MOVING YOU FURTHER
Power Train
(HL635V/HL665V)
2022.03.30 ~ 03.31
Hyundai Construction Equipment
Global Education Center Y. G. Lee
Contents
• Torque Converter, HL635V
• Transmission
• Gear & Clutch Arrangement
• Hydraulic Circuit
• Gear Train
• Transmission, HL665V
• Gear & Clutch Arrangement
• Power Flow
• Hydraulic Circuit
• Control Valve
• Overrunning Clutch
• Planetary Gear System
• Axle
• Air Compressor System
1
Torque Converter & Transmission HL635V
Pilot Pump
T/C
T/M
Main/Steering Pump
2
Torque Converter HL635V
T/M Pump
Pilot Pump
Engine
Connection to T/M
Main/Steering Pump
Combination Valve
3
Torque Converter HL635V
4
Transmission HL635V
Model : ZL30
Max output speed : 2500r/min
Max output torque : 896N.m
Max input power : 82Kw
Type: fixed axis, constant meshing, hydraulic shift gear
F1 : 8.5 kph
F2 : 13.0
F3 : 24.0
F4 : 37.0
R1 : 9.4
R2 : 27.0
Oil type: SAE 15W40
Transmission pump : CB32
Working pressure : 1.1-1.5MPa
5
Transmission HL635V
Ventilation
• Rated power : 82KW Cover Control
Valve
• Rated speed : 2500rpm
• Operation oil pressure : 1.1~1.5 MPa (11~15 bar)
• Lubricating oil pressure : 0.05~0.15 MPa (0.5~1.5 bar)
1st/3rd
• Speed : 4 forward speeds, 2 reverse speeds
• Maximum input torque : 896 N-m
• Transmission oil : SAE 15W40 (42 L) Reverse
• Working oil temperature : <100 ℃ 2nd/4th
• Brake safety valve operation pressure : > 0.55Mpa
Output
6
Gear & Clutch Arrangement HL635V
1 Reverse
2
2
Input
3
shaft
1st/3rd flange
1
Dog
4
Clutch
2nd/4th 3
Output
shaft 4
Front output
flange, Rear
Shoe brake output
Dog
Clutch flange
7
Clutch & Gear Arrangement HL635V
1st/3rd 1st/3rd
2nd/4th Reverse
2nd/4th Reverse
8
Clutch Pack HL635V
2 3 4 5
6
1
7
1 driving gear
2 bleeding valve
3 clutch housing
4 piston
5 brake disc
6 brake plate
7 driven gear
8 sealing
8 14 9 lubricating piping
10 housing cover
9 11 oil inlet piping
10 11 12 13 12 piston seal
13 spring
14 driving shaft
9
Hydraulic Circuit HL635V
Hose C for T/M and Converter pressures
Converter inlet valve at the same level
Combination valve
B
Combination
valve
A T/M Control
Valve B
Regulating A
Valve
(1.1~1.5 MPa)
oil
Oil sump
Lubrication
10
T/M Control Valve HL635V
Back Pressure
valve(0.5 ~ 1.5bar) A : from combination valve
Clutch C : 1st/3rd Clutch
T/M T/C
D : 2nd/4th Clutch
Control
Valve E : Reverse Clutch
Converter
Spool Inlet valve
(3 ~ 6 bar)
Brake Valve Combination
Valve
E
Regulating valve
Return (11 ~ 15 bar)
D
Lubrication
Strainer
Brake Valve
B
A
11
Combination Valve HL635V
Adjust regulating pressure (1.1 ~ 1.5 MPa)
Loosen the locked nut and adjust
Oil coming from Pump
Lubricating for converter bearing
Oil going to transmission
controller（1.1 ~ 1.5 MPa）
Pressure relief pore
Oil going to torque converter
（0.3 ~ 0.6 MPa）
Relief valve
12
Gear Train HL635V
Gear Lever Speed
Clutch Speed
F1 F2 R Lever
O 1st/3rd F1
Low
Rear O 2nd/4th F2
O 1st/3rd F3
High
O 2nd/4th F4
Low R1
O Rear
1st/3rd High R2
2nd/4th Dog
2
Clutch
3
Low High
Output Speed Speed 4
High
Low
13
Clutch Engagement HL635V
F1 F4 R2
1st/3rd Clutch 2nd/4th Clutch Reverse Clutch
+ Low Speed + High Speed + High Speed
14
Maintenance HL635V
Oil drainage Oil filling and dipstick Oil lever check
Service Procedure (15W40)
1. Park the vehicle on horizontal road, and run the engine.
2. Open the oil filler of transmission to check the oil level.
3. The oil filler has an oil dipstick. Check the engine with the same method.
15
HL665V Transmission
Rated Input Power: 154Kw
Rated Input Speed: 2,000 rpm
Model: ZL50B
Type of torque converter: single-stage, dual-phase, four-element
Mechanical drive ratio of gearbox:
F1 : 2.547
F2 : 0.683
R1 : 1.864
Control oil pressure: 1.10-1.40 MPa
Torque converter oil inlet pressure: 0.30-0.45 MPa
Torque converter oil outlet pressure: 0.20-0.30 MPa
Lubricating oil pressure: 0.10-0.20 MPa
Max. allowable temperature of torque converter outlet: 120℃
Oil : SAE 15W40 (49 L)
Normal working temperature : 80 ~ 90oC
16
Hydraulic Pump Mounting HL665V
Steering
Pump
Main
Pump
17
Internal Look HL665V
Clutches
OR R F1 F2
Input Clutches
Output
18
Sectional View HL665V
Transmission PUMP
Clutch Selection
F1
Engine PTO F2 Overrunning
R
Hyd. Oil PUMP
INPUTs
(Torque Converter) F1 CLUTCH
F2 CLUTCH
Reverse
CLUTCH
Overrunning
CLUTCH OUTPUT Gear
Front Axle
OUTPUT Flange
Output SHAFT
Rear Axle OUTPUT
Flange
19
Gear & Clutch Arrangement HL665V
TRANSMISSION PUMP
PTO1
Reverse piston
Input shaft Forward piston(1st)
(Engine)
Forward piston(2nd)
Second gear drive shaft
Intermediate input shaft
Overrunning Front axle output flange
clutch
Rear axle output flange Output shaft
20
Overrunning Clutch HL665V
T/C housing Pump
Wheel
Flywheel Guide Wheel
Secondary Output Gear
Primary Output Gear
Overrunning Clutch
N2 > N1 : disengaged for low load, high travel
N2 < N1 : engaged for heavy load, low travel
Engine
Overrunning Clutch
Outer ring gear
Inner ring gear
Output
Flexible Primary
Plate Turbine
Spring Roller (24ea)
Secondary
Turbine Intermediate Input Shaft
21
Power Flow HL665V
Forward 1st
N2
+
N1
+ + +
NF1 = Zs/(Zs + Zr) x N1
At high load & low speed
(speed N1<N2) NF1
overrunning clutch is engaged
22
Power Flow HL665V
Reverse
N2
+
N1
+ + +
NR = Zs/Zr x N1
NR
23
Power Flow HL665V
Forward 2nd
N2
NF2 = N1
NF1 = Zs/(Zs + Zr) x N1
N1
NR = Zs/Zr x N1
NF2 > NR > NF1
NF2
24
Hydraulic Circuit, Control Valve Concept
T/C Inlet Safety Valve
Pressure Regulating Valve
3 ~ 4.5 bar (11 ~ 14 bar)
Check
Valve
Bypass
Valve Filter
(5.4bar)
Converter
Cut Off Valve
Shifting Valve
Outlet: 2~3 bar
Gear
Pump
R F2
F1
Oil Cooler N
F1
Reverse
(1~2bar) Lubricant
Circuit F2
Oil sump
25
Control Valve, Transmission HL665V
Pressure Gauge hose
Locating Sleeve
(Spring)
System Valve
Shifting Valve
Cut Off Valve
(Shut Off Valve)
26
Control Valve, Transmission HL665V
27
Control Valve Mounting HL665V
Transmission
System Valve
To filter
Shifting Valve From filter
Control Valve
Check
Valve From pump
To Converter
F2 F1 R
Reverse Neutral F1 F2
28
Input Gears HL665V
2 Input Gears driven by torque converter
- Input Primary Gear driven by Turbine1
Input Primary Gear
- Input Secondary Gear driven by Turbine2
Input Secondary Gear
29
Overrunning Clutch HL665V
G1 At high load & low speed
(speed G2<G1)
overrunning clutch is engaged
G2
30
Planetary Gear System HL665V
Forward 1
Reverse
31
F2 Clutch HL665V
Piston
Clutch Disc
Third shaft a
ssembly
32
Maintenance HL665V
Oil drainage Oil fill Oil lever check
Service Procedure
1. Park the vehicle on horizontal road, and run the engine.
2. Open the oil drain valve of gearbox, and fill the hydraulic drive oil into the gearbox.
3. Until the drive oil flows out of its oil drain valve (flows out slowly in a strand).
33
Axle
Front & Rear HL635V HL665V
Reduction Differential 4.222 4.625
Ratio Hub 4.8 4.94
Oil (85W90) 19 L 27 L
34
Axle
35
Sectional View
- Reduction Gear - Service Brake - Differential
1 Stage planetary Caliper Disc Conventional for Front & Rear
36
Service Brake
Brake Pad Brake Pad
Brake disk
Oil entry
piston
piston
Inner brake Exterior brake
Air Bent
Brake assembly
Brake Pad
37
Air Compressor System
Air tank
Air compressor Combination valve Hand brake valve
Air brake valve
Service Service
brake brake
Service Booster pump Booster pump Service
brake brake
Brake air
chamber
Parking brake
Clutch Cutoff
(Option)
38
Service Brake System
1. Rear axle brake 2. Hose 3. Booster pump 4. Hose 5. Pressure switch
6. Front axle brake 7. Hose 8. Booster pump 9. hose 10. Hose 11. Brake pedal
12. Hose 13. Gasholder 14. Hose 15. Separator 16. Hose
39
Service Brake System
Safety valve
Front Axle
Oil/Water Air compressor
Separator
Booster Pump
Rear Axle
Booster Pump
Air tank Brake Valve
40
Service Brake Piping
Air Booster
Front Axle
Air Booster
Brake
Valve Rear Axle
Oil/Water
Air Tank Separator
41
Air Compressor
1. Intake pipe 2. Exhaust pipe 3. Piston pin 4. Cylinder body
5. Crankcase 6. Crankshaft 7. Crankshaft oil seal 8. Oil sump
9. Oil return pipe joint 10. Drive sub 11. Piston ring 12. Cylinder cover
13. Intake valve 14. Exhaust valve 15. Piston
42
Oil-Water Separator Combination Valve
- System pressure control : 7.1 ~ 7.84 bar
- Safety Valve : 9 bar
- Cleaning air from water, oil and other impurities
Pressure Regulator
Safety Valve
Air Outlet
Air inlet
Relief Pressure Outlet
43
Oil-Water Separator Combination Valve
8 9
7
1. Valve Assembly 6
2. Regulating valve 10
3. Ear drum 4 5
3 11
4. Valve rod
5. Regulating spring 1
6. Upper cover
7. Regulating screw
D
8. Control piston ass’y
9. Safety valve
10.Orifice plug
11.One-way valve 12
12.Filter 15
13. Oil collector 14 13
14.Air bleed piston
15.Housing
44
Air Tank
Tire
Inflation
Air Air
Inlet Outlet
Drain
45
Brake Valve
46
Booster Pump
47
Booster Pump HL635V
1. Cylinder block 2. Y-seal ring 3. Piston 4. Return spring 5. End cover 6. Oil cup (approx.1 liter)
7. Push rod seat 8. Hydraulic piston 9. Pump body 10. Bleed screw 11. Brake light switch
12. seal cup 13. X-seal ring 14. Rebreather 15. Push rod
48
Brake Disc, Service
Brake Pad Brake Pad
Brake disk
Oil entry
piston
piston
Inner brake Exterior brake
Air Bent
Brake assembly
1
1
1 Air vent
2
2 Oil inlet
2
1
49
Brake Disc, Service
50
Parking Brake Manual Control
51
Parking Brake Pilot Control
Parking brake is on when air is introduced into brake chamber
1. Control valve 2. Tank
3. Brake chamber 4. Brake
52
Daily Maintenance
Brake oil check
Oil Level : about ¾ of reservoir height
Oil : DOT3
Oil Replacement Interval : 500 operating hours
53
Daily Maintenance
Brake disc check
Check and replace brake pads before wearing marking is almost gone
54
