SERVICE MANUAL
Contents
1. IUE AEN ZL15 LL HEB y RERE as ZL152. ZL15 SHANTUI ZL15 series Power shift Transmission SERVICE MANUAL TORQUE CONVERTOR FACTORY SHANTUI CONSTRUCTION MACHINERY CO LTD LEE LII AE ZL15 Brief introduction of Torque Converter Factory Shantui Construction Machinery CO LTD SHANTUI Hydraulic Torque Converter Factory a subsidiary of Shantui Machinery CO is specialized in manufacturing all kinds of hydraulic torque converter in china It possesses advanced technology superior equipment accurate inspection and scientific control on quality Based on the technology of converter track roller and carrier roller introduced from Komatsu Japan in 1980s and after innovation and improvement SHANTUI Hydraulic Torque Converter Factory can produce annually 50000 units of torque converter and 60000 pieces of roller will be sold all over the country The yield of main production base parts of construction machinery and medium and small power bulldozer Its main products consists of various hydraulic torque converter applied for construction machinery such as bulldozer loader etc and oil machinery track rollers carrier rollers and idler ass y series used of crawler machinery such as bulldozer excavator and tracked paver TB80 trimming dozer series and T70 80 T100 track bulldozer series Years of experience states that SHANTUI Torque Converter Factory if forwarding depending on technology improvement u
3. Astern High Clutch gt aii I 3 2 13 12 SW OO TW 10 LL HE IBC AEN ZL15 b Astern high Clutch No Code Description ty Remark ne aioe sie ft 2 meon 8 snap rino 2 fp fi s ease mm o o meme eese MEKE Spring 1 BD05 01010 2 support seat BD05 01005 2 Clutch spring ESL died Je Hs 10 BD05 01003 Pressure plate 2 Of clutch eem fe BD05 01300 Friction disc s 12 0 13 003452 2 2 O ring 93 Il EJ rk e kr as ZL15 15 BD05 01103 9 Airproof ring BD05 02100 Forward low clutch 07043 00108 m Plug 1 21 BD05 01008 3 Airproof ring 22 GB276 82 Bearing 308 EI GB893 1 86 l Snap Pg D E BD05 02001 152 Snap ring 01014 31235 Bolt MI2X 35 e BD05 02201 geca h I BD05 02202 m Gear BD05 02002 44 Snap ring BD05 02002 JEEZ washer UTERE DH LUI ARAB RS ZL15 c Intermediate Shaft Assembly IE 2 AE AS ZL15 c Intermediate Shaft Assembly No Code Description 01010 31025 Bol tM10X25 01602 11030 iR Washer 10 BD05 00
4. ERR Ee ESI WE SSES lt SENN NIN NIADA Ni Tu EMG DESSEN TELE BS 1 Valve block 2 Speed selection valve 3 Direction selection valve 4 5 9 Spring 6 Cut out valve core 7 Seal 8 Cut out valve piston 10 Steel ball Direction selection valve consists of direction selection valve lever 3 spring 4 and steel ball pulling the lever of direction selection valve forward gear neutral and reverse gear is carried out The combination of speed selection valve and direction selection valve can carry out forward gear IL and reverse gear II For example when pulling out the direction selection lever pressure oil from main retainer valve is entered in direction selection valve and entered in forward clutch of transmission by bore A oil pressure make piston moving and clutch friction plate is engaged forward gear of transmission is engaged Forward gear lor Ilis engaged if Speed selection valve lever at gear 1 1 position When pushing in the direction selection lever pressure ZL15 oil putted in reverse clutch of transmission by bore B oil pressure make piston moving and clutch friction plate is engaged reverse gear I or 1 of transmission is engaged Cut out valve cut out valve consists of control valve group valve core 6 spring 5 When loader traveling on road cut out valve at middle position if it doesn t brake if driver braking that
5. 25 ZL15D 1 Manipulative 26 JB982 77 18 Assembly washer 1 gs 29 JP300 81WWAWT 125 Pipe Ji 33 zuisao0013 48 fe gt 34 Bbo5 13000 aema Pilter 2H cr E I A 35 JB982 77 3 amp 48 Assembly 1 washer 36 Bp05 00027 mae Prue h LL HE IBC AEN ZL15 37 zi58 01000 ER washer 38 07281 00289 weii Hoop 2 EX Pipe 39 HG4 761 74 1 19X 1000 4o 48000004 e Tiin 1 CBC25 FLX 1 41 Gear pump L2 BD05 00022 8 ricini aa 07260 02645 weit Pipe LE E ni 45 BD05 00021 1 Pipe cover TUER bD505 153000 UE BLU CU AER ae ZL15 BD05N Addenda 1 BDOSN diagram 62 5 ji cu LS e 2 CD 7 E 4 9 54 NI T H 1 P H 1 i To Jam ES ei D Jat U vil pm ll 4 4065
6. oil Change strainer Change a new pressure gauge Change a new oil seal Change a new O ring UE BLU CU RERE ate Pump can t supply enough oil Oil seal is damaged Oil lever in oil tank is too low Strainer is clogged Pressure gage doesn t work Oil Seal is worn O ring is worn too low Oil leak Familiar trouble and remedies of transmission Reason Remedy 1 Gear position 1 Put gear lever to right position or is inexact check control value 2 Clutch piston 2 Check or change O ring leakage 3 Seeas following 3 Pressure of speed 4 Dismantle and clean and dredge changing is low 4 Oil piping are blocked 1 Modulating value is 1 Adjust or replace spring not adjustable or spring 2 Addoil to the mark of dipstick break off 3 Clean or dredge 2 Oil level of 4 Change O ring transmission is low 5 Check or change 3 Case strainer or oil path is blocked 4 Oil leakage from clutch 5 Transmission pump is defective Trouble No gearing Transmission And hydraulic circuit Pressure of speed changing is low ZL15 Stop or idle for a few time Add oil to overflow hole Check oil pressure and seal ring UR E Check clutch control 011 piping or position of control lever 1 Change O ring of piston Change seal ring 3 Check and remedy Change seal ring 1 Tighten joint 2 Change seal ring Q ty Rema
7. pressure oil from traveling brake system is putted in control valve housing and push down piston 8 moving valve core is forced to move and pressed spring by moving piston At this time the cut out valve core would cut off the oil path bore A or B between direction selection valve and clutch of transmission the forward or reverse clutch is released and couldn t be transmitted power in this way not only benefiting to the loader brake but also all power can be used in implement at the loader shoveling and loading VI Hydraulic system ti 0 3 8 6 p p a i eee a 1 Torque converter 2 Transmission 3 Oil strainer 4 Cooler 5 Control valve 6 Main modulating valve 7 8 9 Pressure gauge 10 Temperature gauge 11 Filter 12 Pump Pump 12 is installed to housing of torque converter on transmission oil is UE BLU CU RERE ae ZL15 sucked from transmission case through strainer 3 Oil from pump is flowed in main modulating valve 6 through filter 11 Now the oil is distributed in two ways one way to control valve 5 oil pressure 1 2 1 4Mpa the other way to torque converter 1 through main pressure valve oil pressure 0 4 0 55Mpa oil is flowed in two clutches through cooler 4 after the oil is flowed through torque converter oil pressure 0 15 0 25Mpa and the friction plate of clutch is lubricated At last oil is returned to transmission VI Installation and regulation Installation 2211
8. state of maximum efficient when torque converter MBg n 35 7 N m pump rotates at 1000 rpm Efficient Tie 0 81 Transmission Transmission type Power shift stable shaft LL HE BC y RERE a ZL15 Transmission ratio Forward gear 2 4693 Forward gear II 0 8784 Reverse gear 2 5242 Reverse gear II 0 8980 II Transmission system 1 Engine 2 Torque converter 3 Transmission 4 Parking brake 5 Wheels 6 Final drive 7 Differential 8 Driving axles 9 Main drive 10 Driving shaft The loader driving system consists of hydraulic torque converter transmission driving shaft driving axles The power from engine is changed torque by torque converter 2 and transmitted to transmission 3 by driving shaft then transmission change the speed by multi gear and bring different direction and different driving LL HEB CAI AER ZL15 ratio by different gear grawwing transmit to driving shaft 10 driving shaft obtain different direction and different speed so bring forward gear 1 and reverse gear I II Driving shaft transmit the power to main drive gear 9 of driving axles 8 and final drive 6 through differential 7 so wheel 5 rotating and make the machine driving III Working principle s ole z H to 1 CA Hydraulic torque converter 18 a driving equipment using liquid as working medium The torque is passed with the change of moment of mom
9. 018 imi End cover 07000 02085 0 O ring 85X2 5 m BDS05 00017 505 00019 BD05 00003 Intermediate Shaft BD05 00004 mii End cover 10 11 2 1 PERZI AE dS ZL15 d Output Shaft Assembly d Output Shaft Assembly Code Description Qty Remark 04050 04030 Split pin BD05 00010 LARE Nut BD05 00011 KA washer BAU48 70 10 0il seal ty BD05 00008 1 Bearing seat 3 N o 1 BD05 00014 Tap 07000 02105 0 O ring GB297 84 Bearing 7308E export shaft d l 1 1 1 10 2 3 4 5 16 bBD05L 00003 Ud AE ZL15 Z JAS Bearing seat 01010 31235 BoltM12X35 4 19 ZL15E 00002 1 Arrester seat BSAS ds BX Arrester DFX 2 15A 01602 01030 34 washer 10 GB70 85 BoltM10X30 BD05K 00001 Flange 01010 31025 WR MIOX25 Bb Import Assembly gt H e UE BLU CUT RERE ae ZL15 Ud AE ZL15 e Import Assembly Z Description Remark AU ni BDX05 00001 Bearing cover BDX05 00004 Bearing seat fey A Yds Tk BDX05 01000 1 Import Flange BDX05 00006 Washer BDX0
10. 5 00009 Import Shaft 10 BDX05 00011 1 Wheel box case 12 04050 04030 Split pin Ud AEN ZL15 14 01602 11236 3 Washer 12 a 15 BAU48 70 10 0il seal 1 ws 0 16 07000 02105 O ring 2 5X105 17 GB276 82 Bearing308 1 18 GBZ76 82 Bearingl06 1 19 01010 31030 Bolt M10X30 5 20 01602 11030 34 Washer 10 21 21 01010 31025 Bol tM10X25 0 22 07000 03032 O ring 3X32 23 01643 32260 HRS B LS 24 BD05 00010 WERE Nut NN f Housing Assembly HJ eja LS f Housing Assembly cc s a mos1000 t Pine 1 5 mos1 00 bie 1 7 pp0s oo01s_ 8 Washer on BD05 00012 m End plate w N 9 07044 12412A Plug 1 o 07002 02434 0 O ring a 01602 11030 Washer 10 22 BD05 03004 HR washer 2 BD05 03001 HEBsh BD05 03002 i Cover 07043 00108 We Plug ds 17 JB982 77 27 Assembly 7 washer 18 znisc 20000 e Tiecin no 19 jz58 0001 Mb Boc 2 HEREA as ZL15 2o zar h UKR 10 20a BD05L 00006 JB982 77 drain value 21 mos 0402 88 eun h 22 mos o01 cover h 23 pos 86 Bolt e a AR THAR ERA BY
11. 5 transmission assembly matching so well with 495 4100 series of engines in capabilities as to match series of homebred loading machine and they can be installed to be used straightway The installation and orientation rely on the dimension of 04716 on mantling wheel axes to be united with flywheel of the engine The power is transferred by the engine fly wheel locked with stretch board by twelve bolts z115 transmission assembly is connected with the shell of engine flywheel by nine bolts so as to be riveted in the forepart The gear box is connected with bodywork by bracket at double deck so as to be riveted in the back part Some colloid mat and some adjustive mat will be used between them or else it will effect the normal work of transmission Regulation Startup the engine checkup and regulate the oil way system after the oil pump begin work regulate the oil pressure of shifting at 1 2 1 4 Mpa at the same time the cracking pressure of relief valve on the torque converter is 0 4 0 55 Mpa the lubricating oil pressure in transmission will be 0 15 0 25 Mpa the shifting handspike and the organization that to be connected with must be agility any locking IUE AEN ZL15 phenomenon must to be avoided and the shifting position must be nicety and obviously Treadle down the brake and turn engine accelerograph to the maximal the vehicle must not start and loosen the tread board the vehicle must start right now The cheer
12. XI Overall diagram ZL15 Parts Lists 1 ZL15 a Forward Low Clutch Cay ae ar 4 3 eS 1g OT Ji NV y SESS Wy 0 N i H iq 3 E EY lt 4 SS 2 AEE a Forward Low Clutch No Code Description BD05 01012 TES Snap ring BD05 01011 4 Snap ring GB277 82 7K 50208 Bearing 2 BD05 01001 Snap ring 1 GB894 1 86 Snap ring 50 NN BD05 01002 Gear 2 yC Z JAB Spring support 0 7 seat EXE DE BD05 01005 Clutch spring 9 0893 6 Snap ring 150 Ec ESL died Be Hd 10 BD05 01003 Pressure plate 2 Of clutch piston meu esas p 12 BD05 01300 Friction disc 0 O ri 53X5 3 Ud AE ZL15 15 BD05 01103 2 Airproof ring 16 BD05 01200 Forward low 1 clutch case 21 10Y 15 00015 3 Airproof ring GB276 82 Bearing 308 E GB893 1 86 138 Snap ring 68 BD05 01009 Snap ring 25 GB276 82 Bearing 308 D o Mac T UE BLU CU RERE ae ZL15 b
13. entum The following is its working principle The torque converter pump impeller is connected to the engine s flywheel by input power parts and it absorbs and converts the mechanical energy into kinetic energy of the working liquid The turbine absorbs the energy of the working liquid and turns it to the mechanical energy and passes it out by output power parts Stator changes the flowing direction of the working liquid and gives a reactive torsion so it can adjust automatically the moment of torsion and the rotational speed Owning to the special structure and function it is applied in the construction machinery to adjust out put torque according to the outside loads and to absorb shock So the torque converter is suitable for the construction machinery at UE BLU CUT AER s ZL15 the towing state and it can prevent the engine from stopping when the load rises suddenly and it can extend the service life of the engine and the transmission after comfortable operation The power from engine is changed torque by torque converter and transfered to the gear Z1 which is connected to the turboshaft When speed control lever and steering control lever is in middle position namely neutral although Z1 Z2 Z3 is engaged the clutch isn t engaged gear Z2 Z3 is turned for idling so vehicle is stopped When steering control lever is putted in forward position and speed control lever is putted in low speed position control
14. f aluminum iron or copper in order to analyze that circs abrasion for accessories in wheel box and torque converter or if there is something failure measure should be taken IX Familiar troubles and remedies Troubles and remedies about hydraulic torque converter Remedy Increase the speed of engine Check oil level in oil case Check leakproofness Check whether oil is ineffective Reduce the oil temperature Check leakproofness and whether the valve work right Decrease loads or raise the speed of engine Refill oil Check leakproofness Check whether oil is ineffective Change oil type Repair or change the valve Increase the oil pressure Check water case and refill water Check the oil input system Change the back pressure valve Check input pipe Reason The rotational speed of engine is down Some gas in oil The temperature of oil is too high The input or output oil pressure is too low Work time at low efficiency is too long Oil level is low in oil case or there some gas in oil Oil kind is not suitable The oil pressure is too low Water lever in cooling system is too low It can t supply enough oil Back pressure valve doesn t work Input pipe is jammed Trouble The power is output low Temperature of oil is too oil is high The pressure ZL15 Repair or change the pump Chang a new oil seal Refill
15. late 3 Driven friction plate 4 Driven hub 5 Piston 6 Spring 7 Shaft 8 11 V ring 9 Ring support 10 Plate 12 Prof seal ring 13 O ring The transmission have four clutches namely forward clutch reverse clutch clutch and clutch II The basic compose and working principle of four clutches are same The above figure is the diagram of clutch The clutch type is wet clutch Driven friction plate 2 and driven friction plate 3 have each four plates outer spline of active gear 1 is connected with inner spline driving friction plate furthermore can move along it outer spline of driven friction plate 3 is connected with inner spline of driven hub 4 and also can move on it one side of spring 6 support left of piston the other side support shaft 7 by supporting ring 9 and V ring 8 when pressure oil is entered in right oil house of piston the piston resists of force of spring and moving left all of driving friction plate and driven friction plate are pressed close the clutch was engaged and power is LL HEC y RERE a ZL15 transferred V Working principle of control valve Control valve of transmission consists of speed valve direction valve cut out valve and valve body arc Speed selection valve consists of speed valve lever 2 spring 9 and steel ball Pulling lever of the speed selection valve each speed of gear neutral and gear Il is carried out mm WSN FESSA Sena
16. lever must in the dipstick direction extension and regulate organization connected with brake so as to make the arrester worked well VII Maintenance Oil quality 2115 transmission system uses SAE10W 30 No 6 driving oil or No 22 turbine oil the cheer lever must in the dipstick direction extension and it must be higher than the oil purifier after the torque converter and pipeline full of oil The oil must be clean any impurity must be avoided drastically Oil temperature and pressure The oil temperature should not be over than 95 centigrade after a long time work and it should not be over than 120 centigrade after a short time work or else the vehicle must be stopped and should be checked over or else the seal ring will be destroyed so the oil will be leaked The oil pressure of expiation in torque converter and that of outlet or shifting pressure in control valve must be in the required range Oil change The oil in new vehicle must be changed entirely after working for 50 hours and since then the oil must be changed again every one thousand hour s work or each year s work at least ZL15 Cleanout The oil strainer on transmission must be cleaned after the first 50 hour s work and since then it must be cleaned after every 500 hour s work and it must be changed in time if there is something destroyed Pay attention to see if there 18 any chipping o
17. nder the modern management SHANTUI Torque Converter Factory renovates and improves aiming at budgeted This made it take the first place in the fields of construction machinery in china A system of researching testing producing marketing and servicing has been formed SHANTUI Torque Converter Factory is highly praised by the mass of customers due to the high quality products and good service LL HE IBC AE ZL15 CONTENTS I MAIN TECHNICAL DATA 19 I TRANSMISSION SYSTEM sss sess 20 Jil WORKIMG PRINCIPL E soos 1 IV WORKING PRINCIPLE OF CLUTCH 7 23 V WORKING PRINCIPLE OF CONTROL VALVE 24 Vi HYDRAULIC 1 5 VII INSTALLATION AND REGULATION pp 26 Vill s 7 IX TROUBLE SHOOTING GUIDE ee ee 28 Xo WEARING 0 5 DIAGRAM Ud AEN ZL15 I Main technical data Rated power 40 50 kw Rated speed 1800 2600 rpm Control pressure 1 2 1 5 Mpa Torque Converter YJ280 is a single stage one phase three organs and centripetal turbine impeller type hydraulic torque converter Main technical specification Item Symbol Value Unit Stall torque ratio KO 3 7 Torque at stall when torque MBg0 29 8 N m converter pump rotates at 1000 rpm Torque at
18. pressure oil 1 2 1 4MPa is putted in the transmission valve pressure oil from the control valve and put in clutch piston through pipe and forward low speed cover and oil path of clutch shaft oil pressure make piston moving and F I clutch friction plate is engaged Power is transmitted from the input gear Z1 through Z2 Z6 Z7 Z8 Z9 Z10 Z11 to output shaft to realizes forward gear I When steering control lever is putted in forward position and speed control lever is putted in high speed position the same to gear pressure oil is putted in clutch piston oil pressure make piston moving and F II clutch friction plate is engaged Power is transmitted from the gear Z1 through Z2 Z4 Z5 Z8 Z9 Z10 Z11 to output shaft to realizes forward gear II The course of reverse gear and reverse gear ll realizing is same to forward gear it s not recite depicting The driving route as follows Reverse gear Power is transmitted from the input gear Z1 through gear Z3 clutch R gear Z5 Z4 clutch I gear Z6 Z7 Z8 Z9 Z10 Z11 to output shaft to realizes reverse gear Reverse gear II Power is transmitted from the input gear Z1 through gear Z3 clutch R II gear Z8 gear Z9 Z10 Z11 to output shaft to realizes reverse gear II LL HEB y RERE ate ZL15 IV Working principle of clutch 1 Driving gear 2 Driving friction p
19. rk 50 80 130x3 1 290x3 5 o 85x2 5 Q ty Remark o 85x3 5 32x3 5 o 105x3 1 20 7x3 4 o 53x5 3 10 N 5 ole 1 Work time is too long 2 Oil too much or too less 3 Clutch slide Clutch could not be disengaged 1 O ring of the piston of the gear is damaged 2 Seal ring of the oil piping is damaged 3 01 piping leakage oil or blocked Seal ring on shaft end leakage l Joint is loose 2 Sealring is damaged Description Ring seal Ring seal O ring O ring O ring Seal oil Description O ring O ring O ring Ring seal O ring Ring seal O ring Combination washer IE CU RERE as Oil temperature is too high Oil pressure of one of gears is low Gear in disorder System release oil X Wearing Parts Torque converter Part No YJ265 00014 ZL30D 11 19 ZL30D 11 54 GB1235 76 GB3452 1 82 07000 02085 Index No 1 ON 9 Transmission Part No 07000 02085 07000 03032 07000 02105 10Y 15 00015 07002 02434 93 GB3452 1 82 JB982 77 Index No 1 oo r2 LL HEC y e ae ZL15 9 JB982 77 Combination washer 1 48 10 JB982 77 Combination washer 4 27 11 07012 70048 Seal oil 1 48 12 130 2402052 Seal oil 2 13 130 2402050 Oil plate 2
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