02 2 Powertrain Transmission

KT4036Slide 1

Structure and Function

Power Train - Transmission

KT4036Slide 2

Power Train Skeleton

KT4036Slide 3

Damper

KT4036Slide 4

Drive Shaft

KT4036Slide 5

1 4

56

37

2

Transmission Piping

KT4036Slide 6

290L/min : BCV ON

Rear Brakes Only310L/min E/G:1900rpm419L/min E/G:2450rpm

Brake Cooling Oil Control Valve

KT4036Slide 7

Torque Converter /PTO

KT4036Slide 8

Lockup Torque Converter

KT4036Slide 9

Main Flow Rate Selector ValveMain Relief Valve

Torque Converter Relief Valve

Pressure Switch

Flow Rate Selector Solenoid Main Relief Pressure Select Solenoid

Torque Converter Valve

KT4036Slide 10

Output Sensor

Intermediate Input

Transmission

KT4036Slide 11

Transmission

KT4036Slide 12

Time when gear cannot be shifted

KT4036Slide 13

Shift Down F7-F6-F5 ---, Even Operator tries from D-Position to L

Only N-Position, possible to start the Engine

More than 4km/h, impossible to change the direction. E/G speed lowered

1) Down- Shift Inhibitor Function

2) Neutral Safety Function

3) Directional Inhibit Function

4) Power Train Overrun Rear Brake function

If the E/G Speed rises to more than 2,350rpm ( at RH, 2,000) the central warning.Lamp flashes and the alarm buzzer sounds. If the E/G speed rises to more than

2,600rpm ( at RH 2,250rpm ), Rear Brake is automatically is automatically actuated

5) Reverse safety

After dumping, if the body isn’t completely seated, Keep 1st speed

6) Self- Diagnostic Function

The details of Self-Diagnosis are displayed on the Monitor as Action Code, The T/M System Caution Lamp, Warning Lamp or Alarm Buzzer sounds

Transmission safety Function

KT4036Slide 14

HD785-7 Transmission

T/C valveT/M valve

T/M Harness

OutputCoupling

Oil Pan

InputCoupling

Trunion

Lubrication valve

KT4036Slide 15

Torque Converter

* L/U pressure control valve on -5 in Torque Converter Valve has modified to ECMV on T/M valve seat.

T/C Valve has New Function to reduce Power Loss1) Flow Change Valve with Tandem Pump2) Main Pressure Switching Valve3) T/M Lubrication Flow change valve

1. Torque Converter Valve

2. PTO gear

3. T/C pressure sensor

4. Trunnion Shape

5. Lockup Clutch

The difference Points compared with -5 parts

Right Upper: Brake Cooling Pump Left Upper : S/T Hoist & Hoist & Hoist Control PumpRight Lower : T/C, T/M Charge Pump, Brake Cooling, Brake Control Pump

PTO Gear Torque Converter Valve

T/C pressure sensor

Coupling size Up

KT4036Slide 16

(4) Coupling - Size up #10C #11 - fixed Type Slide type To match Increased E/G Rated Output Power

(2) T/C pump capacity up (Changed T/C pump Vane Angle) Lowered E/G Rated Revolution 2000rpm 1900rpm to lower the Noise

(5) Stator Bush contains Silica employed to increase Heat Resistance ( R&M cost reduction )

(7) PTO Helical gear to lower noise

HD785-7

(8) Piston Sealing material changed from cast iron to Teflon ( R&M cost reduction )

(6) Reduce the Shock of Connection of Lock Up clutch L/U Valve change to ECMV. T/C Oil Pressure Sensor installed. to detect inside pressure of T/C to control Half Lock Up

(1) Lock up Clutch Disks Number Up ( 2 3 discs ) to ensure the Torque Capacity of E/G Output Up

(3) Trunion with wear sleeve for R&M cost reduction

HD785-5

: Improvement of Productivity

: Improvement of Comfort

: Improvement Reliability to reduce life cost

Torque Converter Improvement Contents

KT4036Slide 17

T/C Inside Pressure

By the completion of T/M Shift, keep a small high pressurethan inside pressure of T/C.This pressure is called Half Pressure.

T/C Travel to Direct Travel Operation T/C Travel Operation Direct Travel( From T/C Travel to

Direct Travel )

T/C Lock Up Clutch ( Half Pressure ) [No.1]

KT4036Slide 18

T/C Oil Outlet Passage

T/C Oil Inlet Passage

T/C Oil Circuit

T/C Inside Pressure is calculated with T/C Inletand Outlet Pressure Sensor as an average.


InsidePressur

e

KT4036Slide 19

L/U Oil Circuit

P1

P2

T/C inside is always applied internal Oil Pressure, because of this pressure, L/U Piston is pushed to relieve side of engagement, when L/U engages, oil Pressure should be higher than T/C internal Pressure to push L/U clutch piston.

Therefore, by sensing T/C internal pressure and give a higher current to proportional solenoid of ECMV to win the T/C internal pressure.

P1 : T/C Internal Pressure P2 : L/U Half Pressure a : Inflated Pressure P2 = P1 + a

P1 T/C Internal Pressure

L/U Oil Pressure Modulation

a


T/C Inside Pressure is calculated with T/C Inletand Outlet Pressure Sensor as an average.

InsidePressure

KT4036Slide 20

ECMV type was changed fromlarge ECMV Small ECMV

(11) Harness cover Material was changed to woven braid to increase the durability

(11) Unifying the T/M Oil with Retarder Oil T/M Oil Pan became large

(9) To reduce Power Loss and Fuel consumption 1) Flow Change Valve with Tandem Pump2) Main pressure Switching Valve3) T/M Lubrication Flow change valve




Transmission Improvement Contents [No.1]

KT4036Slide 21




(1) Reverse Grade ability increased Reverse speed is RL and RH • RL Reduction Gear Ratio 3.934 5.244 • Single Reverse planetary Gear was

applied to increase the efficiency

Medium shaft is size up to increase the durability 69.9 74.6

(3) Clutch Disk Durability improvement Material

- Ray flex G525 2) Number of discs increased

High : 4 5 discs 3rd : 3 4 discs

(4) Coupling size up #12 #14 to match increased ENG Max torque

Transmission Improvement Contents [No.2]

KT4036Slide 22

T/C Relief Valve

Main Relief Valve

Flow Change Valve

Pressure Switch for Main Pressure Change Valve

Solenoid for Main Pressure Change

Solenoid for Flow Change Valve

Pressure Switch for Flow Change Valve

Torque converter valve

Torque Converter Valve

KT4036Slide 23

By separating T/C and T/M Pump and according to the Engine Rev. T/C Pump Oil will be Merged or Divided.

Engine Rev. Less than 1000rpm: Merged

Engine Rev. More than 1100rpm: Divided

( A > B )

T/C Oil Flow will be pressurized according to the T/C Necessary Pressure

T/M, T/C Oil Pump

Relief valve( H )When ENG Rev, is low

or Oil Temp is low

Relief Valve ( L)

T/M

T/C

T/C Pump

Flow Chg valve

T/M

T/M Pump

Relief valve ( L )

Relief valve ( H )

T/C

T/M Controller

Overflow

Supplied Oilto T/C is lowered

<HD785-5> <HD785-7>

T/C,T/M Pump tandem

KT4036Slide 24

B

B

C CB

B

T/C T/C

Solenoid OFF Solenoid ON

When the solenoid (1) is disengaged, no oil flow to chamber A. Then spring (3) pushes the flow change valve(2) to the left. Then all oil from pump (B ) and (C) flow into T/M through main relief Valve( 4).

When the solenoid (1) is engaged, Oil flow to chamber A. and pushes the flow change valve(2) to the right. Then oil from pump (B) flows to T/M

Operation

Disengagement Engagement

through main relief valve and oil from pump (C ) bypassed and flows to torque converter.

C: T/C PumpB: T/M Pump

E/G Rev : Less than 1000rpm E/G Rev : More than 1100rpm

B

B

C CB

B

Flow change valve [No.1]

KT4036Slide 25

Below F3 : 35kg/cm2Above F4 : 21.5Kg/cm2

Signal

T/M Controller

T/M Pump

Solenoid Valve

Main Relief valve

Pilot Pressure

T/M Main Relief Pressure

According to the using Shift

Range,Main Relief Pressure

Will be changed

Changing main relief pressure

T/C

T/C

KT4036Slide 26

Outline : Switching Main relief pressure according to the shift range

Operation


When the solenoid (1) isn't energized, no oil pressure works in chamber A. Force of pressure in chamber B and spring force is balanced. Normal setting of main Relief Pressure.

When the solenoid (1) is energized, Oil pressure works in chamber A. So force of pressure of chamber A works main relief valve (3) to the left. So force of pressure in chamber B balanced by spring force decrease.

Disengagement Engagement Low Pressure High Pressure

Main relief pressure switching valve [No.1]

KT4036Slide 27

Operation condition Main Pressure 35 kg/cm2 (Solenoid OFF) Speed rage N, R1, R2,F1, F2, F3Main Pressure 21.5kg/cm2 (Solenoid ON) Speed rage F4, F5, F6, F7

Main relief pressure switching valve [No.2]

R1 R2 F1 F2 F3 F4 F5 F6 F7

35 kg/cm2

21.5 kg/cm2

Main Pressure 2 stage

Speed range

40

35

30

25

20

15

10

5

0

SPEED

HL

L/U

KT4036Slide 28

REDUCES POWER LOSS due to Viscous drag inside ‘free’ clutch

packs!

Changing T/M lubrication oil volume

KT4036Slide 29

Lubrication Oil Flow Switching Valve

Lubrication Flow Switching Valve

Solenoid for Lubrication Flow Change

Drain

To T/M Lubrication

Drain

FM: Oil Cooler

Side View

T/M lubrication flow switching valve [No.1]

To T/M Lubrication

KT4036Slide 30


Operation

Operation condition Normal Lubrication Flow (Solenoid OFF) Speed Range F1-F5, R1, R2 Reduce Lubrication Flow ( Solenoid ON )(15%down) Speed Range F6,F7

When the solenoid (1) isn't energized, no oil pressure works in chamber A, because by connecting to drain port. So spool (2) is pushed to the right by force of spring (3).

When the solenoid (1) is energized, Oil pressure works in chamber A in chamber A. So spool (2) is pushed to the left; so lubrication flow will be squeezed.As the result, amount of oil flow to relief valve (4) increased, so Lubrication Oil flow to T/M inside will be reduced.

Narrow Passagelow lubrication

Disengagement Engagement

NormalLubrication

Oil Flow Volume

From Oil Cooler

To ReliefValve ( 4 )

REDUCES POWER LOSS due to

Viscous drag inside ‘free’ clutch packs!

T/M lubrication flow switching valve [No.2]

From Oil Cooler

To ReliefValve ( 4 )

KT4036Slide 31

Clutch Idle Rotation Loss (Whole Idling Clutch ) Except engaged Clutch, other ones are Idle Rotation under the condition of oil between Disks and Plates. This is the time of generating Hydraulic Loss.

Gears Chewing Loss (Whole Chewing Gears )Power Line Gears generate mechanical Loss

Ring Seal Loss (Whole Ring Seals )Ring Seals are moving under pressure ofLubrication or Clutch Oil Pressure, so generate Hydraulic Loss.

T/M internal hydraulic [No.1]

KT4036Slide 32

Agitation Loss Generally, Inside Agitation Loss will be generated.Specially, High Speed make a big influence.

REDUCES POWER LOSS due to Viscous

drag inside ‘free’ clutch packs!

T/M internal hydraulic [No.2]

KT4036Slide 33

Type of ECMV

There are 3-Type of ECMV1. L/U2. L,4th

3. R,1st,2nd,3rd,

From the Left (Front Side) ECMV (high Clutch) ECMV (Low Clutch) ECMV (Lock Up Clutch) ECMV (4th Clutch) ECMV (R Clutch) ECMV (3rd Clutch) ECMV (2nd Clutch) ECMV (1st Clutch)

ECMV Supply Filter

Transmission control valve (ECMV) [No.1]

KT4036Slide 34

HD785-5HD785-7

Application : HD465-7,HD325-7 Application :

HD325-6,HD785-5,HD1500-5,WA1200,D575,D475,D375


KT4036Slide 35


KT4036Slide 36

4th Revolution Clutch

Bleed OFF

Revolution Ring Seal

Bleed off has a role when Clutch is OFF, because of revolution Clutch is rotating all the time, if oil is remaining in the clutch port this will act as centrifugal force and moves piston to the right direction and push disk, as the result, unnecessary torque will be created ( Clutch Slipping ).So, when Clutch is OFF, Clutch port oil will be drained for preventing the centrifugal force from 2- 1 drilled hole. On the other hand, when Clutch is ON, oil is leaked all the time.

Body ofRevolution

Fixed Part

Clutch Pressure

Revolution Ring seal is sealing oil as moving from fixed oil circuit inside T/M to revolving clutch.Therefore, Oil is leaking from this Ring Seal all the time.

Rotary clutch

KT4036Slide 37

Reverse Grade ability increase Reduction reverse gear ratio increase (New Gear Train)

R1

The reason of current gear train dose not make large reverse gear ratio.

1. It will work by reducing the teeth number of Sun Gear and increase the teeth number of Ring gear theoretically, but if increasing the teeth number of Ring Gear, disc size will be large and it is necessary to increase the disc size on 3rd, Rev, 2nd, 1st at the same time. Unnecessary cost.

2. Double planetary gear set like -5 is less efficient.

Single PlanetaryGear Set

Double Planetary

Single Planetary

1. By locating R Clutch at the rear-most position of T/M, Only R-disc Size Up will become enough.2. It is possible to apply single planetary gear set and efficiency is increased about 6%.

HD785-5

HD785-5

HD785-7

HD785-7

HD785-7

Reverse grade ability

KT4036Slide 38

Traveling downhillLubrication

Bearing damage

Lubrication

Do not move the gear shift lever to N position !!

There may be damage to the transmission and other parts of the power line.

Because there will be lack of lubrication oil due to down E/G speed.

Precautions during operation

KT4036Slide 39

Last chance filter does NOT have any

scheduled PM time! Judge by method of visual

inspection as shown at right!

Last chance filter – for ECMV Supply

KT4036Slide 40

End of Power Train - Transmission

Section 2_1

EXIT

02 2 Powertrain Transmission

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