变速箱知识培训

1、Product Training: Transmission and options,Powershift Transmissions,变速箱型号系列,克拉克动力换档变速箱共有13个系列：T12000、T16000、18000、T20000、24000、T26000、28000、32000、T30000、T36000、T40000和1000系列，其中1000系列包括4000、5000、8000、16000几种。,变矩器型号系列,克拉克公司共生产7个系列的变矩器： C2000、C270、C320、C5000、 C8000、C9000、C16000。,Hydrodynamic vs. hydros

2、tatic,Hydrodynamic drive Generic name for Torque Converter Drive Features Simplicity Robustness Low pressure Higher Peak Efficiency Better High Speed Performance Fluid in movement Hydrostatic drive Features More finite control High Pressure Limited Speed Capabilities Need for extreme cleanliness Les

3、s robust than hydrodynamic Stationary fluid,Powershift vs Powershuttle,Powershift Technological enhancement Shifting without loss of TE Less shift movements 1 shift lever No mechanical linkage Better shift quality Improved performance in load/carry and load/dig mode Improves vehicle + driver efficie

4、ncy Electronic vehicle protection Modulation in range and direction,Powershuttle Technology less sophisticated More shift movements 2 shift levers Needs mechanical linkage lever to transmission Higher mechanical efficiency Lower market price No vehicle protection (downshift),Transmission Assembly,La

5、yout,Remote (R),engine,converter,transmission,R MODEL The R series is a remote mounted transmission with an engine mounted converter. This assembly allows for flexibility of transmission installation.,cardan,Layout,Integral (HR),HR MODEL The HR series is an integral transmission and torque converter

6、 assembly mounted directly to the engine. As a single compact package, it minimizes external piping and eliminates a drive shaft. Flexplates needed,Layout,Mid Mount (MHR),engine,converter,transmission,damper,Not supplied by Dana,MHR MODEL The MHR series is an integral transmission and torque convert

7、er assembly mounted to the engine by means of a driveshaft. The assembly allows for installation flexibility, while minimizing external piping.,cardan,Plumbing HR & MHR model,Plumbing HR & MHR model,OPTIONAL : REMOTE FILTER,Plumbing R model,Version,Short Drop Intermediate Drop Long Drop Inline Varia

8、ble Drop Transmission,Configuration,Inline,Short Drop,Intermediate Drop,Long Drop,Variable Drop Transmission (VDT),4 Axles,3 Axles,17 Offset,Drop,Drop Dimensions,POWERSHIFT / POWERSHUTTLE &,HYDROSTATIC TRANSMISSION PRODUCT LINE,37 - 80 Kw 50 - 107 Hp,60 - 80 Kw 80 - 107 Hp,60 - 80 Kw 80 - 107 Hp,50

9、- 82 Kw 67 - 110 Hp,56 - 82 Kw 75 - 110 Hp,60 - 90 Kw 80 - 121 Hp,60 - 90 Kw 80 - 121 Hp,67 - 97 Kw 90 - 130 Hp,50 - 110 Kw 67 - 148 Hp,90 - 120 Kw 121 - 161 Hp,97 - 120 Kw 130 - 161 Hp,60 - 130 Kw 80 - 174 Hp,140 - 160 Kw 188 - 215 Hp,93 - 168 Kw 125 - 225 Hp,120 - 190 Kw 161 - 255 Hp,150 - 195 Kw

10、201 - 261 Hp,100 - 200 Kw 134 - 268 Hp,150 - 200 Kw 201 - 268 Hp,150 - 240 Kw 201 - 322 Hp,185 - 260 Kw 248 - 349 Hp,210 - 275 Kw 282 - 369 Hp,220 - 295 Kw 295 - 396 Hp,224 - 313 Kw 300 - 420 Hp,250 - 320 Kw 335 - 429 Hp,260 - 410 Kw 349 - 550 Hp,330 - 750 Kw 443 - 1006 Hp,0,100,200,300,400,500,600,

11、700,800,T12000,PSR08,PS08,T16000,TE08,PSR09,PS09,T20000,HSE07,24000,TE10,HSE09,TE13,32000,TE15,T33000,HSE2+3,TE17,36000,5000,TE27,6000,T40000,TE32,8000,16000,Kw,0,100,200,300,400,500,600,700,800,Brugge,Statesville,Transmission options,Drive Design,Flex Plate Drive,Flexplates,Different sizes ( Bolt C

12、ircle Diameter) Number dependent on torque With or without welded nuts To absorbs shock from the engine Only for HR model,Flex Plate Drive,WITH WELD NUTS :,WITHOUT WELD NUTS :,METRIC,UNF,Flexplates diameter matrix,Freewheel,Freewheel converters are used in vehicles with a high duty cycle in a travel

13、ling or transmission neutral mode Stator is no longer fixed, and converter is working as hydraulic coupling. Result is higher efficiency and increased torque ratio above approximately 0.85 speed ratio Disadvantage is increase in complexity and cost Available in: CF2000, T12000, T20000, FHR24000 Appl

14、ication: BHL, TBH, High speed mobile cranes,Lockup,Purpose: to have a solid connection from the turbine shaft to the impeller cover so that converter is bypassed and all engine torque goes directly into the transmission Engagement of lockup when: engine speed = turbine speed Lockup is controlled thr

15、ough an external valve either manually or automatically activated Result: improved efficiency, improves vehicle engine braking, increase top speed and lower fuel consumption,Charging Pump and pump drive ratio,Charge pump Charge pump capacity Pump drive ratio,Charging pump,Charging pump sucks the oil

16、 out of the sump and pumps it through the filter. Gear Pumps Oil needed for: Pilot pressure in valves Clutch pressure to close clutches Lubrication + cooling Oil for torque converter After cooler, oil drains back in sump,Pump gear train,Impeller pump drive,Auxilary pump places,Idler,A,B,C,Variable D

17、isplacement Pump,Standard housing VDP VDP : more pump capacity : more space 36000 short drop only,long drop uses offset boxes Standard feature on T40000 Mickey Mouse layout,Offset Boxes,For big pumps and more pump clearance: use of offset boxes,Charging pump matrix,Auxilary pump drives,SAE “C” 2 Bol

18、t or 4 Bolt,9 oclock Position C,3 oclock Position A,Auxilary pump drives,Adaptor sleeves possible: Example from SAE “C” to SAE “B” Single or dual drive (mounted on the charging pump) Rotation same as or opposite to engine Pump drive ratio Check technical specifications for possibilities,SPLINE SAE A

19、: 9 T SAE B: 13 T SAE C: 14 T SAE BB : 15 T,MOUNTING SAE “A” 2 or 4 bolt SAE “B” 2 or 4 bolt SAE “C” 2 or 4 bolt SAE “BB” 2 or 4 bolt SAE “B” high capacity 2 bolt SAE “C” high capacity 2 or 4 bolt,Pump drive ratios,Right Hand 1 : 1 (A position),Left Hand 1.1 : 1 (C position),EXAMPLE T40000,Pump disc

20、onnect,Pumps can be disconnected Ex. Mobile crane: pumps disconnect on road,Filter,Charge Pump for Remote Filter - option,Integral to charging pump Remote Different filter capacities,Flywheel Housing Size,Remote converters,Transmissions,All dry, except C16000!,PTO (Power Take-Off),Optional PTO (8000

21、 series),Bi-directional PTO : linked with Forward/Reverse clutch. Put transmission in Total Neutral. For example used in railway applications.,Flanges,Quick DisconnectTM,S.A.E.- Quick Disconnect Flange Yokes,XS FlangeYokes,Conventional SAE & DIN Flanges,Proven Design Good interchangeability Industry

22、 Standards Can Use Extended Pilots for Improved Balance,Up to 12 Sets of Fixing Bolts Tooling Access can be Poor Control of Fixing Torque More Difficult Frictional Torque Capacity Limitation Higher Angles with Short Installations Need to Support Shaft During Installation,Advantages:,Disadvantages:,C

23、ross-Serrated Flanges,Proven Design Good interchangeability ISO Standards Only 4 Fixings Torque Transmitted Through Teeth - No Bolt Shear Positive Centering,Larger Fixing Bolts Higher Fixing Torques Higher Angles with Short Installations Need to Support Shaft During Installation No Real Benefits for

24、 Smaller Applications,Advantages:,Disadvantages:,Wing-Bearing Style,Proven Design Good interchangeability Ease of Installation / Service Torque Transmitted Through Key-Way Off-Highway Standard,No Universal Standard Bending Loads Imposed on Fixing Bolts Need to Support Shaft During Installation,Advan

25、tages:,Disadvantages:,Half-Round End YokesTM,Proven Design Less System Cost & Weight Ease of Installation Ease of Service Lower Joint Angles Improved Quality Proven Durability,Unique Design Unable to use Staked Joints for Light Applications,Advantages:,Disadvantages:,Flanges Input,A whole range of i

26、nput flanges possible MHR R / MT - RT Please look into technical specification what is available,Input flange,Flanges Output,A whole range of output flanges possible Please look into technical specification what is available,Output - rear,Parking brake - option,Output - front,Parking brake options,D

27、rum brake (ex. 12x3) Disc brake Positive brake Negative brake (Spring Applied Hydraulic Released),SAHR brake: when pressure falls, disc closes when operating, high pressure in system, brake opens,Disconnect,Output disconnect (Front and/or rear) Towing disconnect,Output Disconnect,Air / Hydraulic act

28、uation Mechanical actuation Front and/or rear output disconnect Example: mobile crane on road and axle disconnected Advantages: Lower fuel consumption No winding up of the driveline,Towing disconnect,Internal disconnect/External disconnect (BPS) Only on long drop applications For railway application

29、s,Emergency steering pump drive option (ESPD),Mounted on the idler shaft,Only possible on long drop versions On 24000,32000, 36000, T40000 SAE A 2 bolt Pump not supplied by DANA,For safety reasons Additional steering system via the wheels when normal system fails,Control,Valves Modulation Inching De

30、clutch Speed sensors,Valves,DECLUTCH,FWD/REV clutch cut the power/torque when braking Brake pedal activated system to cut pressure to engaged clutch once specified brake line pressure reached and re-engage pressure when foot lifted from pedal Allows use of high engine speed without the need to hold

31、the transmission on the vehicle brakes or put into neutral Actuated hydraulically, pneumatically or electrically FLT application where inching is not used,INCHING,Proportional control of clutch pressure by brake pedal movement in order to create reduced traction Can be either mechanically, electrica

32、lly or hydraulically actuated through a valve on the control valve Provides same benefits as declutch regarding high engine RPM but allows in addition the ability to “Inch” forward when releasing the brakes after stopping,MODULATION,Sometimes called “Soft Shift” Included in the transmission control

33、valve system to provide controlled delay of clutch pressure in the engaging clutch Operates on a valve and spring accumulator system Only operates on forward and reverse clutches Speed clutch modulation is provided by step piston Modulation time is fixed for a given specification but options are ava

34、ilable,Speed Sensors,Output Speed sensor (Speedo Drive)(optional - only for Long Drop),Turbine Speed sensor,Engine Speed sensor (Tacho drive),Engine Speed Sensor,Results in 81 counts/revolution (Turbine input shaft),Partnumber : 4200572 Type : inductive sensor Sensing distance : 0 - 0.6 mm Coil resi

35、stance : 1050 ( 100 ),Partnumber : 4200573 Type : inductive sensor Sensing distance : 0 - 0.6 mm Coil resistance : 1050 ( 100 ),Turbine Speed Sensor,(Turbine output shaft),Type A : Results in (66 x 42 / 43) = 64.5 counts/revolution,Type B : Results in (66 x 44 / 41) = 70.8 counts/revolution,Type C :

36、 Results in (66 x 46 / 39) = 77.8 counts/revolution,Transmission Designation,MODEL DESIGNATIONT20000,120XFRMT20XXXXX,ConverterWheel Designation,Freewheel,Remote MountW/O Converter,Mid MountW/Converter,Engine MountW/Converter,Basic Capacity,Forward Speeds,Specific Ratio,Specific Model,MODEL DESIGNATI

37、ON36000 - Series,1X.XLMHR36XXXXX,ConverterWheel Designation,Lockup,MidmountW/Converter,Engine MountW/Converter,Remote MountWithout Converter,Forward speeds,Specific Ratio,Specific Model,Odd n: short dropEven n: long drop,MODEL DESIGNATIONTE-SERIES,340FTE17310-44,Converter Wheel Group,Additional Convert. Detail,Type converterLockup = LFreewheel = F,Mounting typeEngine Mount. = TRemote = RT