmission files：4 forward gears, 3
reverse gears
• The regular range of shifting oil pressure
：1.6-1.8MPa (16-18bar)
• Max. torque converter oil let in pressure:
0.85MPa (8.5 bar)
• Torque converter start oil circle pressure:
0.5MPa (5.0bar)
• Regular working oil temperature ：80-
110℃，when support heavy load , allow
up to 120℃ in a short time .
• Electronic control system voltage：DC24V
3. The basic information of T/M
3. The basic information of T/M
3. The basic information of T/M
3. The basic power transmission route of wheel loader
3. The basic information of T/M
3. The basic information of T/M
3. The basic information of T/M
3. The basic information of T/M
3. The basic information of T/M
3. The basic information of T/M
3. The basic information of T/M
3. The basic information of T/M
3. The basic information of T/M
3. The basic information of T/M

T/M filter
Connect
to pump

clutch

Clutch

clutch
3. The basic information of T/M

Control
Valve

T/C

Output
flange
3. The basic information of T/M
3. The basic information of T/M

吊环

Torque • Control
convertor valve

Joint • sensor
flange

Charging
Pump
• Suction
(inside)
tube

Sensor
• Behind
flange
TM
housing

Oil filling • Bleeding

tube plug
3. The basic information of T/M
B. Function_oil hole(1)

The founction of TM’s oil hole

MEASURING POINT FOR MEASURING POINT FOR

PRESSURE OIL RESSURE OIL BEFORE
2.SPEED (M10x1) CONVERTER

MEASURING POINT FOR MEASURING POINT FOR

PRESSURE OIL PRESSURE OIL
1.SPEED (M10x1) 3.SPEED (M10x1)

MEASURING POINT FOR MEASURING POINT FOR

PRESSURE OIL
PRESSURE OIL
REVERSE SPEED (M10x1
FORWARD SPEED (M10x1
)
)
MEASURING POINT OF
TEMPERATUR BEHIND
CONVERTER
(100°C;FOR A SHORT
TIME 120°C
MEASURING POINT OF
SYSTEM PRESSURE
MEASURING POINT FOR (15+2 bar)
PRESSURE OIL
M10x1/15 DEEP
4.SPEED (M10x1)
3. The basic information of T/M

PRESSURE OIL BEFORE

CONVERTER INDUCTIVE SENSOR
TO MEASURE
THE OUTPUT SPEED
(M24×1.5)
3. The basic information of T/M

Inlet of fine
filter

Outlet of fine
Oil inlet filter

Oil inlet to T/C Oil return Oil inlet to T/C

port and retaining
valve
Oil inlet of
Oil inlet of oil suction
pump pipe

Oil outlet from

T/C Oil outlet to
(Connect with Cooler
retaining valve
of T/C outlet)

Oil Temp Test T/M Inlet

Port port
3. The basic information of T/M

Oil outlet of Oil inlet of

Charging pump Charging pump
3. The basic information of T/M

Fine filter Inlet of fine

filter

Outlet of fine
filter