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If Variator Boss length is too short
Table of Contents
Variator Boss length is too short or Fan is too thin, What should be done
Preface
In order to make the video is easier to be understood by the audience (newcomers), the presentation of this video is not like the real situation but in an exaggerated one, so please consider it is just a reference carefully before you watch.
Basic
It is one engine Crankshaft , it is driven by the energy produced from the fuel.
It is a Fan, already installed at the restricted position (the innermost). The Crankshaft and the Fan are rotated synchronously.
It is a Ramp Plate, installed at the innermost position, the Crankshaft and the Fan rotate together but the Ramp Plate does not rotate.
It is a Boss, When it is installed, the Fan blade will move back a little bit (to the right side). Although the Fan is in contact with the Boss, the boss does not rotate when the Fan rotates. At this stage, only the Crankshaft and the Fan rotate.
It is a Variator, Even after Variator is installed, only the Crankshaft and Fan did rotate.
Finally, even after the V-belt (section view) is installed, still only the Crankshaft and Fan did rotate. Strange? Why is this? Because the Lock Nut does not exist!!!
It’s a Lock Nut, After it is locked, a pressing force (pressure) is produced to compress all the components and make the rotating crankshaft will drive all related components rotate together.
The strength of locking torque must meet the specifications from various manufacturers, too high or too low is a problem.
Power Transfer Process
In the previous explanation, it already said the sequence of installation about every component is not the real case, the purpose of this explanation is just to tell everyone that transmission of each component has its order. This chapter will have further discussion in detailed.
First of all, the Crankshaft makes the fan rotate, and then there will be two routes for power transfer:
- Route one: Fan ⇨ Boss ⇨ Ramp Plate ⇨ Variator ⇨ V-belt ⇨ Fan (back to origin point).
- Route two: Fan ⇨ V-belt ⇨ Variator ⇨ Ramp plate ⇨ Boss ⇨ Fan (back to origin point).
The two routes are carried out at the same time, and both will return to the original point, but the sequence is reversed.
In some vehicles the V-Belts are in contact with the boss even it’s at idle state. The power transfer process will be a bit different from the above mentioned, but after acceleration, the V-Belt position will move outwards, which will be the same.
When the Boss is too short
When the Boss is too short (red), the position of Fan will move inward, and the V-Belt position will be forced to move outward, which makes the Low-Speed gear ratio value becomes smaller.
When the Crankshaft rotates, it will be founded that the boss is still inactive, other parts are operating normally, and the vehicle can be ridden normally, but this situation will not last very long, and problems will soon occur.
What are the hazards
Since the Variator and the Boss do not rotate synchronously, it means that the two parts are rubbing against each other. The working temperature is higher than normal state due to friction heat. In severe cases, the Variator and the Boss may jam.
In addition, the initial acceleration of vehicle becomes lower, and the V-Belt life will be shorter.
Why doesn’t the Boss move?
Do you remember the power transfer process?
- Route one: Fan ✗ Boss ✗ Ramp Plate ✗ Variator ✗ V-belt ✗ Fan (back to origin point).
- –The Ramp Plate is unable to drive the boss to rotate.
- Route two: Fan ⇨ V-belt ⇨ Variator ⇨ Ramp plate ✗ Boss ✗ Fan (back to origin point).
- -The Fan is unable to drive the Boss to rotate.
The V-belt, Variator, and Ramp Plate can be rotated, but the transmission efficiency will become worse and the synchronization rate will decrease.
How to judge the length of the Boss is sufficient
Discussion from the conclusion, after the boss is installed, the height of Boss needs to exceed the yellow line, which means that the boss can directly contact the fan.
At the same time, this is also the extreme inner point where the Fan is installed inside.
If the Fan is really installed on this yellow line, it means that the Boss is not in direct contact with the Fan.
Install the Ramp Plate, Variator, Boss, etc., all three parts and push them to the bottom position and the top portion of Boss is beyond the yellow line boundary, then this is correct.
Take a section of the boss and take a look about the inside portion that will be more clearer.
Now, changing to a shorter Boss even if the Fan has been installed more inside (moved to the left), the fan still do not touch the boss.
In other words, even if the Crankshaft drives the Fan to rotate, the Fan still unable to make the Boss to rotate.
What to do if the Boss is too short
The most economical method is by installing the gasket(Washer) to fill the gap until it exceeds the yellow line position.
Now the entire height has exceeded the yellow line position, so the Crankshaft can be rotated to drive all parts to rotate
When the thickness of Fan is too small
After Fan’s installation must be beyond the yellow line position. Take a section of the Fan and take a look about the inside portion that will be clearer.
At the same time, the yellow line is the limit point at which the lock nut can be able to be locked. It can be seen that this is no problem now.
Changing to a thinner fan, lower than the yellow line boundary now. At this state, the lock nut “locked” still is not in contact with the Fan (moving to the left) even the Lock Nut is locked.
This is a problem, that represents the locking force, axial force, and pressing force Not effective on all parts.
The crankshaft drives the fan, but all other parts are found to be in a stationary state. And it is easier to find its abnormalities because the vehicle may have problems even at the start.
What should be done if the Fan thickness is too low
The most economical way is by installing spacers (Washer), it makes up the thickness needed, then the axial force of the locked Lock-Nut can be heavily pressured on the Fan, even on all parts.
So when the Fan rotates, it can drive all the parts!
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