ZF Sachs AG Ernst-Sachs-Strae 62 97424 Schweinfurt Germany phone:

+49 9721 98-0 fax: +49 9721 98-2290 www.zf.com

Torque Converters

For Construction Machinery and Lift Trucks

Driveline and Chassis Technology

ZF Sachs AG-Construction Machinery-Torque Converter-04/2010

More Comfort and Less Fuel Consumption Torque Converters by ZF Sachs

What applies to commercial vehicles in general is also true for construction machinery in particular: Requirements for vehicles are on the rise. On the one hand, construction machines are supposed to be versatile, economically viable, and reliable, while on the other hand of course they should also be saving fuel. With its highly efficient and individually adaptable torque converters, ZF Sachs AG is masterfully bridging these two sets of requirements for its area of expertise. With millimeter-precise accuracy for maneuvering, swift loading and unloading, a high and even level of power transfer, quick and smooth shift processes construction machinery has to be highly versatile and reliable. And all of this more so than ever! In order for lift trucks, telescopic handlers, backhoe loaders, wheel loaders and dump trucks to successfully complete the tasks assigned by their owners or drivers, all components of the driveline have to be optimally harmonized with one another. Today, no one can conceive of working without the valuable assistance of vehicles equipped with hydrodynamic torque converters. ZF Sachs offers a broad spectrum of torque converters here in different model versions. Due to its ongoing development work, ZF Sachs is able to provide production-ready solutions today that already meet the requirements of the future.

Torque for Every Construction Machinery Application

With a hydrodynamic diameter of 280 up to 400 millimeters, torque converters by ZF Sachs can easily be used for engine torques up to 2,700 Nm. Thus, not only the entire torque converter range of construction machinery is covered, but also all individual requirements of manufacturers and operators can be fulfilled. The individual matching of performance and model type to the respective application makes torque converters from ZF Sachs extraordinarily effective.

Application

Backhoe Loader/ Lift Truck Telescopic Handler

Wheel Loader

Dump Truck

Torque Converter

W280

W300

W280

W300

W300

W340

W400

W400

Free-wheel Unit

Torsional Damper

Lock-up Clutch LUC

Standard

Optional

Future Trend

Engine torque [Nm]

Torque Converters for Every Torque Range

The task:
Hydrodynamic torque converters are used in construction machinery with automatic transmissions. The engine torque is passed to the transmission via the torque converter using oil as a transfer medium. A high and even level of power transfer as well as quick and smooth shift processes are a must. Because hydrodynamic power transfer is fuel-intensive, lock-up clutch ensures direct torque flow between engine and transmission after the drive-off process. To protect the transmission, torsional vibrations have to be filtered out.

Torque for every construction machinery application 3,000 2,500 2,000 1,500 1,000 500 0 W280 W300 W340 W400 The required converter size depends on the engine torque to be transmitted.

The technology:
Torque converters from ZF Sachs are known for their robust design. Thanks to individual adaptation of engine and converter characteristics, they are optimally designed for any given application with respect to both function and service life. After the drive-off process, the optional lock-up clutch enables torque flow to be transferred directly and thus with no loss of power between the engine and the transmission. This contributes substantially lowering fuel consumption levels and enhancing cost-effectiveness for construction machinery. ZF Sachs torque converters are featuring new free-wheel designs to cope with the highly dynamic gear-shifting processes which occur in transmissions these days. The vibrational problems that arise in the driveline when engines are optimized for fuel consumption and emissions are being addressed by integrating torsional dampers into the torque converter.

Converter size [mm]

Design of W340 LUC/TD for wheel loaders

Engine connection

Impeller Lock-up clutch with torsional damper Turbine

Stator

Free-wheel Oil pump drive

Power take-off

W300 LUC/TD 4

W400 LUC 5

Comparison of vibrational decoupling for converters with and without torsional damper (TD) Angular acceleration [1/s] Benefits Longer service life thanks to protection of driveline components Reduced fuel consumption because required rpm levels can be lowered Reduced noise emission

Details of Lock-up Clutch Systems

Converter with lock-up clutch with 1 friction facing in dual-line system Lock-up clutch disengaged Lock-up clutch engaged Torque converters with lock-up clutch using a dual-line principle are used primarily in backhoe loaders and telescopic handlers. The lock-up clutch can transmit up to 500 Nm of torque.

Operational range Converter without TD Converter with TD 500 1,000 1,500 2,000 2,500 Speed [rpm]

Oil flow Torque converter efficiency Like every other hydraulic machine, torque converters do not work without losses. The efficiency of a torque converter in hydrodynamic mode is about 90%. A torque converter lock-up clutch enables torque flow to be transferred directly between engine and transmission. As soon as the lock-up clutch is engaged the efficiency of the torque converter is approximately 100%.

Torque flow

5 approx. 100 % 4

Converter with lock-up clutch with 1 friction facing in open three-line system

Lock-up clutch disengaged

Lock-up clutch engaged Torque converters with lock-up clutch using an open three-line principle are also used primarily in backhoe loaders and telescopic handlers. The threeline system and the enhanced heat transfer mean that the lock-up clutch can be engaged earlier. This optimizes fuel consumption all the more.

Gear

2 approx. 100 % 1 max. 90 % Without lock-up clutch max. 90 % Lock-up clutch engaged in fourth gear Lock-up clutch disengaged max. 90 % Lock-up clutch engaged as of second gear Lock-up clutch engaged

Oil flow

Torque flow

Reduced fuel consumption with lock-up clutch + refuel refuel without lock-up clutch Fuel savings of up to 15 % with lock-up clutch Fuel consumption can be lowered by up to 15%, depending on the load cycle and service conditions, as well as the gear in which lock-up clutch is engaged.

Converter with lock-up clutch with 4 friction facing in closed three-line system

Lock-up clutch disengaged

Lock-up clutch engaged Torque converters with lock-up clutch using a closed three-line principle are used primarily in dump trucks and wheel loaders. In addition to the advantages of the open three-line system, here there is a longer service life. This is because the lock-up clutchs shift function can be better modulated thanks to the closed control line.

Fuel consumption

with lock-up clutch

Driving time/distance

Oil flow

Torque flow