Structure and Function

Power Train - Transmission

Slide 1

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Power Train Skeleton

Slide 2

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Damper

Slide 3

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Drive Shaft

Slide 4

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Transmission Piping
7

6
Slide 5 KT4036

Brake Cooling Oil Control Valve

290L/min : BCV ON
Rear Brakes Only 310L/min E/G:1900rpm 419L/min E/G:2450rpm

Slide 6

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Torque Converter /PTO

Slide 7

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Lockup Torque Converter

Slide 8

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Torque Converter Valve

Pressure Switch

Flow Rate Selector Solenoid

Main Relief Pressure Select Solenoid

Main Relief Valve

Main Flow Rate Selector Valve

Torque Converter Relief Valve

Slide 9

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Transmission
Intermediate Input

Output Sensor

Slide 10

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Transmission

Slide 11

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Time when gear cannot be shifted

Slide 12

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Transmission safety Function

1) Down- Shift Inhibitor Function Shift Down F7-F6-F5 ---, Even Operator tries from D-Position to L 2) Neutral Safety Function Only N-Position, possible to start the Engine 3) Directional Inhibit Function More than 4km/h, impossible to change the direction. E/G speed lowered 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 isnt 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
Slide 13 KT4036

HD785-7 Transmission
T/M valve T/C valve

T/M Harness

Input Coupling Trunion

Output Coupling

Oil Pan Lubrication valve

Slide 14

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Torque Converter
The difference Points compared with -5 parts

PTO Gear

Torque Converter Valve

1. 2. 3. 4. 5. T/C pressure sensor

Torque Converter Valve PTO gear T/C pressure sensor Trunnion Shape Lockup Clutch

T/C Valve has New Function to reduce Power Loss 1) Flow Change Valve with Tandem Pump 2) Main Pressure Switching Valve 3) T/M Lubrication Flow change valve

Coupling size Up

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

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

Slide 15

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Torque Converter
(7) PTO Helical gear to lower noise (3) Trunion with wear sleeve for R&M cost reduction

Improvement Contents
(1) Lock up Clutch Disks Number Up ( 2 3 discs ) to ensure the Torque Capacity of E/G Output Up (2) T/C pump capacity up (Changed T/C pump Vane Angle)

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

Lowered E/G Rated Revolution 2000rpm 1900rpm to lower the Noise

HD785-7 HD785-5

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

: Improvement of Productivity

: Improvement of Comfort
: Improvement Reliability to reduce life cost

Slide 16

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

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

T/C Inside Pressure

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

Slide 17

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T/C Lock Up Clutch ( Half Pressure ) [No.2]

T/C Oil Circuit

T/C Oil Inlet Passage

T/C Oil Outlet Passage

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

Inside Pressur e

Slide 18

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T/C Lock Up Clutch ( Half Pressure ) [No.3]

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.
P 2 P 1 Inside Pressure

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

L/U Oil Pressure Modulation

a L/U Oil Circuit P1 T/C Internal Pressure

T/C Inside Pressure is calculated with T/C Inlet and Outlet Pressure Sensor as an average. Slide 19 KT4036

Transmission Improvement Contents [No.1]

: Improvement of Productivity : Improvement of Comfort : Improvement Reliability to reduce life cost

(11) Harness cover Material was changed to woven braid to increase the durability ECMV type was changed from large ECMV Small ECMV

(9) To reduce Power Loss and Fuel consumption 1) Flow Change Valve with Tandem Pump 2) Main pressure Switching Valve 3) T/M Lubrication Flow change valve

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

Slide 20

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Transmission Improvement Contents [No.2]

: Improvement of Productivity : Improvement of Comfort : Improvement Reliability to reduce life cost

(3) Clutch Disk Durability improvement Material - Ray flex G525 2) Number of discs increased High : 4 5 discs 3rd : 3 4 discs

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

Medium shaft is size up to increase the durability 69.9 74.6

Slide 21

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Torque converter valve

Solenoid for Main Pressure Change Pressure Switch for Main Pressure Change Valve

Solenoid for Flow Change Valve

Pressure Switch for Flow Change Valve

Flow Change Valve

Main Relief Valve

T/C Relief Valve

Torque Converter Valve

Slide 22

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T/C,T/M Pump tandem

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 <HD785-5>
T/C Relief Valve ( L) Overflow Relief valve( H ) T/M T/M Controller Flow Chg valve T/C Pump T/M Pump Supplied Oil to T/C is lowered T/C T/C Oil Flow will be pressurized according to the T/C Necessary Pressure

<HD785-7>
Relief valve ( L )

Relief valve ( H )
When ENG Rev, is low or Oil Temp is low

T/M

T/M, T/C Oil Pump

(A>B)

Slide 23

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Flow change valve [No.1]

Operation
Disengagement

E/G Rev : Less than 1000rpm

Solenoid OFF

E/G Rev : More than 1100rpm

Engagement
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).

B C

C: T/C Pump B: T/M Pump

T/C

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

Slide 24

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Changing main relief pressure

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

According to the using Shift Range, Main Relief Pressure Will be changed

T/M Controller Signal Solenoid Valve

T/C
T/M Main Relief Pressure

Main Relief valve Pilot Pressure

T/C
T/M Pump

Slide 25

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Main relief pressure switching valve [No.1]

Outline : Switching Main relief pressure according to the shift range
Operation
Disengagement Solenoid OFF High Pressure Engagement Solenoid ON Low Pressure

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.

Slide 26

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Main relief pressure switching valve [No.2]

Operation condition Main Pressure 35 kg/cm2 (Solenoid OFF) Speed rage N, R1, R2,F1, F2, F3 Main Pressure 21.5kg/cm2 (Solenoid ON) Speed rage F4, F5, F6, F7
Main Pressure 2 stage 40 35 kg/cm2 35 30 25 20 15 10 5 0 R1 R2 F1 F2 F3 F4 F5 F6 F7 21.5 kg/cm2 SPEED HL L/U

Speed range

Slide 27

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Changing T/M lubrication oil volume

REDUCES POWER LOSS due to Viscous drag inside free clutch packs!

Slide 28

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

Solenoid for Lubrication Flow Change To T/M Lubrication To T/M Lubrication

Side View
Drain

Drain

FM: Oil Cooler

Lubrication Oil Flow Switching Valve

Lubrication Flow Switching Valve

Slide 29

KT4036

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

Operation
Disengagement

Solenoid OFF

Engagement

Solenoid ON Operation condition

Normal Lubrication Oil Flow Volume

Narrow Passage low lubrication

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

To Relief Valve ( 4 ) From Oil Cooler From Oil Cooler

To Relief Valve ( 4 )

REDUCES POWER LOSS due to Viscous drag inside free clutch packs!

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.

Slide 30

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T/M internal hydraulic [No.1]

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.

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

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

Slide 31

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T/M internal hydraulic [No.2]

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!

Slide 32

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Transmission control valve (ECMV) [No.1]

Type of ECMV
There are 3-Type of ECMV 1. L/U 2. 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 Supply Filter

ECMV (R Clutch) ECMV (3rd Clutch) ECMV (2nd Clutch) ECMV (1st Clutch)

Slide 33

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Transmission control valve (ECMV) [No.2]

HD785-7

HD785-5

Application : HD465-7,HD325-7

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

Slide 34

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Transmission control valve (ECMV) [No.3]

Slide 35

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Rotary clutch
4th Revolution Clutch

Bleed OFF

Body of Revolution

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.

Clutch Pressure Fixed Part

Revolution Ring Seal

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.

Slide 36

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Reverse grade ability

HD785-7
Reverse Grade ability increase Reduction reverse gear ratio increase (New Gear Train) R1
Single Planetary Gear Set

Single Planetary

HD785-7

HD785-5
Double Planetary

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

HD785-5

1.

2.

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. Double planetary gear set like -5 is less efficient. By locating R Clutch at the rear-most position of T/M, Only R-disc Size Up will become enough. It is possible to apply single planetary gear set and efficiency is increased about 6%.

HD785-7 Slide 37

1. 2.

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Precautions during operation

Traveling downhill
Lubrication Lubrication

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

Bearing damage

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.
Slide 38 KT4036

Last chance filter for ECMV Supply

Last chance filter does NOT have any scheduled PM time! Judge by method of visual inspection as shown at right! Slide 39 KT4036

End of Power Train Transmission

Section 2_1

EXIT
Slide 40 KT4036