SEULU1I503-0 UMNLL LMSLRGCLION MANUWALE PLANETARY GEAR TYPE TRANSMISSION (BASIC) ele KOMATSU LTD. PUL Slee oi baths Sina oylads 28 . 129PLANETARY GEAR TYPE TRANSMISSION (BASIC)FOREWORD This manual describes fundamentals of construction and fune- tion of the planetary gear transmission used in the TOROF LOW system for bulldozers, dump trucks, scrapers, motor graders and 80 on. This manual contains the contents of Training Aid TA2251E, TA22-52E, TA22-55E and TA22-56E. In addition, the details of the clutch and each section of the actual transmi described here. This manual explains the planetary type transmission in general. For disassembly, assembly and adjustment, refer to. the diagrams, specifications and work procedures contained in the shop manual for each particular machine. This manual aims at giving information of the following: 1) Basic construction and function of the planetary gear system, 2) Examples of application of the planetary gear system to the transmission, 3) Construction and function of the transmission (excluding hydraulic circuits).INTRODUCTION .. ! SINGLE STAGE PLANETARY GEAR SYSTEM geen DUAL STAGE PLANETARY GEAR SYSTEM Povo 5. CONTENTS Construction and components of the planetary gear system When the planet carrier is held stationary When the ring gear is held stationary When the sun gear is held stationary Planetary gear system with dual planet pinions .. Construction of dual stage planetary gear system Planetary gear system with single planet pinions Application of single pinion type planetary gear system Planetary gear system with dual planet pinions . .. Application of planetary system with dual planet pinions AN APPLICATION OF THE PLANETARY GEAR SYSTEM TO TRANSMISSION 1 2) 3. 4. MISCHELLANEOUS NOP ONS Construction of planetary gear system applied to transmission See eer eeeee Directional change mechanism ‘Speed change gears Examples of transmission TORQFLOW transmission description Hydraulic system . CD chderoraarene i Ball check valve in rotating clutch . Planetary gear P.T.O. Bevel gear adjustment...I INTRODUCTION 1. FUNCTION OF TRANSMISSION Torque Universal Engine converter joint scree se ‘Transmission Bevel pinion Steering clutch ‘Steering brake ‘Sprocket, Generally, the transmission is connected to an engine or electric motor through a clutch or torque converter. It functions to match the torque and speed of the motor with load. When the load is large, the transmission reduces the input speed which is delivered by the engine and raises the ‘torque, When the load is small, transmission output speed is increased while output torque is reduced.2. TYPES OF TRANSMISSION ‘Among hydraulic and mechanical transmissions, mechanical ones are commonly used. Mechanical transmissions are classified as follows: © Manual shift type * Direct mesh type * Constant mesh type * Full synchro-mesh type © Hydraulic power shift type * Planetary gear type * Counter shaft type { With the manual st } the engine and transmission since it is required to temporarily cut off power delivered by the engine when shifting the transmission. The hydraulic power shift type transmission, however, does not require any external clutch mn, a clutch must exist between type transmis because it incorporates a hydraulic clutch. This manual describes the hydraulic power shift type planetary gear | transmission.Il SINGLE STAGE PLANETARY GEAR SYSTEM 1. CONSTRUCTION AND COMPONENTS OF THE PLANETARY GEAR SYSTEM This is a planetary gear system. Let us study how this gear system transmits power. The illustrations below show a planetary gear system. Planet pinionLet us hold sun gear (1) stationary and turn planet pinions (2). The pinions will rotate on their own axes and, at the same time, revolve around the sun gear. In our solar system, planets including the earth which are rotating on their own axes are, at the same time, revolving around the sun. This is the origin from which the planetary gear system has been named. Rotation This is also the origin from which sun gear (1) and planet pinions (2) received their names. The frame which supports the planet pinions’ shafts, and rotates as the pinions revolve around the sun geer, is called the planet carrier, The ring gear, as its name suggests, surrounds the other gears and meshes with the planet pinions.WHEN THE PLANET CARRIER IS HELD STATIONARY. First, let us see how the gear system functions when the planet carrier is held stationary and the sun gear is rotated. The planet pinions which mesh with the sun gear and ring gear will ‘transmit the sun gear rotation to the ring gear. Then the ring gear will rotate in the direction opposite to the sun gear rotation. Planet pinion Put marks where planet pinion and ring gear CN% oe mesh with each other. Sun gear rotation angle sun ger tation ae Then rotate the sun gear by the degree indicated by the dotted arrow. Again, put marks where both gears currently mesh with each other, and rotate the sun gear. The ring gear has been rotated in the direction opposite to the sun gear rotation but at a lower speed than the sun gear, (since the ring gear has more teeth than the sun gear).REFERENCE: The sun gear and ring gear rotation speeds have the following relation ship: Sun gear speed ___Number of ring gear teeth Ring gear speed Number of sun gear teeth Increase the ratio of the number of the ring gear teeth to sun gear teeth (gear ratio) in order to increase the ratio of the sun gear speed to the ring gear speed (speed reduction ratio). Reduce the gear ratio to reduce the speed reduction ratio. ‘We have seen that the ring gear will be rotated by the sun gear in the opposite direction when the planet carrier is held stationary. “Transmission case Planet pinion ‘Sun gear Ring gear‘The illustration on the previous page shows the reverse gears included in a planetary gear transmission as an example. When the reverse clutch is engaged, the planet carrier is held stationary by the transmission case. Then the ring gear will be rotated by the sun gear in opposite directions and at a lower speed than the sun gear speed. As a result, a vehicle upon which the transmission is mounted will back up. When the reverse clutch is disengaged, the planet carrier can rotate and rotation of power cannot be transmitted from the sun gear to the ring gear.3. WHEN THE RING GEAR IS HELD STATIONARY Let us rotate the sun gear while the ring gear is held stationary. The planet pi ns will revolve around the sun gear, along with the planet carrier. The sun gear rotation will, therefore, be transmitted to the planet carrier. In this case, a relatively large speed reduction ratio can be obtained. Initial ring gear rotation nial angle velative to In gear rotation Base standing still, Base rotation Ring gear turning angle = on the sheet fon tie sheet anata relative tothe base ‘Sun gear turning angle ‘Sun gear turning angle Preparing a model of the planetary gear system will help you understand the operation. Put ‘the model on a base. First, let us hold the planet carrier stationary and rotate the sun gear. The ring gear has been rotated in the direction opposite to the sun gear rotation. Next, rotate the base in the opposite direction to cancel the initial ring gear rotation angle, The ring gear will return to its initial position. Repeat the same step. The ring gear will return again to its initial position The same thing may occur when you are row- ing a boat up stream, While you stay at the initial position, anything floating in a stream will proceed downstream. As to the planet carrier, it has been rotated with the base by the base rotation angle.Base turning speed The planet carrier has thus been rotated by the sun gear in the same direction as when the ring gear was held stationary. The sun gear has rotated by its own rotation angle plus the base rotation angle. This is just like rowing a boat in a stream. The boat speed is its own speed, which is relative to the “flow speed, plus the flow speed. SUMMARY: When the ring gear is held station- ary, the planet carrier will be rotated together with the base, while the sun gear is rotated by its own rotation angle plus the base rotation angle. In brief, the sun gear will be rotated more than the planet carrier. As a result, the rotation speed will be reduced when power is transmitted from the sun gear to the planet carrier, and increased when the transmission direction is reversed. When the ring gear is held stationary, the planet carrier and sun gear will be rotated in the same direction.REFERENCE: Let us examine the ratio of the sun gear speed to the planet carrier speed. The base has been rotated by the ring gear rotation angle. The planet carrier has remained stationary relative to the base. Using ‘the ring gear speed given in Section II-2, the base rotation speed is arrived at by: Base rotation speed = Number of sun gear teeth Number of ring gear teeth The sun gear speed is equivalent to the total speed of the base rotation speed plus the sun gear speed relative to the base. Using the base rotation speed obtained above, the sun gear speed is: Sun gear speed = (Sun gear speed relative to base) x Number of sun gear teeth, Number of ring gear teeth ‘The planet carrier speed is just the same as the base speed. Planet carrier speed = (Sun gear speed relative to base) x Sun gear speed relative to base Number of sun gear teeth ‘Number of ring gear teeth The ratio of the sun gear speed to the planet carrier speed can be obtained from the above equasion. a Sun gear speed iNPBP Sn AC gMRBM Sth Planet carrier speed Number of sun gear teeth (Sun gear speed relative to base) x ant~~ Drive shaft Planet pinion ‘Sun gear Ring gear ~ Planet cartier The above illustration shows a planetary gear type final drive which is incorporated in the wheel of a heavy-duty dump truck. ‘The ring gear is fitted with splines to the drive shaft housing and is always held stationary. The planet carrier is fitted to the hub. The sun gear is fitted to the drive shaft. The wheel will, therefore, be driven as the planet carrier is rotated by the sun gear. | | 124. WHEN THE SUN GEAR IS HELD STATIONARY The sun gear may be held stationary while the ring gear and planet carrier are permitted to rotate. In this case, the ring gear and planet carrier will be rotated in the same direction and the ring gear speed will be higher than the planet carrier speed. Hold the planet carrier stationary and rotate the sun gear, Then the ring gear will rotate in the opposite direction. Next, rotate the base to cancel the initial sun ‘gear rotation. The sun gear will appear as if it has remained stationary. The planet carrier has been rotated together with the base. The ring gear has been rotated by its own rotation angle plus the base rotation angle. Actually, the ring gear has been rotated faster ‘than the planet carrier and in the same direction. 13REFERENCE: Let us examine the ratio of the ring gear speed to the planet carrier speed, The ring gear speed is its own speed relative to the base plus the base speed. Since the base speed is equal to the sun gear speed, i Ring gear speed = i ‘Sun gear speed relative to base + Ring gear speed relative to base Since the planet carrier rotates together with the base and the base and |I| sun gear speeds are equal, Planet carrier speed = Sun gear speed relative to base Asa result, Ring gear speed 19 gear speed relative to base Ring gear speed ___,_, Ring gear speed relative to base Planet carrier speed 1 +-Sun gear speed relative to base Using the sun gear speed relative to the baso given in Section 11-2: | : Number of ,-—_ Number of Ring gear speed __ting gear teeth Sun gear teeth | Planet earrier speed ‘Number of ring gear teethPLANETARY GEAR SYSTEM WITH DUAL PLANET PINIONS Planet pinion ‘Sun gear This is @ planetary gear system which has coupled or dualized planet pinions. In this system, the ring gear will rotate in the same direction as that of the sun gear when the planet carrier is held stationary. When the ring gear is held stationary, the planet carrier will rotate in the direction opposite to the sun gear rotation. The above illustration shows the reverse gears which are incorporated in a planetary gear transmission. When the reverse clutch is engaged, the ring gear will be held stationary by the transmission case. The planet carrier will be rotated in the direction opposite to the sun gear rotation. The vehicle which is mounted with the transmission will back up. 15| Hold the planet carrier stationary and rotate Ring gear rotation angle : ' | relative to base ‘the sun gear. The ring gear will rotate in the same | | Sun gear rotation nale—girection as that of the sun gear because of the dual planet pinions. As to speed, the sun gear will rotate faster than the ring gear since the ring gear has more teeth than the sun gear. Next, rotate the base to cancel the initial ring gear rotation, The ring gear will appear as if it had remained stationary. Actually, the planet carrier has been rotated in the direction opposite to the sun gear rotation When the ring gear is held stationary.DUAL STAGE PLANETARY GEAR SYSTEM CONSTRUCTION OF DUAL STAGE PLANETARY GEAR SYSTEM Clutch 8 Planet carrier B anes _-Ring gear B Output shaft Ring gear A _—Sun gear 8 Planet carrier A~ Sun gear A Input shaft In this part, dual stage planetary gear systems are explained. The operating principles are as easy to understand as the single planetary gear system, though the construction is more complicated. The planet carrier will simply be called the carrier from here on. Rotate the sun gear and hold the ring gear B by engaging the clutch B. Then the carrier B and ring gear A will rotate in the same direction as that of ‘the sun gear rotation, Thus in the left-hand planetary gear system, the sun gear A which rotates in the same direction as that of the ring gear rotation will transmit power to the carrier. In combined planetary gear systems, power will often be transmitted from one component to another while the sun gear, carrier and ring gear are all rotating. 72, PLANETARY GEAR SYSTEM WITH SINGLE PLANET PINIONS Lot us see the rotational relations on the three components - - - sun gear, carrier and ring gear - -- when all of them are rotating, Let us use the planetary gear system model which is put on a base. Rotate the sun gear clockwise by a few degrees when the carrier is held stationary. The ring gear has been rotated counterclockwise. This is the start (1) ing gear rotation 1 Carrier rotation Sun gear rotation P= (2) 18 Rotate the base clockwise more than the initial ring gear rotation angle. During this time, the ring gear is held stationary relatively to the base. The sun gear, carrier and ring gear have been rotated in the same direction, The former component has a greater rotation angle (speed) than the latter one, Refer to (6) where the three components are rotated in the same direction, Rotate the base clockwise to cancel the initial ring gear rotation made to reach the start position. The ring gear will appear as if it had remained stationary. We find that the sun gear rotates faster than the carrier, but in the same direction when the ring gear is held stationary. (Refer to Section II-3)@ O) 6) Rotate the base clockwise by an angle less ‘than the initial ring gear rotation angle. Now we find that the sun gear will rotate faster than the carrier when the ring gear rotates in the direction opposite to the sun gear and carrier rotation. The sun gear speed is higher and the ring gear speed is lower, when compared with the carrier held stationary. Rotate the base counterclockwise by an angle less than the initial sun gear rotation angle. We find that the ring gear will rotate faster than the carrier when the sun gear is rotated in the direction opposite to the ring gear and carrier rotation. The sun gear speed is lower and the ring gear speed higher, when compared with the carrier held stationary. Rotate the base counterclockwise to cancel the initial sun gear rotation, This experiment proves that the ring gear will be rotated faster than the cartier but in the same direction. (Refer to Section II-4) Rotate the base counterclockwise by an angle more than the initial sun gear rotation angle. ‘The three components will be rotated in the same direction as in (1), but the relation of speeds is reversed. When the three components are rotated in the same direction, the sun gear or ring gear speed is highest while the carrier speed is always second highest. 193. APPLICATION OF SINGLE PINION TYPE PLANETARY GEAR SYSTEM These are the same two-speed gears incorporated in a planetary gear transmission as illustrated in Section III-1, In this system, the left-hand carrier will be driven by the input shaft, At first speed, the sun gear, carrier and ring gear will all be rotated in the left-hand planetary gear system. Clutch (8) _-Planet cartier (B) - Ring gear (B) Ring gear (A)~ —~Sun gear (B) Planet carrier (A)~ ou Sun gear (A) Let us examine the second-speed operation first. When the second: speed clutch (A) is engaged to hold the ring gear stationary, the sun gear and carrier will be rotated in the same direction as explained in (2), Section III-2. ‘The output shaft will be driven by the sun gear. 202nd speed ‘st speed ar (Al Another planetary gear system will be combined to reduce the output speed. When the first-speed clutch is engaged to hold the ring gear (B) stationary, the first-speed sun gear will rotate faster than the carrier but in the same direction. The carrier (B) will rotate with the ring gear (A) and both sun gears will rotate at the same speed, In the second-speed planetary gear system, therefore, the sun gear will rotate faster than the ring gear (A) and in the same direction. When the sun gear and ring gear rotate in the same direction with the former at a higher speed than the latter, the ring gear will rotate at a lower speed than the carrier as shown in (1), Section III-2. The first-speed carrier which rotates with the ring gear will rotate at a lower speed than the second- speed carrier. As a result, the first speed will be realized which is lower than the second speed. 2122 This is another example of the two-speed gears incorporated in a planetary gear transmission. Both sun gears will be driven by the input shaft. ‘The carrier is integrated and common to the first- and second-speed gears. The ring gear (b) is connected to the output shaft. At high speed, the right hand sun gear, carrier and ring gear will all be rotated. Lowsspeed clutch High-speed clutch Ring gear (a) Ring gear (b)Let us examine the low-speed operation first. When the low-speed clutch is engaged to hold the carrier stationary, the ring gear (b) will be driven by power transmitted from the sun gear in the direction opposite to the sun gear rotation, Low-speed Hith-speed ee -owsveed ch eile High-speed clutch Ring gear (b): To shift the gears to high speed, the high-speed clutch will be engaged to hold the ring gear (a) stationary as shown in the above right figure. The carrier will be rotated in the direction opposite to the sun gear rotation since the planet pinions are dualized in the high-speed gears. (Refer to Section II, page 15. Also refer to (3) for this part.) In the high-speed gears, the ring gear will rotate faster than when the carrier is held stationary (low speed) since the carrier is common to both systems, as shown in (4), in Section I1I-2. Low speed will be realized in this way. 23:4, PLANETARY GEAR a Ring gear rotation Carrier rotation Sun gear rotation 2 24 SYSTEM WITH DUAL PLANET PINIONS. Let us examine the rotational relations of the sun gear, carrier and ring gear in a planetary gear system with dual planet pinions, ‘A model of the planetary gear system will help you grasp the relations. Hold the carrier stationary and rotate the sun gear clockwise. The ring gear n angle. hhas been rotated clockwise by an angle less than the sun gear roti This is the start position of our experiments. Initia ring gear tation relative to the base | Initia sun gear rotation angle relative to the base Rotate the base clockwise. The sun gear, ring gear and carrier have been rotated in the same direction. The former component has a greater speed than the latter. Refer to (6) where the three components are rotated in the same direction, Rotate the base counterclockwise by an angle less than the initial ring gear rotation angle, This experiment proves that the sun gear will rotate faster than the ring gear when the carrier is rotated in the direction opposite to the sun gear and ring gear rotation.(3) a 5) (6) Rotate the base counterclockwise to cancel the initial ring gear rotation. We find that the sun gear will rotate in the direction opposite to the carrier rotation when the ring gear is held stationary. (Refer to Section 11-5). Rotate the base counterclock\ e by an angle more than the initial ring gear rotation angle but less than the sun gear rotation angle. We find that ‘the carrier will rotate faster than the ring gear when the sun gear rotation is opposite to the ring ‘gear and carrier rotation. Rotate the base counterclockwise to cancel the initial sun gear rotation. We find that the carrier rotation is faster than the ring gear rotation but in the same direction when the sun gear is held stationary. Rotate the base counterclockwise by an angle more than the initial sun gear rotation angle. In ‘this case, the three components are rotated in the same direction as in (1), but the relation of speeds is reversed, When the three components are rotated in the same direction, the sun gear or carrier speed is highest and the ring gear speed is always second highest. 255. APPLICATION OF PLANETARY SYSTEM WITH DUAL PLANET PINIONS This is the forward-reverse gears which are incorporated in a planetary gear transmission, The sun gear (b) which will be driven by the input shaft will transmit power to the output shaft through the carrier. When the gears are shifted for forward travel, the sun gear, carrier and ring gear will all be rotated. Forward clutch / Reverse clutch INPUT SHAFT Sun gear (a) —_ Ring gear Carrie San gear to) Let us study the reverse-travel operation first. When the reverse clutch is engaged to hold the ring gear stationary, the carrier will be rotated in the direction opposite to the sun gear rotation as in (3), Section III-4, This case is shown below at the left. 26Roverse travel Forward travel To shift the gears for forward travel, the forward clutch will be engaged to hold the sun gear (a) stationary and cause the carrier to rotate in the same direction as that of the sun gear rotation. Look at the left-side planetary gear system in the above figure of forward travel. The ring gear rotation will be faster than the carrier rotation and in the same direction, as in (5), Section M2, This relation holds true also in the right-side planetary gear system, since the ring gear and carrier are common to both systems. Since the right-side planetary gear system employs dual planet pinions, the carrier and ring gear will be rotated in the same direction as that of the sun gear rotation, as in (1), Section III-4. Thus forward travel will be realized, 27WV AN APPLICATION OF THE PLANETARY GEAR TRANSMISSION 1. CONSTRUCTION OF PLANETARY GEAR SYSTEM APPLIED TO TRANSMISSION Jp Rg ge INPUT SHAFT lic j OUTPUT SHAFT This is a sectional view of the planetary gear transmission which is mounted on the D55S-3 dozer shovel. The transmission is schematically illustrated below to help you understand the gear arrangement and power flow. 28INPUT SHAFT. OUTPUT SHAFT The transmission includes four units of planetary gears. The two right- hand units are coupled with the left-hand units in the middle part. The left- hand units select forward or reverse travel. The right-hand units select first or second speed. In most planetary gear transmissions, the gears can be divided into sets of forward-reverse gears and speed change gears. Thus, it is easy to separate- ly study the function of each set of planetary gears, in order to understand the power flow and gearshifting operation in the transmission, With various types of planetary gearing, gearshifting operation is separately explained below for the forward-reverse gears and speed change gears. 29)2. DIRECTIONAL CHANGE MECHANISM INPUT SHAFT OUTPUT SHAFT First, let us see how the forward-reverse gears function in the planetary gear transmission as illustrated in the preceding page. In the illustration above, the right-hand unit contains the forward gears (F-gears) and the left- hand unit the reverse gears (R-gears). The sun gears in both units are connected to the input shaft. The F-carrier is connected to the output shaft. ‘The R-ring gear and F-carrier are also mechanically connected. INPUT SHAFT| OUTPUT SHAFT When the F-clutch is engaged to hold the F-ring gear stationary, the F- carrier and sun gear will be rotated in the same direction, and the input and output shafts will also be rotated in the same direction, 30INPUT SHAFT OUTPUT SHAFT When the R-clutch is engaged to hold the R-carrier stationary, the R- ring gear and F-carrier will be rotated in a direction opposite to the sun gear rotation, As a result, the input and output shafts will be rotated in opposite directions. If both clutches are disengaged, the transmission will not transmit power from the input shaft to the output shaft. If both clutches are engaged, the transmission will be stuck. (2 Ba OUTPUT SHAFT INPUT SHAFT (1) In the illustration above, planetary gears with dual planet pinions are utilized for reverse. In this construction, the sun gear and carrier will be rotated in opposite directions when the ring gear is held stationary. Both F- and R-sun gears are connected to the input shaft. The carrier, which is ‘common to the F- and R-gears, in connected to the output shaft. 31INPUT SHAFT OUTPUT SHAFT Therefore, the input and output shafts will be rotated in the same direc- tion when the F-clutch is engaged, and in opposite directions when the R- clutch is engaged. (3) FH OR FL oureur SHAFT This is an example of the two-forward and one-reverse speed transmis- sion, with the FLL-gears added to the preceding example. The F-gears in (2) are renamed as FH-gears here, The FL- and FH-gears have the same construc- tion but the FL-sun gear has less teeth than the FH-sun gear. The carrier will be rotated at a lower speed when the FL-ring gear, rather than the FH-ring gear, is held stationary. Thus, two forward speeds will be realized. 32(a) QUTPUT SHAFT. In this illustration, the transmission consists of three sets of planetary gears. Each pair of the left (F) and middle sun gears, the middle and right (R) ring gears, and the middle and right (R) carriers are mechanically connected and will be rotated together. The R-sun gear is connected to the input shaft, and the R-carrier to the output shaft. The F-carrier does not rotate since it is fixed to the transmission case. INPUT SHAFT. OUTPUT SHAFT The R-planetary gear system employs dual planet pinions. When the R-clutch is engaged to hold the ring gear stationary, the R-carrier and sun gear will be rotated in opposite directions and the machine will travel backward. 33~\ INPUT SHAFT. OUTPUT SHAFT When the F-clutch is engaged, the F-sun gear will be held stationary. Since the middle sun gear also remains stationary, the middle ring gear will be rotated faster than the carrier in the same direction. In the R-planetary gears, the rotational relations between the ring gear and carrier remain the same as in the middle gears. The two components will be rotated in the same direction as for the sun gear rotation, As a result, the input and output shafts will rotate in the same direction: Refer to Section III-5 for more details. SPEED CHANGE MECHANISM. a 2ND-SPEED 1ST-SPEED INPUT SHAFT OUTPUT SHAFT First, let us see how the planetary gear transmission illustrated in Section IV-1 selects the first or second speed. The second-speed carrier is connected to the input shaft. The first- and second-speed sun gears are connected to the output shaft. The second:speed ring gear and first-speed, carrier are also mechanically connected. 342ND-SPEED 2 When the second-speed clutch is engaged to hold the ring gear stationary, the sun gear will be rotated at a higher speed than the carrier but in the same direction, INPUT SHAFT. When the first-speed clutch is engaged to hold the first-speed ring gear stationary, the first-speed carrier will be rotated at a lower speed than the second-speed carrier. Therefore, the sun gear speed will be lower in this instance than when the second-speed clutch is engaged. Refer to Section III-3 for more details.36 (2 1ST-SPEED3AD-SPEED 2ND-SPEED INPUT SHAFT OUTPUT SHAFT This is a three-speed transmission. In this example, the first-speed clutch is added to the two-speed transmission described in (1) in Section IV 3. When the first-speed clutch is engaged, the input shaft is directly coupl- ed with the output shaft, The second- and third-speed planetary gears are so designed that the output speed becomes higher than the input speed at different rates. (3) 3RD-SPEED 2ND-SPEED 1ST-SPEED INPUT SHAFT ‘OUTPUT SHAFT In this example, the arrangement of the planetary gears and first-speed clutch differs from (2) in Section IV-3. When the first-speed clutch is engag- ed, the third-speed ring gear and sun gear will be rotated together. This produces the same effect as when the input shaft (or carrier in this case) is directly coupled with the output shaft.Co) 2ND-SPEED 1ST-SPEED INPUT SHAFT. Youreur sHarr This is the transmission which was introduced on page 28. The first and second:speed carriers are connected to the input shaft. Both sun gears are fixed to the output shaft. Since the first-speed sun gear has more teeth than the other, the output speed will be higher when the second-speed clutch is engaged. 6) iB ot input sHaet () ‘Sj ourrursuarr In this transmission, both sun gears are fixed to the input shaft. The right hand side ring gear is connected to the output shaft. The two planetary gears have a common carrier. 37INPUT SHAFT. OUTPUT SHAFT When the L-clutch is engaged to hold the carrier stationary, the right hand side ring gear will be rotated at a lower speed than the sun gear but in the opposite directions. INPUT SHAFT. OUTPUT SHAFT When the H-clutch is engaged to hold the ring gear stationary, the carrier and sun gear will be rotated in opposite directions. Then the right hand side ring gear will be rotated faster than when the cartier is held stationary with the L-clutch engaged. Refer to Section III-3 for more details, 384. EXAMPLES OF TRANSMISSION This is the two-forward and two-reverse speed transmission that was illustrated in Section IV-1. This combines forward-reverse gears (1) in Section IV-2 with speed change gears (1) in Section IV-3. The travel direc- tion is determined by whether the R-clutch or F-clutch is engaged. The travel speed is basically determined by whether the first-speed or second-speed clutch is engaged. The illustrations below show the scheme of gearshifting in this transmission, The clutches indicated by arrows are engag- ed, F 1ST-SPEED Forward-1st speed INPUT SHAFT OUTPUT SHAFT 2ND-SPEED. oe Ee Xe : J 3940 1ST-SPEED j) OUTPUT SHAFTFL 2NDSPEED 1ST-SPEED aa) OUTPUT SHAFT Forward:-reverse shift gear assembly <—|—> 1st-2nd speed shift gear assembly This is a fourforward and two-reverse speed transmission which consists of forward-reverse gears (3) in Section IV-2 and speed change gears (1) in Section IVv-3, The forward-reverse gears select low-speed forward, high speed forward or backward. The speed change gears, in addition, select high or low travel speed. Since these gears are combined, forward travel speed can be varied ‘over four ranges and reverse speed over two ranges. The inner output shaft takes out power for the work equipment and has nothing to do with travel power. This is a three-forward and three-reverse speed transmission that Combines forward-reverse gears (4) in Section IV-2 with speed change gears (2) in Section Iv-3, The left-hand forward-reverse gears select forward or backward travel, and transmit power to the right-hand speed change gears, The speed change gears select first, second or third speed, As a result, both forward and reverse ‘travel speeds can be varied over three ranges. 4l42 ‘OUTPUT SHAFT t Forward-reverse shift gear assembly ~—|—~ Ist-2nd-3rd speed shift gear assembly This is also a three-forward and three-reverse speed transmission. This ‘employs forward-reverse gears (2), in Section IV-2 and speed change gears (3), in Section IV-3. The left-hand forward-reverse gears select forward or backward travel and transmit power to the right-hand speed change gears through the carrier. The speed change gears select first, second, or third speed. As a result, both forward and reverse travel speeds can be varied over three ranges. The inner output shaft takes out power for the work equipment and has nothing to do with travel power. \2ND-SPEED 1ST-SPEED| ‘OUTPUT SHAFT Forward-reverse | -—|—* 1st-2nd speeds | ——i—> Highiow speods Snitgearasombly | siviegearassembly | shift gear assembly This is a fourforward and four-reverse speed transmission that combines forward-reverse gears in Section IV-2 with speed change gears (4) and (5) in Section IV-3. The left-hand forward-reverse gears select forward or backward travel. The middle and right-hand two-speed gears select high or two travel speeds respectively. As a result, both forward and reverse travel speeds can be va over four ranges. The i equipment and, again, has nothing to do with travel power in this transmis- sion. iner output shaft takes out power for the workV MISCELLANEOUS 1. TORQFLOW TRANSMISSION DESCRIPTION Lik re Meme fe ss umn! | a 42 4 40 39 38— a7 36 3a 30 9 28 7 2 2 m4 a 1. Pin 17, Shatte 33, Tie bolt A 2. No.1 clutch piston 18, Nut 3a. No.1, 2and Seawies 5. Washer spring 19) Bearing 35. Tronsiniston case € 4 No.2 clutch piston 20. Gover 36. Spacer 5. 5S. shat 21. Bearing cage 37, Coupling E 8. No.3 clutch piston 22. Bearing 38. Holder F 7 Snap 38. Bote S. 8) No. a'cluteh piston 40. Shate 8 9, Gear 41 case E Third planetary pinion 10. Bram 26. No.4 careae 42) Cage 4: Third Fina gear M1 Spring No.3 and 4housings 43. Plate i. Fourth sun ges 1, No. Bhousing 28. Bole LC Fourth planetary pinion 13, Cheek ball 29. Stecve Wi 14, Rear cae 30, No.2 housing 16. No, 8 clutch piston 31. Pl 9: 16. Cage 32, No. housing44 HYDRAULIC SYSTEM The planetary gear transmission has several built-in clutches which are selectively engaged and disengaged by gearshifting operation. A hydraulic system that includes a hydraulic pump operates the clutches. A clutch is engaged when the pump applies oil pressure to the clutch piston, which pushes the clutch discs. The clutch will be disengaged when oil pressure applied to the piston is released and it travels backward. Gearshifting operation sets up oil passages in a control valve so that oil pressure will be applied to some clutches and not to others. If non of the clutches receives oil pressure, they will all remain disengaged and the trans- mission will transmit no power. Piston Forward speed clutch Control valve Piston Reverse speed clutch \, Control valve ‘to transmission case Another element involved in the transmission is a modulating valve. ‘A sudden ise in oil pressure applied to the clutches will cause them to be engaged abruptly and the vehicle to be accelerated suddenly. The modulating valve which is commonly used in bulldozers allows the oil pressure to rise gradually. Refer to the unit instruction, SEULU 1504, for details of the hydraulic system.3. CLUTCH ooeone Locking Ring Gear (Carrier) For locking the ring gear, the disc clutch is incorporated. It comprises a piston (2), plate (48), disc (46), pin (1), piston return spring (47), washer spring (3), and wave spring (24) The disc's internal teeth engage with the ring gear's external teeth. The plate, whose notch on the outside dia- meter engages with pin (1) on housing (32), is locked against the rotating direction. The piston also is locked against the rotating direc: tion, The housing (32) and other housings are tightened to transmission case. Clutch Engaged (Locked) Fluid from the control valve flows under pressure through the port in housing (32) to the back of piston (2). The piston presses dis (46) and plate (45) together, and the frictional force developed stops the disc revolution, thus locking ring gear (C) mesh- ing with the disc's internal teeth. Clutch Disengaged (Free) With shut off of the fluid supply from the control valve, piston (2) returns to the initial position under the force of piston return spring (47), thus relieving the frictional force between plate (45) and disc (46), bringing the ring gear in neutral. Spring washers (3) provid: ed between plates (45) ensure quick return of the piston at clutch disengagement as well as smooth disengagement of disc and plate, thus preventing reverse revolution of the disc. Wave spring (24) provided on No. § clutch performs the same function as the washer spring. 45BALL CHECK VALVE IN THE ROTATING CLUTCH A rotary type clutch is employed in the certain model. The fluid at the bottom of cylinder (12) remains under centrifugal force due to the revolu- tion even when the clutch is disengaged. The disc spring cannot overcome this force to instantly return piston (15), and the clutch is partially engaged. Because of this, the partially engaged condition persists even when the operator puts the gear lever in neutral, thus causing difficulty in continuing the gear shift operation. Ball check valve (13) mounted on the piston of the rotary clutch functions to avoid this kind of mal-function. © Clutch Engaged (Locked) The fluid from the control valve is supplied under pressure through the port of housing (12) to the back of piston (15). Then, ball check valve (13) closes the piston port, and the piston presses disc (50) to plate (49), engaging the disc's internal teeth and gear’s, external teeth, the plate’s external teeth and the drum’s internal teeth, thus effecting clutch engagment. © Clutch Disengaged (Free) With the shut off of fluid supply from the control valve, ball check valve (13) is displac- ed outward under centrifugal force due to the revolution, allowing fluid at the back of piston (1) to be discharged through the gap in the ball check valve, As a result, the fluid centrifugal force is completely eliminated. Wave spring (24) between plates (49) and the plate helps the piston to return to the initial position, thus preventing the reverse rotation of the disc by achieving smooth disengage- ment of disc (50) and plate when the clutch is disengaged.5, PLANETARY GEAR The planetary gear is allowed to rotate by needle bearing (1). Thrust plate (2) prevents the gear side surface from directly contacting the carrier. Shaft (3) which supports the planetary gear is held stationary relatively to carrier (4) with ball or key lock (5). 6. P.T.O. The PTO (Power Take-Off) provided at the rear part of the transmission provides power for a towing winch. 477. BEVEL GEAR ADJUSTMENT One or more shims (6) are installed at the rear part of the bevel gear bearing case. The position of the bevel gear system can be adjusted in the axial direction by changing the shim thickness. This is required to adjust the backlash and engagement of the bevel gear system. Taper bearing (7), properly installed, will automatically receive proper preload. If a gap exists between the bearing outer cage and cover (8), the bearing will not assume its proper position nor receive proper preload. To prevent this, press-fit bearing (7) completely and adjust the thickness of shim (9) so that there is no gap between the bearing and outer race. 48TO: Komatsu Subsidiary + Komatsu Liaison Office PROPOSAL FOR MANUAL REVISION No. Wey} — & % [| NAME OF COMPANY YOUR REFERENCE No, SEER - @ | DEPARTMENTI/SECTION DATE: $ a = - = eae Few i WANUAL CONCERNED a eB MANUAL No. - are Pa | MACHINE MODEL 7 | PROPOSAL | ATTACHED PHOTO OR SKETCH, IF NECESSARY. IF YOU NEED MORE SPACE, USE ANOTHER SHEET = | enor 2 He i NOTE: 1 ONE SHEET SHOULD BE USED FOR EACH PROPOSAL (DON'T WRITE IN BLUE INK\) 2. "MANUAL No." REFERS TO THE No. APPEARING IN THE UPPER RIGHT HAND CORNER ON THE COVER. ee KOMATSU LTD.No. PROPOSAL FOR MANUAL REVISION eer NAME OF COMPANY YOUR REFERENCE No. SAB - 3 DEPARTMENT/SECTION - DATE: g - & | NAME EE MANUAL CONCERNED cn ee T | a WANUAL No. ae ae] MACHINE MODEL a PROPOSAL, ATTACHED PHOTO OR SKETCH, IF NECESSARY. IF YOU NEED MORE SPACE, USE ANOTHER SHEET T i ? REPLY) Ty. # a wo & tt] NOTE: 1 ONE SHEET SHOULD BE USED FOR EACH PROPOSAL (DON'T WRITE IN BLUE INK). 2 "MANUAL No.” REFERS TO THE No. APPEARING IN THE UPPER RIGHT HAND CORNER ON THE COVER. ee KOMATSU LTD.Coen) 12:83 (01) 03004