SECTION 3 POWER TRAIN SYSTEM

GROUP 1 STRUCTURE AND OPERATION

1. POWER TRAIN DIAGRAM
1) STRUCTURE

4 5

20L7PT26

1 Engine 3 Drive shaft 5 Brake

2 Transmission 4 Drive axle

3-1
 2) SPECIFICATION

Item Specification

Model ZF 280 27 613/G7, KAPEC 280DB

Torque converter Type 3 Element, 1 stage, 2 phase
Stall ratio 2.9 : 1
Type Full auto, Power shift
Gear shift (FR/RR) 1/1
Transmission Adjustment Electrical single lever type, kick down system
FR 1.143 : 1
Gear ratio
RR 1.143 : 1
Type Front-wheel drive type, fixed location
Axle Gear ratio 14.2 : 1
Gear Spiral bevel gear type
Q'ty (FR/RR) 2/2
Wheels Front 6.50-10-12PR
Rear 5.00-8-10PR
Travel Front wheel, wet disk brake
Brakes
Parking Ratchet, wet disk brake
Type Hydro static, power steering
Steering
Steering angle 81°to both right and left angle, respectively

3-2
2. TORQUE CONVERTER
1) STRUCTURE

7
6

4 5

3
2
1

14
14
20
15
17 11 21
16
18
19
28
12
11
10

9
8
13

24 22

23
25

26
27
15L7APT03

1 Hexagon bolt 11 Plug 21 Air breather

2 Plain washer 12 O-ring 22 Magnetic plug
3 Flexible plate 13 Torque converter housing 23 Temperature sensor
4 Torque converter assembly 14 Hexagon bolt 24 Inner oil strainer
5 Shaft 15 Torque converter cover 25 Oil strainer spring
6 Snap ring 16 O-ring 26 O-ring
7 Gear 17 Plug 27 Oil strainer plug
8 Hexagon bolt 18 Spring 28 Gasket
9 Copper washer 19 Ball
10 Charging pump assembly 20 Plug

3-3
2) OPERATION
The torque converter is connected with a flywheel by a flexible plate, engine output is delivered from
the flywheel to the flexible plate.
The exterior of the torque converter is protected by the torque converter housing.
The torque converter housing forms the oil path for the oil pump, it includes the oil strainer filtering
sucked oil through this oil path and the oil level gauge measuring oil level of the transmission inside.

3) TORQUE CONVERTER HYDRAULIC CIRCUIT

Torque converter assy

Torque
converter
P T

Inlet port S Outlet port

To control valve
Inlet pressure Outlet pressure
detector port F G detector port
Main relief valve
C I To cooler

Gear pump

A D H
Drain Drain
Strainer

20D7PT04

3-4
3. TRANSMISSION
1) STRUCTURE

1 8 6 7 5 4 2

14

15

13

12

9
10
11

15L7APT28

1 Control valve 9 Output gear

2 Torque converter 10 Temperature sensor
3 Turbine wheel 11 Oil strainer
4 Impeller wheel 12 Idle gear
5 Stator wheel 13 Forward clutch pack
6 Forward clutch gear 14 Input shaft
7 Oil pump 15 Reverse clutch pack
8 Reverse clutch gear

3-5
2) INSTALLATION VIEW

1 3 5 6 4

2 7
15L7APT05

1 Torque converter 5 Air breather

2 Temperature sensor 6 Transmission oil filter
3 Control valve 7 Transmission output (Universal joint link part)
4 Oil level pipe and dipstick

3) OPERATION
The torque converter is an automatic fluid drive.
It transmits engine torque by means of hydraulic force.
The torque converter leads and the power which is delivered rotated the charging pump.
Oil is drawn from the transmission reservoir by the charging pump.
The pump delivers its entire output to a full-flow oil filter for cleaning.
From the oil filter, the oil supply is sent to the control valve.
The main pressure regulator valve provides pressure for clutch pack, directs oil to the solenoid
valve.
Moving the solenoid valve allows oil to charge the selected (forward or reverse) clutch line and to
engage that clutch.
The remaining oil appropriating clutch pressure flows into the torque converter.
A converter pressure regulator valve in the converter-in line limits the oil pressure there.
The oil pressure input to the torque converter is adjusted 4~7 kgf/cm2 (57~100 psi).
The oil pressure output from the torque converter is adjusted below 2~4.5 kgf/cm2 (28.4~64 psi).
The torque converter is continuously filled with oil during operation.
Rotation of the converter impeller imparts energy to the oil which, in turn, drives the turbines.
The oil then flows between the stator vanes which redirect it to the impeller.
At this time, torque is increased.
The oil from the torque converter enters the cooler.
The cooler is a heat exchanger in which the oil flows through air cooled passages.
After refrigerated, it is in charge of clutch lubrication through the lubrication oil path of the clutch
shaft. A lubrication valve between the cooler and lubrication system returns all excess oil to the
transmission reservoir.

3-6
 4) OPERATING MODES
(1) Forward

Input → Torque converter → Clutch shaft →

Forward clutch gear → Output gear →
Output

15L7APT29

(2) Reverse

Input → Torque converter → Clutch shaft →

Reverse clutch gear → Output gear →
Output

15L7APT30

3-7
5) TRANSMISSION CASE AND CONTROL VALVE
(1) Structure

20

18
17
22
13

10 19
21
9 25
23
11
12

24
26

4
14 5
15 6
7

28
29
30
31
2 32
1
3

16
15L7APT07

1 Transmission case 12 Socket bolt 22 Cylinder gear

2 Plug 13 Oil gauge 23 Idle gear
3 Oil seal 14 Clamp 24 Output gear
4 Ball 15 Socket bolt 25 Socket bolt
5 Spring 16 Flange bolt 26 Lock pin
6 O-ring 17 Control valve 28 O-ring
7 Plug 18 Solenoid valve 29 Adapter
9 Bolt 19 Gasket 30 O-ring
10 Transmission oil filter 20 Hexagon bolt 31 Plug
11 Pipe 21 O-ring 32 Socket bolt

3-8
(2) Operation
The transmission case includes the function of a control valve, an oil filter and a parking brake.
The oil filter is charge of filtering sucked oil by an oil pump before transmitting sucked oil to a
control valve and a torque converter.
Oil transmitted through an oil filter delivers oil pressure to the piston of the forward and reverse
clutch through the solenoid valve.
At this time, the solenoid valve is in charge of the important function of transmitting oil pressure for
forward and reverse through an electric signal by the forward and reverse selection lever of the
truck.
Oil pressure chosen for forward or reverse by the solenoid valve is transmitted to the forward
clutch through the formed oil path between transmission case or the reverse clutch through the
pipe of transmission outside.
Parking brake works by the band brake installed on parking drum which is linked to the output
shaft of the forward clutch.

3-9
6) CONTROL VALVE

(1) Operation

7 8 4

1 2 3 5 6

15L7APT08

1 Modulation 5 Inching valve pressure check port

2 Solenoid valve 6 Forward clutch pressure check port
3 Inching spool 7 Main pressure check port
4 Main relief valve 8 Reverse clutch pressure check port

The control valve consists of the main relief valve, solenoid valve, modulation valve and inching
valve.
The discharged oil from the gear pump enters main relief valve of the control valve and its
pressure is adjusted 10.8~14.9 kgf/cm2 (154~212 psi).
The oil adjusted pressure by the main relief valve is decided on the direction of forward or reverse
by the solenoid valve.
The decided oil is delivered the power transferred from the torque converter to drive axle through
the oil path between torque converter housing and transmission case.
The modulation valve provide a soft plugging when changing gears.
The modulation valve to absorb the small shocks of rapid pressure build up and quick release
during gear changes.
When full pressure builds up, the modulation valve shuts the modulation off and allows it to empty,
so it is ready to function again during gear change.
The inching valve permits the clutch to partially disengage, so that engine rpm can be increased
for lifting while travel speed remains low.

3-10
(2) Structure

Main relief valve

Modulation

8
2
7
26
4 5 10
6
25
Forward clutch pressure 9
check port 24
10
11 23
Inching valve pressure
check port
22
21

27

28 Reverse clutch pressure

12 20 check port
2 19
1 18 29 Main pressure
check port
17

16

15
14
13
Inching spool

Solenoid valve

15L7APT22

1 Plug 11 Spring 21 Stopper

2 O-ring 12 Solenoid valve 22 Spring
3 Spring 13 Seal 23 Spring
4 Plug 14 Snap ring 24 Valve
5 Plug 15 Plate 25 Piston
6 Spring 16 Spool 26 Plug
7 Piston 17 Valve 27 Screw
8 Plug 18 Spring 28 Body
9 Plug 19 Stopper 29 Gasket
10 O-ring 20 Nut

3-11
7) CLUTCH
(1) Operation

3 2 Reverse Forward

1
15L7APT31

1 Forward clutch plugging pressure delivery line ( )

2 Reverse clutch plugging pressure delivery line ( )
3 Clutch pack lubrication line ( )

When (forward/reverse) mode is selected through the solenoid valve of control valve, the flux
flowed by the oil pump flows into forward (reverse) clutch pack in 9~14.2 kgf/cm2 (128~202 psi) of
pressure through the oil path of transmission inside.
This oil make plugging of clutch pack by giving pressure at the piston of clutch pack.
At this time, the clutch shaft is always revolving while connected with the turbine of torque
converter.
According to be plugging, the clutch gear is connected and revolved with drum.
This power is delivered with linking output gear in touch with clutch gear.

3-12
(2) Structure

7
8
9
8
9
21
20
19
18
17
15
14
13
12
10 6
11 5
11
22 16
1

29
28
4 27
3 26
25
26
25
2 24
21
20
19
18
17
15
14
13
12
23
11
11
16

15L7APT11

1 Shaft 11 Seal ring 21 Wire ring

2 Seal ring 12 Piston 22 Plate
3 Needle bearing 13 Quad ring 23 Clutch drum
4 Ring 14 Quad ring 24 Spacer
5 Seal ring 15 Plate 25 Snap ring
6 Bushing 16 Friction plate 26 Ball bearing
7 Reverse clutch gear 17 Plate 27 Forward clutch gear
8 Ball bearing 18 Snap ring 28 Spacer
9 Snap ring 19 Spring 29 Ball bearing
10 Clutch drum 20 Back plate

3-13
8) OUTPUT GEAR
(1) Operation
The output gear is engaging the forward clutch gear and reverse clutch gear together.
If a driver selects forward, the forward clutch gets plugging, the forward clutch gear revolves and
the power of forward clutch gear is delivered to output gear.
If a driver selects reverse, the reverse clutch gets plugging, the reverse clutch gear revolves and
the power of reverse clutch gear is delivered to output gear.

(2) Structure

15L7APT14

1 Output gear 4 Oil seal

2 Ball bearing 5 Seal ring
3 Cover

3-14
4. DRIVE AXLE
1) INSTALLATION VIEW

1 2 3 4 5

15L7APT15

1 Carrier assembly 3 Traveling brake 5 Oil level gage

2 Drive axle housing 4 Hub

2) STRUCTURE

4 3 2 4

7 6 5 1
15L7APT16

1 Piston shaft 4 Axle shaft 7 Hub

2 Ring gear 5 Traveling brake
3 Differential device 6 Hub reduction

The drive axle is connected with the transmission output gear and universal joint.
The power transferred by the universal joint is connected to the pinion shaft of drive axle, the
pinion shaft delivers the power to the differential device through the ring gear.
The power transferred to the differential gear is delivered to final drive through the axle shaft in
reduced at the hub reduction.

3-15
3) CARRIER ASSEMBLY

(1) Operation
Carrier sub assy includes differential device and parking brake.
The pinion shaft is supported by the taper roller bearing in the carrier case and the bolt at the end
of pinion shaft and transfers the power which is delivered from the drive shaft assy to the ring gear
assembled from bolts at a differential device.
This power makes the differential device run.
Since the differential device is connected with an axle shaft and a spindle, the power transferred to
differential device is delivered to final drive through the axle shaft.
Parking brake, like as traveling brake system is consists of several friction plate functions braking
by sticking to each friction plate when pull parking hand lever.

15L7APT21

3-16
(2) Structure

10
5
6 2
7 4
9

15L7APT18

1 Parallel pin 5 Actuator 9 Eccentric shaft

2 Parking plate 6 Push pin 10 Lever
3 Friction plate-parking 7 Parking spline
4 Cone spring 8 Carrier case cover

3-17
4) DIFFERENTIAL DEVICE
(1) Operation
Since the ring gear is linked with the right of the differential case and the bolt, the power
transferred to the ring gear makes the differential device revolve.
And also, the left and right of the differential case are connected with the left and right of the axle
shaft and the spline respectively, it delivers the power to the final drive.
If the load concerning in the left and right of the final drive is different, the shock is transferred to
the drive axle, the differential gear in the differential device runs, the power transferred to the
differential device adjusts the delivering rate to the left and right axle shaft.
Consequently, it guarantees for safety of drivers.

(2) Structure

10

5
6

9
8
10

4 6
3 5

15L7APT19

1 Differential case (right) 5 Thrust washer 9 Socket bolt

2 Differential case (left) 6 Differential pinion gear 10 Taper roller bearing
3 Thrust washer 7 Differential spider
4 Differential side gear 8 Spring pin

3-18