Dana Unveils Technological Innovations in Transmission Program while Introducing New Drivetrains at Bauma 2010

MUNICH, GERMANY.  Apr. 19, 2010 – At Bauma 2010 today, Dana Holding Corporation announced technological advances in the company’s drivetrain development program as well as the addition of new drivetrains for construction and material-handling equipment.

Dana has also added Authorized Spicer® Service Centers in Peru and the United States to the company’s global network of off-highway affiliates.

“Despite the downturn in the economy, Dana has remained focused on developing new technologies to improve the efficiency and reliability of our drivetrains while reinforcing our global commitment to customer service,” said Pietro Franzosi, vice president of sales and marketing for the Dana Off-Highway Products Group.  “We continue to prove that Dana is the Tier 1 drivetrain supplier that OEMs around the world can trust for innovation and quality.”

Dana shared the results of recent simulations that show a substantial increase in the output of the concept demonstrator Spicer® TE-15HX electric parallel hybrid transmission specifically designed for off-highway vehicles.  By using a high-output electric device positioned to optimize power within a tight design envelope, Dana projects 47 kW (63 horsepower) of output from the electric device at peak.

Dana introduced new drivetrain systems for 16-tonne front-end loaders and eight- to nine-tonne industrial lift trucks, which feature the new Spicer® Model 139 axle.  Dana is also exhibiting a drivetrain system for 17.5-tonne wheeled excavators.

Dana has also added Maestranza Diesel in Peru and North Atlantic Power in the United States to the company’s network of Authorized Spicer® Service Centers for off-highway customers. With the inclusion of these two centers, Dana now has 66 Authorized Spicer Service Centers in 54 countries on six continents to supply genuine Spicer parts and factory-authorized service to off-highway customers.

Dana will exhibit the following drivetrain components and integrated systems in Hall A4, Stand 215/312 at Bauma 2010: 

Spicer® TE-15HX Transmission
Dana Holding Corporation revealed the results of simulations that show a substantial increase in the output of the concept demonstrator Spicer® TE-15HX electric parallel hybrid transmission specifically designed for off-highway vehicles.

Since Dana first announced the development of the Spicer TE-15HX transmission at INTERMAT 2009, testing has advanced on an optimized configuration featuring a high-output, permanent magnet synchronous motor (PMSM) that produces up to 47 kW (63 horsepower) at peak—a three-fold increase in output over earlier configurations.  The new patent-pending design will improve the performance of the Spicer TE-15HX transmission when the PMSM is operational and allow the use of stored electric power during more of the duty cycle. 

Also, by positioning the electric device at the rear of the transmission to interact with drum speed, Dana can use a smaller unit that operates at a higher RPM and provides better performance, lower system costs, and a better fit within the increasingly tight design envelopes of today’s off-highway vehicles.  All told, engineers predict that the Spicer TE-15HX transmission will provide fuel savings of up to 20 percent over conventional transmission designs, depending on duty cycle.

A concept transmission in the evaluation phase, the Spicer TE-15HX is an electric parallel hybrid featuring a dual power path transmission control system.  Targeted for use in shuttling applications such as construction and material handling vehicles, this system continuously monitors operating conditions and selects the proper combination of diesel and electric power to optimize productivity while reducing fuel consumption, emissions, noise, and engine idling. 

Dana has adopted a neutral stance toward energy-storage chemistry in the development of the Spicer TE-15HX transmission, allowing it to integrate with many different energy-storage solutions.  At Bauma 2010, Dana will present a system configured with super capacitors for highly cyclic applications such as front-end loaders and forklift trucks, while other applications that permit longer duration charging under a light load can be outfitted to work with lead-acid storage and other conventional battery technologies.

16-Tonne Front-End Loader System
Dana offers an optimized drivetrain solution for 16-tonne (17.5-ton) front-end loader vehicle applications through a system that includes a Spicer® 319 summing motor, two Spicer® Model 114 planetary rigid axles, and the Spicer® Compact Series Model 2035 driveshaft. 

The Spicer 319 summing motor transfer case provides maximum tractive performance and high efficiency.  Targeted for applications requiring 104 to 164 kW (140 to 220 horsepower), this transfer case employs two hydrostatic motors each with optimized gear ratios.  To maximize efficiency at higher vehicle travel speeds, a clutch automatically disconnects the low-speed, high-gear-ratio motor, allowing the high-speed motor to function alone.

The Spicer 319 summing motor transfer case delivers seamless continuous variable transmission (CVT) performance from 0 to 40 km/h (0 to 25 mph). 

The Spicer Model 114 drive axle includes a limited-slip differential lock that provides a 45-percent locking capacity, delivering excellent tractive force and nimble vehicle steering for front-end loader applications.  The Spicer Model 114 axle can be configured with a variety of other hydraulic-locking differential options, including dog clutch and multi-disc clutch.  Inboard wet disc brakes offer proven fail-safe stopping performance and energy absorption, while a fail-safe park brake featuring internal negative SAHR is available as an option. 

The Spicer Model 114 axle includes 6.00-to-1 ratio outboard planetary wheel ends with 425 mm wheel B.C. mountings, self-adjusting internal wet brakes, and a trunnion mounting option.

Eight- to Nine-Tonne Industrial Lift Truck System
At Bauma 2010, Dana has introduced a new IC-powered driveline system for eight- to nine-tonne (nine- to 10-ton) industrial lift trucks that features a Spicer® TE-08 powershift transmission, Spicer® Model 139 axle, and a Spicer® Wing Series Model 6C driveshaft. 

This solution has been developed to accommodate larger-sized material handling vehicles and builds on the popularity of the drivetrain system designed for five- to seven-tonne (six- to eight-ton) industrial lift trucks that was first introduced at Bauma 2007.

Making its debut at Bauma 2010, the Spicer Model 139 axle is the latest in a line of axles specifically designed for industrial lift trucks.  Suitable for lift trucks equipped with pneumatic or cushion tires, the Spicer Model 139 axle is engineered to handle the highest load capacities while offering the same durability, reliability and ease of maintenance provided by the well-received Spicer Model 137/138 axles already used for smaller lift trucks.

The Spicer Model 139 axle includes integral frame and mast mounting provisions for fixed-mast lift truck applications, and its spiral bevel center section and a 6-to-1 planetary ratio generate 13-to-1 through 17-to-1 overall axle ratios. 

The Spicer Model 139 axle has a planetary design that allows for a small ring gear, enabling engineers to locate the mast as close to the axle’s center line as possible for optimum geometry in load carrying and lifting. 

To simplify service and maintenance, the Spicer Model 139 axle is designed with integrated outboard wet-disc brakes.  The fully enclosed design keeps the brakes sealed from water and dirt ingress to reduce wear and minimize noise.  The axle is designed with a self-adjusting service brake system that minimizes hydraulic actuation oil displacement requirements.

Specifically designed for the industrial lift truck market, the field-proven Spicer TE-08 transmission is available with the brake-by-clutch feature, a single-pedal drive technology that allows the operator to actively decrease the speed of the vehicle by lifting his foot off the accelerator pedal, which engages clutches in the transmission that would otherwise spin free.  The brake-by-clutch system simplifies vehicle operation and reduces operator fatigue by enabling acceleration and deceleration through the use of a single pedal. 

Rated at 55 to 82 kW (75 to 110 horsepower), the TE-08 transmission can be configured with a conventional electric valve featuring hydraulic modulation or a fully electronically modulated clutch control using proportional solenoids.  Full electronic modulation and its associated controllers enable OEMs to use the complete range of controls: safety inhibits, diagnostics, system monitoring, load- and speed-compensated automatic shifting, shift overlap control, electronic inching, and automatic throttle up.

The Spicer TE-08 transmission offers three forward and two reverse speeds, and it is also available as a two-speed forward system.  The TE-08 features a reduced transmission length and output drop, helical gears for noise reduction, and an integral engine pump drive to power the system hydraulics.

17.5-Tonne Wheeled Excavator System
Engineered for 17.5-tonne (19-ton) wheeled excavators, this system is composed of a Spicer® Model 263 planetary steering axle, a Spicer® Model 163 planetary rigid axle with a directly flanged Spicer® Model 369 shift-on-fly hydrostatic transmission, and a Spicer Life® Series Model SPL55 driveshaft.

Specially designed to enhance mobility, comfort, and ease of use, the Spicer Model 369 shift-on-fly hydrostatic transmission provides a proven alternative to expensive powershift solutions and the operational limitations of sliding-collar range-shift transmissions. 

Vehicles equipped with traditional range-shift solutions must completely stop before shifting between ranges, but the gearbox on the Spicer Model 369 transmission allows for quick shifting from low to high range while moving. The Spicer Model 369 transmission enables seamless operation from reverse, full stop, and forward up to speeds of 40 km/h (25 mph). 

The Spicer Model 369 transmission accommodates a single motor, providing a 700 Nm continuous input torque and a maximum input of 4500 RPM.  It offers a wide combination of ratios with a deepest first gear ratio of 4.53:1.  The Spicer Model 369 transmission features a compact layout with a 151 mm drop and can be remote-mounted as well as vertically or horizontally flanged to the axle. 

With a 30,000 daN (static) and 11,500 daN (dynamic) load capacity, the Spicer Model 163 and Spicer Model 263 axles are designed with hydraulic-applied, outboard wet disc service brakes located in the wheel hub to minimize vehicle rocking when operators dig without deploying the outriggers.

This system is also available with an optional spring-applied hydraulically released (SAHR) park brake, which reduces the number parts and eliminates the need for a separate external park brake.

The Spicer Model 163 and Spicer Model 263 axles feature a maximum output of 52,960 N-m (39,061 lb-ft).  They also offer a spiral bevel gear as well as DIN, SAE, and mechanics input flange options. 

The Spicer Model 263 planetary steering axle provides an integrated steering cylinder with a 35-degree maximum steering angle and a 6-to-1 planetary final drive ratio. 

About the Dana Off-Highway Products Group
The Dana Off-Highway Products Group includes research and development and manufacturing operations in Belgium, Brazil, China, Hungary, India, Italy, Mexico, the United Kingdom, and the United States.  It designs, manufactures, assembles, and markets Spicer axles and transaxles, driveshafts and end-fittings, transmissions, torque converters, electronic controls, and brakes. 

The Dana Off-Highway Products Group serves more than 1,000 vehicle assembly and manufacturing facilities in 30 countries.  Dana also supports off-highway customers in more than 100 countries by supplying genuine Spicer service parts, operating two global service parts distribution centers, and certifying 66 Authorized Spicer Service Centers.  Construction, agriculture, forestry, underground mining, material handling, outdoor power, leisure/utility vehicles, and industrial equipment are just some of the markets that demand the quality found in Spicer products and genuine service parts.  For more information, visit www.dana.com/offhighway.

About Dana Holding Corporation
Dana is a world leader in the supply of axles; driveshafts; sealing and thermal-management products; and genuine service parts. The company's customer base includes virtually every major vehicle manufacturer in the global automotive, commercial vehicle, and off-highway markets. Based in Maumee, Ohio, the company employs approximately 21,500 people in 26 countries and reported 2009 sales of $5.2 billion. For more information, please visit: www.dana.com.