Structure & Work Principle of Torque Converter

Structure & Work Principle of
Torque Converter
July,2022
目录
Contents 01 Structure of Torque Converter
02 Benefits of Torque Converter
03 Work Principle of Torque Converter
04 Operation & Maintenance of Torque Converter
05 Common Failures & Trouble Shooting to Torque Converter
Page 2
01 Structure of Torque Converter
Page 3
Torque converter is one of the most important power transmission component of hydrodynamic bulldozer, it is
mounted between the engine and transmission, and it is a kind of hydraulic coupling that can transmit rotating
mechanical power from engine to transmission,
Torque Converter
Power Shift
Engine Transmission
Driving Inlet relief

Gear port
Oil outlet
Oil
temperature Oil inlet
tapping port
Outer Scavenge oil

Casing Scavenge outlet
Pump
Zoomlion bulldozer employs a single-phase single-stage

syntropic type torque converter with three elements
Stage: Number of turbine
Operational phases: Operational stages number of torque

converter. If the only stator is fixed, then it is single phase
which only has torque multiplication mode ; if the stator
can rotate unidirectionally, then it will have two phases,
and the stator that installed on the shaft through a one-
way clutch, with which it can realize two phases. Torque
multiplication and fluid coupling.
The impeller and turbine are flexible, which can rotate around the shaft,
while the stator is fixed on the housing of torque converter, and thus
keep stationary. The impeller and outer casing are bolted together, the
positioning neck of impeller housing is inserted into flywheel of engine,
and there is a gear bolted on the outer casing, which engages with the
ring gear of flywheel, and the output shaft of turbine is connected with
transmission via universal joint.
The hydraulic torque converter assembly is generally consist of impeller, turbine, stator, scavenge pump, return oil filter,
inlet relief valve and etc. There are many three dimensional curved blades in the three basic elements uniformly distributed
along the circumference. The three basic elements are precision cast pieces with high-strength aluminum alloy.
Stator Impeller
Turbine
Page 12
Features & Advantages of Torque Converter
① Enable the machine with great auto-adaptability: it can adjust output torque
automatically according to load, which make the engine can always work at
rated conditions without stalling, and therefore engine efficiency can be fully
exploited.
②Improve the service life of the machine: The torque converter transmits
power by fluid, as a type of flexible power transmission, it can absorb engine
vibration and load fluctuation, thus improving the service life of the engine.
③Improve comfort of the machine and ease the operator: When load increases,
the output torque automatically increases, and the speed decreases; when the
load decreases, the output torque automatically decreases, the speed increases,
so the machine can start-up and accelerate smoothly.
④infinitely variable speeds, no need to cut off power transmission while gear
shifting, makes it easy and convenient, and improved terrain trafficability, the
machine flexible and improves the trafficability of the machine:
⑤Torque-limiting protection function: Engine will never flameout even though

the machine encounter with very heavy load.
Page 14
A most simple hydraulic torque converter can be broken down into three main components : impeller , stator , turbine.
The impeller is connected to the housing and the housing connected to the engine shaft. It has curved and angled vanes. It rotates with
the engine speed and consists of transmission fluid. When it rotates with the engine, the centrifugal force makes the fluid move
outward. The blades of the impeller are designed in such a way that it directs the fluid towards the turbine blades. It acts as a centrifugal
pump which sucks the fluid from the automatic transmission and delivers it to the turbine. The impeller transfers kinetic energy by
flinging fluid around, and hit turbine, push turbine to rotate, and then the turbine drives the output shaft to rotate.
The turbine is connected to the output shaft of the transmission. It is present at the engine side. It also consists of curved and
angled blades. The blades of the turbine are designed in such a way that it can change the direction of the fluid completely that
strikes on its blades. It is the change in the direction of the fluid that forces the blades to move in the direction of the impeller. As
the turbine rotates the input shaft of the transmission also rotates and made the machine to move.
The stator is located in between the impeller and turbine, and it’s fixed to the housing of the torque convertor, so it cannot rotate, it
will force the oil flow to turn around and go back to the impeller. The main function of the stator is to give direction to the returning
fluid from the turbine, so that the fluid enters to the impeller in the direction of its rotation. As the fluid enters in the direction of the
impeller, it multiplies the torque. So the stator helps in the torque multiplication by changing the direction of the fluid and allows it
to enter in the direction of the impeller rotation. As the stator redirect oil flow back from turbine to impeller, the oil flow will
circulate continuously and its route forms a curve like a break circular coil spring .
When the impeller rotates, no matter how heavy the load is, the impeller just fling oil contained in the vane blade and hits the
turbine to drive the turbine to rotate, that is, the speed of the impeller has nothing to do with the strength of the load. The
turbine drive the output shaft through spline hole. If the speed of the turbine is equal to the speed of impeller, oil hitting the
turbine will not be reflected again; if the output load increases and the speed of the turbine decreases, then oil hitting turbine
will be reflected. And the reflected oil volume and speed (i.e. force) increase as the load increases and the speed of the turbine
decreases. The oil that hits the stator, because stator and casing of torque converter are fixed together, so the oil will be
refracted back and hit the turbine, so that the turbine is not only driven by impeller, but also by the constant force of oil
refracted . Therefore, the output torque of the torque converter can automatically change with load change.
As load increases, the output speed of the torque converter automatically decreases, or even drops to zero, speed difference
between impeller and turbine will become bigger, and the output torque will increase automatically to the maximum; when
the load decreases, the output speed of the torque converter automatically increases, or even rises to the same level as the
impeller. The rotational speed of impeller and turbine is almost equal, and the output torque is automatically reduced, even to
zero. This is the automatic torque adaptation of torque converter.
We can see that A torque converter is a type of fluid coupling that transfers mechanical power from the engine to kinetic
energy and hydraulic pressure energy, and the turbine then transfers this kinetic and hydraulic pressure energy into rotating
power to drive load, the stator itself do not transmit energy, but only transfer the hydraulic pressure energy into kinetic
energy and change oil flow direction, the oil just works as a media to transmit energy.
Therefore, the hydraulic torque converter converts the mechanical energy input by the engine into hydraulic energy of fluid,
then converts the hydraulic energy into mechanical energy output again to drive the load, and plays a part in torque
transmission and torque variation according external load.
Hydraulic torque converter is filled up with transmission oil that circulates in the spiral circle passage formed by the three
basic elements; however, some of the oil will inevitably escape from the gap between the three operational components, and
enters oil passage for output shaft and stator adaptor, and then flow out from torque converter for cooling via outlet relief
valve. So it still needs fresh oil feeding to fill up the vacuum that may caused by internal leakage, otherwise cavitation may
happen inside of the torque converter, and cause damage and energy loss. And the oil leaked is also forced to circulate under
pressure. Usually we call oil circulation inside of the three elements internal circulation, and call the circulation of oil in the
housing external circulation.
Inlet relief
In order to compensate the fluid leakage of the hydraulic torque port
converter and prevent from cavitation, some auxiliary devices, Oil outlet
including scavenge pump, inlet and outlet relief valve are

integrated on the torque converter.
The fresh oil enters torque converter from inlet port, where a inlet
relief valve is installed.
When the torque converter works at low speed ratio, the inlet
pressure is low too, so more heat will be generated by torque
converter, and at this moment, only a small amount of fresh oil
overflows from the relief valve, and most of it takes heat away via Oil
circulation inside of the three operation components. As speed temperature Oil inlet
tapping port
ratio increases, the inlet pressure value increase as well, the
amount of fresh oil that bypass from safety valve also increases,
the fresh oil supplied to the torque converter decreases, and Scavenge oil
Scavenge outlet
meanwhile, the air generated by torque converter is also small, so Pump
it plays a certain role of automatic adjustment.
Torque converter inlet relief valve and torque converter

Inlet relief
outlet relief valve are installed on the outside of the Outlet Relief port
torque converter housing. The operation of both valves Valve
is identical.
Inlet relief valve limits maximum pressure of oil that is
flowing to the torque converter. The oil supply comes
from transmission pump. The oil is filtered before
delivered torque converter. The inlet relief valve ensures
that the maximum oil pressure to the torque converter
does not exceed approximately 8.7 bar. The purpose of
inlet relief valve is to prevent damage to the torque
converter when the engine is started and the oil is cold.
Torque converter outlet relief valve maintain minimum
pressure of the oil inside the torque converter, so as to
prevent from cavitation . The outlet relief pressure is
about 4.5 bar
Operation & Maintenance
04 of Torque Converter
Page 22
1. Please use transmission oil as specified
1.1 Characteristics of transmission oil

Transmission oil requires good low temperature fluidity, suitable high temperature viscosity, good thermal oxidation stability,
certain lubricity, anti-wear properties, good anti-foaming and outgassing properties, etc.
1.2 The roles of transmission oil

(1) As a media to transmit power from engine to transmission
(2) Lubricate torque converter and transmission;
(3) The working medium for hydraulic circuit of transmission gear shifting, steering and braking;
(4) Heat carrier for radiation.
1.3. Types of transmission oil in use

Usually we use 6# or 8# transmission oil for transmission & steering hydraulic system in Zoomlion dozer, including torque
converter,.
1.4 Operational Temperature for Torque Converter
When hydraulic components of torque converter work at high temperatures, it will become less reliable, for the working fluid will
deteriorate more quickly, and the seals are tend to age easier. The ideal temperature for transmission oil to work properly is
between 90~120℃，take oil quality in most country into consideration, it is recommended that the upper limit should be
around 110°C. After long time working with heavy load, the oil temperature man rise sharply and exceeds 120°C. then it’s better
to unload the bucket, and let the machine run without load for a while, till oil temperature drops below upper limit, If necessary,
stop and check to find out the cause of the failure.
1.5 Keep transmission oil clean

Transmission oil used in power transmission system and steering system, is not only a medium for transmitting energy, but also
working as lubricant, so it must be kept clean. During transportation, storage and use, the container must be clean and sealed
well, no impurities and other type of oil is allowed to intrude into transmission oil.
2. Precautions for operating hydraulic torque converter
1) Before installing the torque converter on the main engine, check whether the rotating parts rotate flexibly and whether there is
any parts stuck or break, and add a proper amount of transmission oil to transmission or steering clutch case.
2) Start the engine, run the torque converter at low speed for 1 to 2 minutes, and fill the tank again to make sure oil level keeps at
specified level. During filling process, let air go out from the system
3) After the torque converter starts running, it’s not supposed to run immediately at high speed and with heavy load, please let it run
at low speed and then medium speed without load for several minutes before heavy load operation. Keep observing and listening to
torque converter, and check whether there is anything abnormal, please stop the machine for check in case of exceptional situation .
During operation, keep observing oil temperature, make sure it’s within normal range, the transmission oil level should be checked at
least once a week, if it’s below specified level, please fill to standard level in time .
4）As a hydrodynamic dozer, usually the engine will not flameout when the machine stalls, however, the operator should always
keep observing oil temperature, if it rises very quickly, please lift up the bucket a little bit to reduce load, otherwise the machine will
work in an extremely low efficiency zone, where almost all of engine power output is converted into heat to bring up oil temperature,
and seals may aging more quickly.
Maintenance of Torque Converter
1. Daily inspection
(1) Oil level inspection. In any case, oil level in torque converter keep between specified level range, leakage may cause oil level
become abnormal. If oil level is too low, it will cause pressure at inlet and outlet port of torque converter is low , and
therefore results in torque output becoming low, and it may also cause other components are poorly lubricated, and hence
service life is shortened. If the oil level is two high, it will bring extra load to the torque converter, and make it efficiency
becomes low, and oil temperature rise beyond normal range.
(2) Oil temperature observation. Oil temperature of torque converter varies with different working conditions. For ZD220-3
torque converter, its normal operating temperature is 100°C±5°C at the inlet, and the maximum permissible temperature at
the outlet is 120°C, and it can be allowed to reach 130°C in a short period. To measure oil temperature at inlet port , you need
to shut down the engine, and then open the cover of fine transmission filter quickly, and put a thermometer into oil filter and
read temperature before keep it in the filter for about 1 minutes, if you can finish all this in two minutes after engine shut
down, you should add 5~10℃ to the reading value to get the exact temperature. For outlet oil temperature, you can read
directly from the thermometer on the display instrument panel.
3) Inspection of inlet and outlet oil pressure. Check the maximum and minimum value of inlet and outlet pressure when
engine at full speed, and torque converter works at starting-up and idling. When torque converter of ZD220-3 works under
full engine speed, the inlet relief valve should open at 0.87~0.9 Mpa, the outlet pressure should be 0.4~0.5 Mpa, when it
works under idling engine speed, the inlet relief valve is closed, the inlet pressure is 0.4~0.6Mpa, and outlet pressure is
relatively a bit lower, about 0.2~03Mpa, if the pressure is abnormal, check and eliminate possible failure.
(4) Check whether there is any oil leaks from connections of inlet hoses or pipelines , if there is, air may intrude from the
leaking point, and cause performance degeneration to torque converter.

2. Periodic Inspection
◆ When checking oil level, you can dip some oil with you finger from dipstick, and rub between your thumb and forefinger to feel it,
check whether there is any particles, and you can also smell the oil on dipstick, if you found there is any debris, or water intruding, or
abnormal smell, then you need to find out the root cause. Usually, the transmission oil should be replaced every 1000 hours according
to different work conditions. If there is a lot of debris, or it’s working under high temperature frequently and oil already deteriorate,
then you need to change oil immediately , and the filter should be replaced at the same time while change transmission oil, and if
there is any metallic particles in oil, please clean the hydraulic system thoroughly.
◆ Draining and filling oil. Drain oil first with engine stopped. Since there may be residual oil in the torque converter, you can start the
engine to run at 1000r/min for 20-30s, and then drain residual oil, since lubrication is poor in this condition, the engine running time
should not exceed 30s. When refiling, add a certain amount of oil firstly while engine stopped, then start the engine to run at idle
speed to fill the entire system with oil, and then add oil to the specified level after running at idling speed for 2 minutes.
◆ Keep both air vent for transmission & steering clutch case unobstructed. check and clean both air vents frequently. If the vent is
clogged, transmission oil will be rapidly oxidized and thickened, forming sludge. So please clean the air vent every time when you
change transmission oil.
◆ Check the starting condition of the torque converter. The purpose is to check and judge whether the matching between engine and
torque converter meets the design requirements under the starting condition. When checking, firstly preheat the engine and let it run
at idle speed, brake the output shaft of the torque converter, and then increase engine speed gradually to full speed. The time for
torque converter to work under this condition should not exceed 30s, and the outlet oil temperature should not exceeds maximum
permissible oil temperature. Observe whether the engine speed and inlet oil pressure of the torque converter are consistent with the
design data at this moment.
3. Maintenance
◼ Maintenance every 100 hours
Check and clean the oil filter
◼ Maintenance for the initial 250 hours
Change transmission oil and clean strainer
Check and replace transmission oil filter, and check oil level & oil quality
Maintenance every 1000 hours
When changing transmission oil , do not open the drain plug until oil totally cooled down, and check whether there is any
metallic debris or particles in the drained oil, if there is, that means the torque converter need to be disassembled and repaired,
and please clean the filter housing and replace transmission oil filter.
Usually, the torque converter should be disassembled for maintenance after 2400 hours of operation. Change wear parts and
seals. if the torque converter overheats frequently, and there is abnormal noise from it, or if there is heavy internal leakage, which
caused its performance attenuated, then it must be disassemble for repairing as well.
Common Failures & Trouble
05 Shooting to Torque Converter
Page 30
The torque converter may have vary types of faults during operation, and serious accidents may occur if they are not eliminated in
time. Therefore, any malfunction should be taken seriously. When troubleshooting , please observe and analyze carefully before
you remove any parts or disassemble the torque converter, and then take appropriate measures to eliminate them after
meticulous analysis.
The torque converter is installed to the flywheel of engine as a hydraulic element for power transmission, and the transmission oil
is provided by the variable speed hydraulic control system. When analyzing the failure of this hydraulic system, the work principle
of this hydraulic system should be understood, and then analyze the problem according to its work principle , eliminate the
possible causes one by one from easy to difficult , until the problem is solved.
In order to diagnose the failure of hydraulic system, on-site investigation should be carried out according to the failure
phenomenon, asking how the problem happened, roughly determine the scope of causes on the basis of analysis hydraulic
system diagram, make a list of possible causes to the problem, and formulate inspection and diagnosis procedures, and conduct
preliminary inspections to hydraulic system, such as oil level, transmission oil filter, leakage. If oil level is low, or filter is clogged, or
oil deteriorated or contaminated seriously, or there is oil leakage, please eliminate all this phenomenon first, and then check
pressure and flow rate of the hydraulic system. Usually we will check pressure, it should keep in accordance with designed value.
Use pressure gauge to test oil pressure.
Torque Converter Troubleshooting Method
Many failures of bulldozers, such as torque converter overheating, powerless pushing, are indicated by torque
converter, to sort out such kind of problems, we must know the correct way to troubleshoot failures to torque
converter.
To troubleshoot torque converter failures, usually there are three steps to follow:
1. Transmission oil filter inspection

2. Scavenge pump and its filter inspection
3. Inlet and outlet pressure inspection
Step 1: Transmission oil filter inspection
Take the transmission oil filter out, and check whether there is any metallic particles, if there is any aluminum skimmings, it
indicates collision or friction between the three basic elements of torque converter and bearing damage, the torque converter
must be removed for disassembling and inspection.
check the oil quality at he meantime:
• check the color of oil , the transmission oil we use in China are usually 6# and 8# fluid drive oil. Both of them are special oil
with color agents, usually looks red or blue transparent , it should never been mixed with other type and brand of oil. It
should be stored carefully to prevent from contamination, the container and filling utensil should be clean and well sealed,
to avoid from emulsification and deterioration. If it turns black, it indicates that the oil has been deteriorated; if it is in silver
gray, it indicates collision and friction between the three basic elements of torque converter, generates a lot of aluminum
powder, and a lot of heat to make the torque converter overheating as well.
• Dip some oil from dipstick and check smell of oil.

• When checking oil level, you can dip some oil with you finger from dipstick, and rub between your thumb and forefinger to
feel it, check whether there is any particles, , if you found there is any debris, or water intruding, or abnormal smell, then you
need to find out the root cause. Usually, the transmission oil should be replaced every 1000 hours according to different work
conditions. If there is a lot of debris, or it’s working under high temperature frequently and oil already deteriorate, then you
need to change oil immediately , and the filter should be replaced at the same time while change transmission oil, and if there
is any metallic particles in oil, please clean the hydraulic system thoroughly. If there is metallic particles in oil, please
distinguish what kind of material it is, if it’s iron, you can use magnet to test, usually we can the origin of these particle from
its size and shape, for example, metallic flakes, granules, powders origins from welding slag remained in the pipeline, or from
broken gear or abnormal wear. If the color of the metallic particles is yellow or golden, it can be preliminarily judged as copper
scraps, usually it origins from friction disc of transmission.
Step 2: Scavenge pump and its filter inspection
Unscrew the drain plug at the bottom of torque converter, check whether the filter for scavenge pump is clogged, if not,
check the volume of oil drained from torque converter housing, if there is a lot, screw on the drain plug, remove the
discharging hose for the scavenge pump, and start engine, check flow rate of discharged oil by scavenge pump, if it is
beyond specified value, it indicates there is serious internal leakage, it needs to be removed for disassembling and
repairing.
Step 3: Inlet and outlet pressure inspection
Measure the pressures at the inlet and outlet of the torque converter both with full engine speed and idling speed, check
whether it’s within standard range.
Through the three steps above , if nothing abnormal is noticed, it indicates that the torque converter has no problem, you
need to check other components till you sort it out.
Typical Failure
1. Leakage
Oil leaks from the seal at the end of output shaft of torque converter is a common problem we may encounter with,
and the way for oil leaking could be very different, How to find a quick solution to oil leakage and analyze the cause
of oil leakage is an issue that is urgent to be solved. In order to solve the problem as soon as possible and correctly,
find out the root cause of oil leakage, we must learn about the sealing mechanism of seals and work condition
before we can identify the root cause.
The above figure lists the leakage phenomenon and cause analysis, and gives solutions.
Case 1: Torque converter overheats and become powerless when pushing material after two hours operation.
Inspection Steps: PTFE sealing ring
1. Check filter for scavenge pump and oil quality, there is no debris or particles in oil,
and filter for scavenge pump is not clogged.
2. Check scavenge pump, there is no bruise or abnormal wear, there is a lot of oil in
Cast iron sealing ring
the casing of torque converter .
3. Check inlet and outlet pressures of torque converter, with full engine speed, inlet
pressure is 0.4Mpa, and outlet pressure is 0.2Mpa , if both inlet and outlet
pressure are low, which indicates there is internal leakage in torque converter.
4. Remove the torque converter for inspection: Find that the buckle for cast iron sealing on the torque converter output shaft
decoupled, check the size of PTFE sealing ring on the gear, and find that the sealing ring is unevenly worn out.
Root cause analysis:
The oil is deteriorated or contaminated, which cause the PTFE sealing ring worn out , the buckle of cast iron sealing ring decoupled,
which will lead to serious internal leakage, excessive oil will cause oil accumulated in housing of torque converter since it’s beyond
the discharge capacity of scavenge pump, as oil level in torque converter housing rising, it will give more and more extra resistance
to impeller and turbine. And this will cause torque converter overheating, additionally, the low pressure in torque converter will make
it powerless. The machine resumed normal after replaced the two sealing ring.
Case 2: Powerless when pushing material.
After pressure testing, found that both inlet and outlet pressure for torque
converter are very low, and pressure for lubrication is almost zero, and
pressure for gear shifting at every gears are normal, and according to this
tested results, torque converter is under suspicion to have internal leakage.
After disassembled the torque converter, we found that 2/3 of the bolts
for power input gear are damaged, and caused oil leaks into casing of
torque converter.
2. Torque converter overheating
2.1 If classify by speed of temperature increasing, It may be classified into types of overheating to torque converter :
(1) The temperature rises quickly up to more than 120℃ in just about 20~30 minutes.
(2) The temperature rises to above 110℃ after around two hours, and the machine becomes powerless while pushing material.
2.2 If classify by causes of overheating, It may be classified into several situation, cooling system, hydraulic system, working
condition, abnormal wear etc.
2.3 Check and analysis
If the oil temperature rises very quickly, first check oil quality for impurities and observe the color of oil. If the color is silvery white,
it indicates a large number of aluminum skimmings due to friction between the three basic elements of torque converter. If the
color is yellow or golden, and there is yellow powder or flaky, granular foreign matters , there may be serious wear in the friction
disc of transmission, so we can find out a suspect roughly. Usually, this kind of rapid temperature rising is caused by friction
between running components. For example, the three basic elements collided against each other ,or the roller of bearing is stuck,
and sliding friction occurs between roller and roller race. Gears off-center and rub against the housing. The best way to judge
such kind of problem is to check color of oil, and particles in oil.
In some situation, this kind of phenomenon is caused by multiple factors, besides factors listed above, there is internal leakage,
poor radiation, or hose blocked or throttled.
If the operator has changed oil, it will become difficult to find out the root cause from quality of oil, then the only way is to test
pressure and check oil level.
Firstly measure inlet and outlet pressures of torque converter

both under full engine speed and idling speed, compare with
standard values, If it’s incorrect, let the dozer run for more than
ten minutes, check oil level in rear axle case, if it dropped, then
there may be two causes, i.e. one cause is scavenge pump
damaged, which make it incapable to discharge oil in housing of
torque converter in time. The other cause is serious internal
leakage in torque converter, and it’s beyond the discharge
capacity of scavenge pump.
The causes of internal leakage are shown in the figure on right.
Usually it can be recognized by testing pressure as case 1 and
case 2 mentioned in previous slide.
If temperature rises slowly, the major cause is internal leakage.
You need to check internal leakage and pressure.
2.4 Cause analysis

The higher oil temperature in the torque converter, the lower oil viscosity, too high oil temperature will cause the following
adverse effects: ① oil will produce bubbles, oxidation deposit, susceptible to deterioration; ②oil viscosity becomes low, then
transmission system cannot be well lubricated, easy to cause system leakage; ③ Too high oil temperature will cause
deformation and aging of rubber seals, then sealing performance of seals will become very poor, leakage will cause energy
loss, and even accident.
There are many factors will cause torque converter overheating, when trouble shooting it’s better to start from the easier
steps then to more difficult, exclude one by one.
The main causes for torque converter overheating are:

I) Serious internal leakage, and make oil level in the housing of torque converter become high
II) Oil level in transmission is too high, which will put more resistance to the running components,
III) The outlet pressure relief valve setting is too high,
IV. The outlet pressure relief valve is stuck, and cannot open.
V. Scavenge pump is worn out, and oil in the housing of torque converter cannot be discharged timely.
VI. Hose blocked
VII. The system pressure relief valve does not work properly.
VIII. Abnormal wear or damage to torque converter or transmission. For example, the bearing for turbine shaft is loose, turbine
rub against impeller or stator, friction plate of transmission slips, center of gear off-center and rub against housing.
IX. Oil inlet to torque converter is insufficient, for example, oil level in transmission is low, or there is bubbles in oil, seals for
transmission pump worn out, transmission pressure is low, transmission filter clogged etc.
X. Use wrong transmission oil,
XI. The torque converter works at low efficiency area for too long time
XII. Poor cooling caused by fan belt slipping, defective fan, too much clearance between water pump and its housing, low
coolant level, radiator clogged etc.
Steps for trouble shooting to problem of torque converter overheating
3. Powerless material pushing
The output torque of turbine shaft is low, and reveal itself as powerless when pushing material.
The main causes are as follows:

① Oil level in transmission is low , resulting in insufficient oil suction of the transmission pump, and therefore oil discharged will be
insufficient as well. The pressure regulating valve in transmission control valve will give priority to ensure pressure for gear
shifting, and the surplus oil will be delivered to torque converter, so this will cause torque converter cannot be fed with enough oil,
pressure in torque converter will drop, and cause torque output become low.
② The inlet pressure is too low, and there are a lot of air bubbles, oil temperature is too high, due to the low inlet pressure, cavitation
may occur inside of torque converter under centrifugal force of impeller and turbine, and generates a lot of heat, then efficiency
and output torque of torque converter will become low, additionally, cooling effect inside of torque converter will become poor as
well due to insufficient oil supply.
③ Insufficient engine power is also one of the reasons for insufficient output torque of the turbine shaft;
④ Too much internal leakage. Too much internal leakage will cause pressure both at inlet and outlet very low, and at the meantime,
less oil will drive turbine, so energy loss becomes high, The reasons for excessive internal leakage are: the sealing ring in torque
converter is worn out or improperly installed; the sealing ring on the output shaft and stator seat is aging; the gap between stator
seat and the housing is too big, or there is porous hole on impeller, or the drain plug on impeller is loose, the bolts for driving gear
is loose or broken.
⑤ the bearing is damaged, and speed up wearing of sealing, and cause the three basic elements rub against each other, generates a
lot of heat, oil viscosity drops and output torque become low.
⑥ Oil level in transmission is too high, and cause difficult to accelerate for the transmission and turbine of torque converter, and it
may also cause leakage from seals.
⑦ The clutch in transmission slips or cannot be engaged.

The modern bulldozers generally employs hydrodynamic & mechanical transmission system. The key for trouble shooting is to understand
the working principles of system and the functions of each assembly and parts; know location of each check points and the corresponding
standard value, and analyze comprehensively according to the phenomenon. When material pushing of bulldozer become powerless, please
inspect as following trouble shooting diagram.
Usually, the universal joint of bulldozer should accelerate very fast to 1200r/min or above after engine started and accelerate a little bit. If the
universal joint can accelerate soundly, please take transmission and steering system as you major concern for trouble shooting. After starting
engine, use a 6Mpa pressure gauge to test inlet pressure, and at the meantime, step down the brake pedal and shift to gear 1, usually, there
will be three circumstances, and we can have a rough clue for troubleshooting according to these circumstances.
(1) After the bulldozer started, if pressure is low, and when shifting gears, pressure changes very little, this is caused by problem
in transmission and torque converter hydraulic control system. Please check pipeline connection for leakage, air intruding, or
clogging and etc. if nothing abnormal, then open transmission filter, check whether transmission filter is clogged, if transmission
filter is also normal, then inspect or replace transmission pump.
(2) After the machine is started, pressure can reach to 2Mpa, but it drops when shifting gears, this indicates torque converter is
normal, you need to check transmission. Firstly, please check transmission control vale, repair or replace it if there is problem with
it, if it’s normal, then please inspect transmission. For transmission, usually there are two types of failure.
A． Hydraulic system failure——caused by piston ring or seals damage, in this circumstance, just replace the damaged piston
ring or seals..
B. Mechanical failure——repair or replaced the damaged parts.
(3) If pressure is normal, the failure is basically cause by steering & braking system.
① Due to error of mechanical process or improper adjustment, brake booster acts improperly after engine starts, it holds the
driven hub of steering clutch, which will cause material pushing powerless.
②The steering control valve always stays at open position due to improper adjustment of steering control lever, and steering
clutch keeps partially disengaged, and cause power transmission efficiency low. In this circumstance, please adjust the travel of
steering control lever to eliminate the problem. It is worth noting that this fault is often disguised and is difficult to be discovered
when the machine working under light or medium duty. Therefore, if it’s a new machine, it maybe caused by steering and braking
system.
If the rotating speed of the universal joint rises slowly or fails to rise after engine starts, it indicates that there is problem. In
addition, if the universal joint rotate normally when transmission in neutral gear, and speed decreases very fast and even
stops after shifting to working gears, then we can determine that the problem lies in engine and torque converter, and if the
inlet pressure is about 0.8Mpa when engine running at full speed, then the problem lies in the engine system, if the inlet
pressure is abnormal at full engine speed, then the problem lies in torque converter.
If the engine is powerless, then check fuel feeding lines first, fuel feed pressure may be low if fuel feed lines is clogged, hence
engine power output becomes low, if there is clogging along the lines, clean or clear it. If there is no clogging , then check air
intaking pipelines, and then repair engine under guideline of engine shop manual.
If relief pressure is low , then check oil level in transmission. If there is not enough oil supply to torque converter, it will cause
the machine powerless, if oil level is ok, then check whether there is any air intruding, pipelines clogging or loosing connection.
If everything mentioned above is normal, but the relief pressure is still low, then you need to disassemble the torque
converter for inspection, check whether the scavenge pump is damaged, or whether the plug on turbine housing is loose, or
any seals is damaged.
THANKS!
地址:湖南省长沙市银盆南路361号(中联科技园) 邮编：410013
http://www.zoomlion.com Tel:+86 731 89751871

Structure & Work Principle of Torque Converter

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Structure & Work Principle of Torque Converter

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Structure & Work Principle of

02 Benefits of Torque Converter

03 Work Principle of Torque Converter

04 Operation & Maintenance of Torque Converter

05 Common Failures & Trouble Shooting to Torque Converter

Driving Inlet relief

Outer Scavenge oil

Zoomlion bulldozer employs a single-phase single-stage

Stage: Number of turbine

Operational phases: Operational stages number of torque

⑤Torque-limiting protection function: Engine will never flameout even though

including scavenge pump, inlet and outlet relief valve are

Torque converter inlet relief valve and torque converter

1. Please use transmission oil as specified

1.1 Characteristics of transmission oil

1.2 The roles of transmission oil

1.3. Types of transmission oil in use

1.5 Keep transmission oil clean

leaking point, and cause performance degeneration to torque converter.

Torque Converter Troubleshooting Method

1. Transmission oil filter inspection

Step 1: Transmission oil filter inspection

• Dip some oil from dipstick and check smell of oil.

Step 2: Scavenge pump and its filter inspection

Step 3: Inlet and outlet pressure inspection

Case 2: Powerless when pushing material.

2. Torque converter overheating

Firstly measure inlet and outlet pressures of torque converter

2.4 Cause analysis

The main causes for torque converter overheating are:

3. Powerless material pushing

The main causes are as follows:

may also cause leakage from seals.

⑦ The clutch in transmission slips or cannot be engaged.

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