Welcome to

1. Welcome to AfterSalesTraining

2. R105 Electro Mechanical Continuously Variable Transmission (Em-CVT) Type Instructor Name Here

3. Introduction • Your Name • Your Dealership • Previous Training Courses or Past Experience • Hobbies and Interests • Did You Ask to Come on This Course • What Do You Hope to Gain From This Course

4. Comfort & Convenience • Coffee Breaks • Lunch Arrangements • Telephones • Messages • Start & Finish Times • Toilets • Smoking Policy • Fire Precautions

5. Introduction • Course Code : R105 • Course Title : Em-CVT • Course Duration : 1 Day

6. Course Aim : - Introduction To Ensure All Delegates Are Familiar With the Components, Structure and Operation of the Em-CVT Gearbox

7. Course Objective : - At the End of This Course With the Aid of Support Material, the Delegates Will Be Familiar With the Operation, Location & Functionality of the Em-CVT Gearbox and Interfaces and Be Able to Diagnose the Em-CVT Systems Using the Latest Diagnostic Equipment.

8. Introduction Course Content : • Exercises in Fault Diagnosis • Fault Code Retrieval • Vehicle Repair Procedures • A Detailed Insight into all Em-CVT Components, Their Function & Location.

9. Continuously Variable Transmission • Origins Date Back to 1974 • Rubber Drive Belt Construction External to Gearbox • Replaced by a Steel Belt Internal to Gearbox Unit

10. EM – CVT Stepspeed

11. EM-CVT Advantages • Low Engine Revolutions at Constant Vehicle Speeds • Improved Emission Control • Low Noise, Vibration and Harshness Levels • Smooth Acceleration • Flexible Mountain Driving

12. Models Available MGF & MG TF • 1.8i K – Series 16 valve Rover 25/MG ZR • 1.6i K – Series 16 valve • 1.8i K – Series 16 valve Rover 45/MG ZS • 1.6i K – Series 16 valve • 1.8i K – Series 16 valve

13. Operation Primary Pulley Secondary Pulley

14. Planetary Gear Set Multiple Clutches Primary Pulley Steel Drive Belt Secondary Pulley Pinion Shaft Differential Unit Mechanical Layout – Group One Elements Providing Torque Flow Through the Transmission

15. Mechanical Layout - Group Two Elements Relate to the Hydraulic System According to Load and Driver Conditions • Hydraulic Pump • Hydraulic Control Unit

16. Selector Mechanism Speedometer Steering Wheel Switches MGF & TF Only Ratio Control Motor Oil Cooler Connections Park/Neutral Switch Mechanical Layout – Group Three Elements That Have External Connections From the Transmission

17. Group One Torque Flow

18. Torsional Vibration Damper

19. Torsional Vibration Damper • Replaces Torque Converter Used by Conventional Automatic Transmission • Engine Power Connected to Input Shaft of the Transmission Via Torsional Damper • Splined to Input Shaft of Transmission • Bolted to “Drive Plate” on Engine

20. Planetary Gear Set

21. Planetary Gear Set • Planetary Gear Set Provides Drive Torque in Two Directions – Forward & Reverse • Engine Torque Always Enters Transmission Via Planet Carrier Through Input Shaft

22. Forward & Reverse Clutches

23. Clutch Packs

24. Clutches • Two Multiplate Clutch Packs - One Forward One Reverse • Forward Clutch Operates and Epicyclical Gear Set Operates As One Unit – Forward Drive

25. Forward Clutch Applied

26. Clutches • Reverse Clutch Operates • Annulus of the Planetary Gear Set Is Held Stationary • Three Pairs of Planet Gears Driven by Planet Carrier Forcing Sun Wheel to Operate in Opposite Direction – Reverse Drive

27. Reverse Clutch Applied

28. Park/Neutral

29. Primary Pulley

30. Secondary Pulley

31. Pulleys • Each Pulley Consists of One Fixed Half and One Axially Mobile Half Both Having 11º Angles • Distance Between Primary and Secondary Pulleys 155mm

32. Drive Belt

33. Drive Belt • Van Doorne “Push” Type Belt 24mm Wide • Drive Belt Consists of 450 Segments (VT1 CVT Had 350 Segments) • Drive Belt Held Together by 24 Steel Bands – 12 Per Side

34. Belt Construction

35. Differential & Pinion Shaft

36. Layout

37. Group Two Hydraulics

38. Hydraulic Control System Functions • To Match the Belt Tension With Engine Torque to Prevent Belt Slip • To Control the Operation of the Forward & Reverse Clutches at Take off and Also Driving • To Provide Optimum Ratio for All Driving Conditions

39. Oil Pump

40. Oil Pump • Oil Pump Housed Within the Transmission Case • Pump Shaft Splined and Driven by Planet Carrier • Always Runs at Engine Speed

41. Oil Pump • Oil Pressure Used for Controlling Both Transmission Hydraulically and for Lubrication Purposes • Oil Cooler Stabilises Temperature at 80ºc - 120ºc • Operates at 40 Bar (588 Psi)

42. Hydraulic Control Unit

43. Hydraulic Control Unit Controls the Pulleys and Clutches • Primary Pressure Supplied to Primary Pulley to Control Ratio for All Driving Conditions • Secondary Pressure Supplied to Secondary Pulley to Ensure That There Is Always Adequate Clamping Force • Selection of Correct Clutch – Forward or Reverse

44. Primary Valve Secondary Valve Accumulator Valve Throttle Valve Pilot Valve Clutch Valve Safety Valve Cooler/Lock up Valve Manual Valve Hydraulic Control Unit Contents

45. Valve Body Inputs

46. 3 1 2 Primary Valve A Secondary Pressure B Primary Pitot Pressure C Primary Pressure D Return to Sump 1 Ratio Control Motor 2 Cap 3 Valve

47. Secondary Valve 2 A Secondary Pressure B Throttle Pressure C Clutch Pressure D Engine Pitot Pressure 1 Sensing Shoe 2 Valve 1

48. Sensing Shoe

49. Hydraulic Control System

50. Group Three External Connections