威驰底盘新技术培训.ppt

Click to edit Master title style,Click to edit Master text styles,Second level,Third level,Fourth level,Fifth level,*,Chassis,Clutch,Manual Transaxle,C550 Manual Transaxle,C15#Series Manual Transaxle,Automatic Transaxle,U540E Automatic Transaxle,U340E Automatic Transaxle,Drive Shaft,Suspension,Brake,Steering,Tire and Wheel,Chassis,Clutch,Clutch Overall,Dry single-plate clutch operatedby hydraulic pressure is used,-C,-T,-M,Clutch Cover,Type,DST*,1,Size mm(in.),200(7.87),Clutch Disc,Facing Size*,2,mm(in.),200 x 140 x 3.5(7.87 x 5.51 x 0.14),Facing Area cm,2,(in,2,.),160(24.8),Master Cylinder,Type,Conventional,Cylinder Diameter mm(in.),15.87(0.62),Release Cylinder,Type,Non-adjustable,Cylinder Diameter mm(in.),20.64(0.81),*,1,:DST(Diaphragm Spring Turnover)*,2,:Outer Diameter x Inner Diameter x Thickness,Specification,Chassis,Clutch,Reservoir Tank,Clutch fluid reservoir tank and brake fluid reservoir tank are integrated for all models,-C,-T,-M,Clutch Master Cylinder,Brake Fluid Reservoir Tank,Chassis,C550 Manual Transaxle,Overall,C550 manual transaxle is used,basic construction and operation are same as,Yaris,/Echo,-C,Chassis,C550 Manual Transaxle,Specification,-C,Transaxle Type,C550,Gear Ratio(Counter GearRatio Included),1st,3.545,2nd,1.913,3rd,1.310,4th,0.973,5th,0.804,Reverse,3.214,Differential Gear Ratio,3.944,Oil Capacity Litter(US,qts,lmp,.,qts,),1.4(1.48,1.23),Oil Viscosity,SAE 75W-90,Oil Grade,API GL-3,Chassis,C15#Series Manual Transaxle,Overall,C15#series manual transaxle are used,basic construction and operation are same as,Yaris,/Echo,-T,-M,Chassis,C15#Series Manual Transaxle,Specification,-T,-M,Engine Type,1NZ-FE,2NZ-FE,Transaxle Type,C150,C154,Gear Ratio(Counter GearRatio Included),1st,3.545,2nd,1.904,3rd,1.310,4th,0.969,1.031,5th,0.815,0.864,Reverse,3.250,Differential Gear Ratio,3.526,Oil Capacity Litter(US,qts,lmp,.,qts,),1.9(2.0,1.7),Oil Viscosity,SAE 75W-90,Oil Grade,API GL-4 or GL-5,Chassis,U540E Automatic Transaxle,Overall,U540E 4-speed automatic transaxle ECT has been newly used,-C,Temporarily,Chassis,U540E Automatic Transaxle,Specification,-C,Engine Type,5A-FE,8A-FE,Transmission Type,U540E,Gear Ratio,1st,2.730,2nd,1.526,3rd,1.000,4th,0.696,Reverse,2.290,Differential Gear Ratio,4.032,4.350,Fluid Capacity(include differential)Litter(US,qts,lmp,.,qts,),4.7(4.97,4.14),Fluid Type,ATF Type T-IV,Chassis,U540E Automatic Transaxle,Torque Converter,A hydraulically operated lock-up mechanism type torque converter is used,-C,Engine Type,5A-FE,8A-FE,Oil Passage Diameter,215 mm(8.46 in.),Torque Converter Type,3-element,1-step,2-phase(with Lock-up Mechanism),Stall Torque Ratio,1.96,Temporarily,Chassis,U540E Automatic Transaxle,Oil Pump,Trochoid,gear type oil pump is used.As a result oil pump has made more compact and the driving torque has been reduced,-C,-R,-T,-M,Drive Gear,Driven Gear,Pump Body,Stator ShaftAssembly,:Brake,:Clutch,:One-way Clutch,Input,Chassis,U540E Automatic Transaxle,Planetary Gear Unit,U540E effects the shifting of all speeds using 1 set of,ravigneaux,type planetary gear unit,-C,IntermediateShaft,InputShaft,FrontSunGear,Front Ring Gear,Rear Sun Gear,LongPinionGear,ShortPinionGear,Output,B,2,F,B,1,C,1,C,2,C,3,行星齿轮机构结构原理图,:Brake,:Clutch,:One-way Clutch,Input,Chassis,U540E Automatic Transaxle,Planetary Gear Unit Construction,1,st,gear(D or 2 position),-C,IntermediateShaft,InputShaft,FrontSunGear,Front Ring Gear,Rear Sun Gear,LongPinionGear,ShortPinionGear,Output,B,2,F,B,1,C,1,C,2,C,3,Chassis,U540E Automatic Transaxle,Planetary Gear Unit,Function of components,-C,Component,Function,C,1,Reverse Clutch,Connects input shaft and front planetary sun gear,C,2,Forward Clutch,Connects input shaft and rear planetary sun gear,C,3,Rear Clutch,Connects input shaft and intermediate shaft,B,1,2,nd,and 4,th,Brake,Locks front planetary sun gear,B,2,1,st,and Reverse Brake,Locks planetary carrier,F,One-way Clutch,Locks rear planetary carrier from turning counterclockwise,Chassis,U540E Automatic Transaxle,Planetary Gear Unit,Operation condition,-C,*,1,:After engaging,lock-up control is ON*,2,:After engaging,line pressure control is ON*,3,:After engaging,line pressure control is OFF,Shift Lever Position,Gear,Shift Solenoid Valve,C,1,C,2,C,3,B,1,B,2,F,SL1,SL2,SL3,DSL,SL,SR,P,Park,X,X,R,Reverse,X,X/*,2,X,X,/,X,*,3,N,Neutral,X,X,X,D,1,st,X,X,X,X,2,nd,X,X/*,1,X/*,1,3,rd,X,X,X/*,2,X/*,1,X/*,1,X,4,th,X/*,2,X/*,1,X/*,1,X,2,1,st,X,X,X,X,2,nd,X,X/*,1,X/*,1,L,1,st,X,X,X,X,:Signal ON,X:Signal OFF,:Operation,Chassis,U540E Automatic Transaxle,Valve Body,The valve body consist following parts,-C,Shift Solenoid Valve SL2,Shift Solenoid Valve SL3,Shift Solenoid Valve SL1,Shift Solenoid Valve SR,Shift Solenoid Valve SL,Shift Solenoid Valve DSL,Valve Body Assembly,Chassis,U540E Automatic Transaxle,Valve Body,Function of shift solenoid Valve,-C,Shift Solenoid Valve,Function,SL1,Control the B,1,brake hydraulic pressure,SL2,Control the C,2,brake hydraulic pressure,SL3,Control the line pressure that controls the hydraulic pressure for the C,3,clutch and that for the B,2,brake,DSL,Control the lock-up clutch hydraulic pressure,SL,Switch the lock-up relay valve,SR,Switch the solenoid relay valve,Chassis,U540E Automatic Transaxle,Layout of Components,-C,Transmission Control Switch,EngineECU,ECT ECU,Stop Lightswitch,DLC3,Chassis,U540E Automatic Transaxle,Layout of Components,-C,Output Speed Sensor,Input Speed Sensor,Neutral Start Position Switch,Shift Solenoid Valve SL2,Shift Solenoid Valve SL1,Shift Solenoid Valve SL3,Shift Solenoid Valve SR,Shift Solenoid Valve SL,Shift Solenoid Valve DSL,Fluid Temp.Sensor,Chassis,U540E Automatic Transaxle,System Diagram,-C,Engine ECU,Fluid Temp.Sensor,NeutralStartSwitch,Input Turbine Speed Sensor,DLC3,Counter Gear Speed Sensor,SolenoidValves,Stop Light Switch,Combination Meter,ECT ECU,VehicleSpeed,Throttle Valve Opening Angle,Engine Speed,Water Temp.,Torque Reduction?,Chassis,U540E Automatic Transaxle,Centrifugal Fluid Pressure Canceling Mechanism,A canceling fluid pressure chamber is used to prevent the generation of pressure by the centrifugal force,-C,Clutch,Centrifugal Fluid Pressure Applied to Canceling Chamber,Centrifugal Fluid Pressure,Target Fluid Pressure,Input Shaft,Piston,Chassis,-C,ECTECU,EngineECU,Water Temp.Sensor,Shift PositionSwitch,Throttle Position Sensor,Vehicle Speed Sensor,TransmissionControl Switch,SolenoidValve,Control Valve,Lock Valve,Current,Fluid Pressure,U540E Automatic Transaxle,Direct Clutch Pressure Control,Solenoid valve regulated the clutch and brake hydraulic pressure without using an accumulator,C,2,C,3,B,1,and B,2,Chassis,U540E Automatic Transaxle,Direct Clutch Pressure Control,The time lag in an inactive stroke was reduced by controlling a clutch by direct fluid pressure,-C,Time,Direct Clutch Pressure Type,Fluid Pressure,Accumulator Type,Shift Shock Absorbing,Inactive Stroke,Time lag Reduction,Chassis,U540E Automatic Transaxle,Line Pressure Control,Line pressure is optimally controlled in accordance with the engine torque information,-C,Primary Regulator,Throttle Pressure,Pump,Line Pressure,Shift Range,Throttle Valve Opening Angle,Engine Speed,Shift Position,Current,FluidPressure,Solenoid Valve SL3,ECTECU,EngineECU,Chassis,U540E Automatic Transaxle,Engine Torque Control,Retards the engine ignition timing temporarily to improve shift feeling during up or down shifting,-C,ECTECU,EngineECU,Ignition TimingRetard Signal,Water Temp.Sensor,Shift PositionSwitch,Throttle Position Sensor,CrankshaftPosition Sensor,Vehicle Speed Sensor,TransmissionControl Switch,TransmissionControl Signal,Retard,Time,Drive Wheel Torque,IgnitionTiming,Reduced Torque Fluctuations,Shift Change,Chassis,U540E Automatic Transaxle,“N”to“D”Squat Control,When the shift lever is shifted from“N”to“D”range,the gear is temporarily shifted to 2,nd,and then to 1,st,to reduce vehicle squat,-C,Chassis,U540E Automatic Transaxle,Clutch to Clutch Pressure Control,Optimal shift characteristics have been achieved through optimal hydraulic pressure settings,-C,Control Valve,Signals from individual sensors,Disconnect Side Clutch,Solenoid Valves,Connect Side Clutch,Line Pressure,Control Valve,ECTECU,EngineECU,Chassis,U540E Automatic Transaxle,Fail-safe Function,This function minimizes the loss of operability when any abnormality occurs in each sensor or solenoid valve,-C,Malfunction,Input Turbine Speed Sensor,Fluid Temp.Sensor,Solenoid Valve SL1,2,Solenoid Valve SL,Solenoid Valve DSL,Communication Line between Engine ECU and ECT ECU,Crankshaft Position Sensor,4,th,Upshift,Prohibit,Service Point,U540E Automatic Transaxle,Diagnosis System,In the ECT ECU detects a malfunction in the system,it alerts the driver by blinking the O/D OFF light and storing the,DTCs,-C,O/DOFF,O/DOFF,Blinking,Service Point,U540E Automatic Transaxle,Check the DTC,Using SST(09843-18040),connect terminals TC and CG of DLC3,-C,DLC3,TC,O/DOFF,OFF,ON,CG,Service Point,U540E Automatic Transaxle,DTC(Diagnostic Trouble Code),DTC output 2-digit only,-C,DTC No.,Detection Item,38,Transmission Fluid Temp.Sensor Malfunction,61,Output Speed Sensor Circuit No Signal,62,Shift solenoid A Electrical Malfunction(Shift Solenoid Valve SL1),63,Shift solenoid A Electrical Malfunction(Shift Solenoid Valve SL2),64,Shift solenoid A Electrical Malfunction(Shift Solenoid Valve SL),86,Engine speed is not input,97,Neutral start position switch is not input,97,Neutral start position switch multiple input,Service Point,U540E Automatic Transaxle,Clear the DTC,Turn the ignition switch OFF and disconnect the EFI fuse in the relay block at least 30 seconds or more,-C,EFIFuse,Service Point,U540E Automatic Transaxle,Delete the Learning Value of the ECT ECU,-C,NOTE:,When the automatic transaxle assembly or valve body assembly are replaced,deletion of the learning value of the ECT ECU is required.,TC,CG,1.Connect the terminals TC and CG,2.Depress the brake pedal within 3,secs,.after turning the ignition switch ON and keep depressing the pedal until operation 3 is completed,Within3 seconds,Keep the Depressing,Service Point,U540E Automatic Transaxle,Delete the Learning Value of the ECT ECU,-C,3.Shift the shift lever,P,RP,within 1 seconds,repeat 8 times*,4.Turn the ignition switch OFF and turn the ignition switch ON again,Keep the Depressing,*,:When the Step 3 is completed,O/D OFF indicator blink for 2.5,Chassis,U540E Automatic Transaxle,Overdrive Switch,O/D switch changed from ON-OFF lock type to momentary type,-C,Chassis,U340E Automatic Transaxle,Overall,The compact,lightweight and high-capacity4-speed automatic transaxle Super ECT is used,-R,-T,-M,Chassis,U340E Automatic Transaxle,Specification,Transmission Type,U340E,Gear Ratio,1st,2.847,2nd,1.552,3rd,1.000,4th,0.700,Reverse,2.343,Differential Gear Ratio,3.850,Fluid Capacity(include differential)Litter(US,qts,lmp,.,qts,),6.8(7.2,6.0),Fluid Type,ATF Type T-IV,-R,-T,-M,Chassis,U340E Automatic Transaxle,Planetary Gear Unit,U340E automatic transaxle effects the shifting of all speeds using 2 sets of planetary gear unit,-R,-T,-M,:Brake,:Clutch,:One-way Clutch,Input,Output,IntermediateShaft,Rear PlanetaryGear,Front PlanetaryGear,CounterDrive Gear,Counter Drive Gear,B,2,B,1,B,3,C,1,C,2,C,3,F,2,F,1,Chassis,U340E Automatic Transaxle,Valve Body,The valve body has a two-stage construction.All the solenoid valves are installed in the lower valve body,-R,-T,-M,Accumulators(B2,C3,C2),Linear Solenoid Valve(SL),Accumulator(C1),Fluid Temp.Sensor,Upper Valve Body,Linear Solenoid Valve(SLT),Shift Solenoid Valve(ST),Accumulator(B1),Lower Valve Body,Shift Solenoid Valve(S2),Shift Solenoid Valve(S1),Chassis,U340E Automatic Transaxle,Valve Body,The valve body has a two-stage construction.All the solenoid valves are installed in the lower valve body,-R,-T,-M,Solenoid Valve,Action,Function,Shift Solenoid Valve,S1,Switches the 2-3 shift valve,C1 clutch and B1,2 brake pressure control,S2,Switches the 1-2,3-4 shift valve,C1,2 clutch and B1,2 brake pressure control,ST,Clutch to clutch pressure control,3-4 and 4-3 shift valves control,Linear Solenoid Valve,SL,Clutch pressure optimal control,Lock-up clutch pressure control,SLT,Line pressure control,Line pressure,secondary pressure and accumulator back pressure control,Chassis,U340E Automatic Transaxle,Centrifugal Fluid Pressure Canceling Mechanism,A canceling fluid pressure chamber is used to prevent the generation of pressure by the centrifugal force,-R,-T,-M,Clutch,Centrifugal Fluid Pressure Applied to Canceling Chamber,Centrifugal Fluid Pressure,Target Fluid Pressure,Input Shaft,Piston,Chassis,U340E Automatic Transaxle,Line Pressure Control,Line pressure is optimally controlled in accordance with the engine torque information,-R,-T,-M,Primary Regulator,Throttle Pressure,Pump,Line Pressure,Shift Range,Throttle Valve Opening Angle,Engine Speed,Shift Position,Current,FluidPressure,Solenoid Valve SLT,ECT,Engine,Engine&ECT ECU,Chassis,U340E Automatic Transaxle,Clutch to Clutch Pressure Control,The shift solenoid valve minutely controls the clutch pressure in accordance with the engine output and driving conditions,-R,-T,-M,Linear Solenoid Valve SLT,Accumulator Control Valve,C,1,B,1,SolenoidValve ST,3-4 Shift Valve,4-3 Timing Valve,3-4 Timing Valve,Chassis,U340E Automatic Transaxle,Fail-safe Function,This function minimizes the loss of operability when any abnormality occurs in each sensor or solenoid valve,-R,-T,-M,Malfunction,Vehicle Speed Sensor,Input Turbine Speed Sensor,Fluid Temp.Sensor,Solenoid Valve SLT,Solenoid Valve SL,Solenoid Valve ST,Water Temp.Sensor,Knock Sensor,Throttle Position Sensor,4,th,Upshift,Prohibit,Chassis,U340E Automatic Transaxle,Fail-safe Function,Case of the malfunction in the solenoid valve S1 or S2,-R,-T,-M,All Shift solenoids normal,Shift solenoid S1 malfunction,Shift solenoid S2 malfunction,Shift solenoid S1 and S2 malfunction,Solenoid,Gear,Solenoid,Gear,Solenoid,Gear,Solenoid,Gear,S1,S2,S1,S2,S1,S2,S1,S2,ON,ON,1,st,X,OFF,ON,3,rd,ON,X,2,nd,X,X,3,rd,ON,OFF,2,nd,X,OFF,3,rd,ON,X,2,nd,X,X,3,rd,OFF,OFF,3,rd,X,OFF,3,rd,OFF,X,3,rd,X,X,3,rd,OFF,ON,4,th,X,ON,4,th,OFF,X,3,rd,X,X,3,rd,Chassis,U340E Automatic Transaxle,Overdrive Switch,O/D switch changed from ON-OFF lock type to momentary type,-R,-T,-M,Chassis,Drive Shaft,Overall,Drive shaft uses the Tripod type CVJ(Constant-Velocity Joint)on the differential side,and,Rzeppa,type CVJ on the wheel side,-C,-R,-T,-M,WheelSide,Left-hand,Differential Side,WheelSide,Differential Side,Right-hand,Rzeppa,Type CVJ,Rzeppa,Type CVJ,Tripod Type CVJ,Dynamic Damper,Chassis,Suspension,Suspension Line-up,Front:,MacPherson,strut type suspension,Rear:Torsion-beam type suspension with toe-,conrrect,bushings (,eta,beam suspension),-C,-R,-T,-M,Chassis,Brake,Overall,Front:14”Ventilated Disc Brake,Rear:Leading Trailing Drum Brake 14”Solid Disc Brake(Thailand model),-C,-R,-T,-M,Front Brake,Rear Brake,Chassis,Brake,Specification,-C,-R,-M,Model,without ABS*,1,without ABS*,2,with ABS,Master Cylinder,Type,Lockheed+Lockheed,Portless,+Lockheed,Diameter mm(in.),20.64(0.81),Brake B