Power train System20/25/30/33D-7(E)

Basic information for power train system

TRANSMISSION(MSP)- PTO Drive- Gear Train- Clutch Pack- Charging Pump- Control Valve

ENGINE (Kubota)* V3300-Tier 2* V3600-Tier 3

TORQUECONVERTER- Impeller- Stator- Turbine

DRIVE AXLE(MSP)- Mast Mounting- Frame Mounting- Hub- Brake

Other models EngineModel

20/25/30/33D-7(E)

Engine

Kubota

35/40/45D(S)-7

HDF50/70-7(S)

D: HMCS: Mitsubishi

D: HMCS: Mitsubishi

80D-7

100>160D-7(E)

Mitsubishi

Cummins

HMC: Hyundai Motor Co.,

TransmissionModel

20/25/30/33D-7(E)

35/40/45D(S)-7

HDF50/70-7(S)

80D-7

100>160D-7(E)

T/M

MSP

DIC

ZF(3WG94)

ZF(3WG94)

ZF(3WG161)

Gear shift (FR/RR)

1/1

2/2

3/3

3/3

3/3

AxleModel

20/25/30/33D-7(E)

35/40/45D(S)-7

HDF50/70-7(S)

80D-7

100>160D-7(E)

Axle

MSP

DIC

DIC

DIC

Kessler

MobileFluid 424(10.5)

SAE80W-90/API GL-5(12.5)

MobileFluid 424(12.5)

Gear oil: SAE80W-90/API GL-5 Cooling oil: Hydraulic oil +Lubrizol LZ9990A

Axle oil(Capacity)

MobileFluid 424(5)

Structure and OperationPower train DiagramTorque Converter

Transmission

T/M filter

Control valve

Drive shaftBrake (Wet)

Drive Axle

Hub

SpecificationSpecification

ItemTorque converter

Transmission

Model

Z80-D(ZF)

Type

3 Element, 1stage, 2phase

Stall ratio

2.8

Type

Power shift

Gear shift (FR/RR)

1/1

Control

Electrical single lever type

Overhaul ratio

AxleWheelsBrakes

FR

15.886

RR

16.497

Type

Front wheel drive type, fixed location

Gear

Hypoid gear type

Qty (FR/RR)

Single: 2/2, Double:4/2

Travel

Front wheel, duo-servo & auto adjustment type

Parking

Toggle, internal expanding mechanical type

Transmission

Transmission

Control valveTorque converter

Temp. Sensor

Parking brake link lever

T/M oil filterAir breatherT/M output (Drive shift joint)

Dip stick

T/M case, Control valve, Oil pump and Parking brake

Structure

Forward ClutchCutch pack plugging

Cutch pack lubrication line

pressure delivery line

(From control valve)

(From control valve)

9~14.2kgf/

1 Drum gear

4 Clutch gear

2 Clutch piston

5 Forward shift

3 Friction plate and plate

Modification of Transmission Seal type #1 (SB-I-2009-013)

Caution! Forward/reverse clutch pack must be replaced with those 3 parts at the same time

Modification of Transmission Seal type #2 (SB-I-2009-016)

ovedrpmIPiston

Torque Converter (Structure)

Stator

Pump

TurbineInput flangeT/M Pump

Picture of Impeller (Pump) and Turbine (Motor)

Torque Converter (Diagram)

(2~3bar)(7bar)

For clutch lubrication

:To protect converter(13cc/rev)

blades

:To protectoil cooler

Torque Converter (Oil pump & spacer)Oil pump case

Stator shaftDrive gear

Spacer

Control valve

Function of Control valveSort

Function

Remarks

Modulating Valve

It relives oil flows.It decreases impact when changing gear to theforward or backward and quick start and usinginching valve.

Solenoid Valve

It is connected with switch of forward, back wardand it supplies pressure to the clutch of forward,backward.

Inching Valve

It controls pressure of clutch oil depending on how Do not use at highmuch operator presses the inching pedal.travel speed

Regulator Valve

It controls oil pressure to the regulation scope thatis occurred from charging pump of the converter. Main relief valveIt protects valve and oil cooler of the converter.

Useful when abruptgear change is tried.

Hydraulic Circuit

Engine

- Inching

Engine

Engine

Improvement of Jerky starting (SB-I-2008-017)

Improvement of Gear Selector (SB-I-2009-009)(35D/40D/45D-7)

Drive Axle

Drive Axle

Carrier Assy

Axle housing

Brake (wet)

Oil level gaugeHub

StructureAxle shaft

Differential device

Axle shaft

HubBrake

Pinion shaft

Ring gear

From T/M output

Brake

Schematic for wet disc brakeBrake piston

Brake oilpassage

Friction discs & plates

Wheel hub

Return spring

Piston seal

Improvement of brake disc (SB-S-2010-017)2. ImprovementPart name

Current

Improved

Part number Qt'y

Part number

Qt'y

Remark

Plate-friction

XKCF-00138

10

XKCF-00644

10

Developed for A/S purpose

Plate

XKCF-00137

12

Need not to replace.(Reusable)

3. Noise CountermeasureStep 1) Periodic maintenance (Replace MF424 oil at initial 50 hours and every 500 hours.)Step 2) Oil replacing period comes earlier and/or, MF 424 is less effective.

keaBr

Step 3) Replace the improved discs(XKCF-00644) and oil in accordance with below table.HHI's viewRecommended

Axle oilMobil Fluid 424 (* Current)Shell Donax TD 10W30Shell Spirax 80W90 LS

Replaceable

Mobil Infilex33 85W90

Remark

HHI finished real test. (Confirmed)In case, the 2 recommended oilsare not available, you can try.

Caltex Textran TDH

Note) It needs not to replace Plate(XKCF-00137) whenever Friction plates are replaced.

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Brake disc (Wet type)

Brake & hub

Piston seal

Friction disc and plate

Piston seal

Brake piston

Disassembly

Air bleeding & brake oil line

Friction disc(5EA) & plate(6EA)

Troubleshooting - Air bleeding1)Pedal stroke: If the seal in master cylinder is positionedin the left side than hole for brake oil fromreservoir tank, air-bleeding job can not bedone correctly. In this case, you need toadjust for the pedal idle stroke(1~3mm).In other words, rod in master cylinder needsto be pulled out in maximum.2)Master cylinder & Axle (2 persons): Person A press and release the pedal several times(10 times) and press it in the end.Person B slightly release the pipe line in master cylinder outlet to take out the oil (air)in master cylinder. Person A release the pedal (At this point, refill the brake oil in reservoir tank.If the oil level is not reduced, above pedal stroke adjustment is not correctly done.)and repeat above work 4~5 times. Then, tighten the pipe to finish air-bleeding job withmaster cylinder. (Same job for axle bleeding)

Specification1)Disc brakeItem

Specification

Type

Wet disc brake

Master cylinder diameter (non-boosted)

33mm

Pedal height

160mm

Play

1~3mm

Pedal adjustmentBrake oil

Azola zs10(SAE 10W hydraulic oil)

2)Parking brakeItem

Specification

Type

Ratchet, internal expending mechanical type

Parking lever stroke/Cable stroke

12.1/11.5mm

Brake systemParking brakeBrake pedalT/M control valveInching pedalMaster cylinder

Transmission

Pressure switchDrive axle

Use of Brake Oil (SB-S-2009-012)

Caution! Use correct brake oil according to decal for your brake system

Improperly used brake oilDamages the seals andpiston stuck.

Distinction of brake oil

Protection of brake pipe (SB-I-2009-011) Phenomenon

U-clamp installation

Improvement of brake pressure switch (SB-I-2009-023)

34

rab.6

rab69

Inching pedal and linkageStroke: 3~4mmPressure drop: 2~3bar

(Initial position)

Adjustment

(15~20 mm)(1~3 mm)

(160 mm)

(160 mm)

Brake pedal1)Pedal height from floor

- Adjust with stopper bolt

- Adjust with stopper bolt

- Adjust with master cylinder rod

Parking brake

Inching pedal

1)Pedal height from floor

2)Idle stroke

(Stroke: 2~3mm)

2)Adjust bolt so that brake pedalinterconnects with inching pedalat inching pedal stroke 15~20mm

1)After assembling parking brake andparking cable, put parking brake leverreleased.2)Loosen nut for parking brake plateto play up and down.3)Move up the plate so that stopper can beconnected with pin and reassemble nut.

Maintenance Chart for power train systemServiceInterval

Description

Serviceaction

OilSymbol

Capacity()

Check, Add

BF

0.5

Check, Adjust

-

-

Check, Add

-

-

Check, Adjust

-

-

5

Brake oil

6

Parking brake operation

15

Tire air pressure andWheel nut

25

Pedal linkage operation

50hrsor weekly

13

Steering axle linkage

Check, Add

G

-

22

Transmission oil level

Check, Add

MO

10

Initial 50hrs

26

Differential gear oil

Change

GO

5

Initial100hrs

22

Transmission oil

Change

MO

10

23

Transmission oil filter

Replace

-

-

26

Differential gear oil

Check, Add

GO

5

5

Brake oil

Replace

BF

0.5

26

Differential gear oil

Replace

GO

5

22

Transmission oil

Replace

MO

10

23

Transmission oil filter

Replace

-

-

12

Radiator coolant

Replace

C

9.4

19

Hydraulic strainer

Check, clean

-

-

19

Hydraulic oil*1

Change

HO

26

19

Hydraulic oil*2

Change

HO

26

10hrsor daily

250hrsor monthly500hrsor3 monthly1000hrsor6 monthly

*1: Conventional hydraulic oil

ItemNo.

2000hrs

*2: Hyundai genuine long life hydraulic oil5000hrs

ThankThank youyou forfor youryour attentionattention !!