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KT4036
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KT4036
Damper
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Drive Shaft
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KT4036
Transmission Piping
7
6
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290L/min : BCV ON
Rear Brakes Only 310L/min E/G:1900rpm 419L/min E/G:2450rpm
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Transmission
Intermediate Input
Output Sensor
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KT4036
Transmission
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After dumping, if the body isnt completely seated, Keep 1st speed
6) Self- Diagnostic Function The details of Self-Diagnosis are displayed on the Monitor as Action Code, The T/M System Caution Lamp, Warning Lamp or Alarm Buzzer sounds
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HD785-7 Transmission
T/M valve T/C valve
T/M Harness
Output Coupling
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KT4036
Torque Converter
The difference Points compared with -5 parts
PTO Gear
Torque Converter Valve PTO gear T/C pressure sensor Trunnion Shape Lockup Clutch
T/C Valve has New Function to reduce Power Loss 1) Flow Change Valve with Tandem Pump 2) Main Pressure Switching Valve 3) T/M Lubrication Flow change valve
Coupling size Up
* L/U pressure control valve on -5 in Torque Converter Valve has modified to ECMV on T/M valve seat.
Right Upper: Brake Cooling Pump Left Upper : S/T Hoist & Hoist & Hoist Control Pump Right Lower : T/C, T/M Charge Pump, Brake Cooling, Brake Control Pump
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KT4036
Torque Converter
(7) PTO Helical gear to lower noise (3) Trunion with wear sleeve for R&M cost reduction
Improvement Contents
(1) Lock up Clutch Disks Number Up ( 2 3 discs ) to ensure the Torque Capacity of E/G Output Up (2) T/C pump capacity up (Changed T/C pump Vane Angle)
(4) Coupling - Size up #10C #11 - fixed Type Slide type To match Increased E/G Rated Output Power
HD785-7 HD785-5
(5) Stator Bush contains Silica employed to increase Heat Resistance ( R&M cost reduction ) (8) Piston Sealing material changed from cast iron to Teflon ( R&M cost reduction ) (6) Reduce the Shock of Connection of Lock Up clutch L/U Valve change to ECMV. T/C Oil Pressure Sensor installed. to detect inside pressure of T/C to control Half Lock Up
: Improvement of Productivity
: Improvement of Comfort
: Improvement Reliability to reduce life cost
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KT4036
By the completion of T/M Shift, keep a small high pressure than inside pressure of T/C. This pressure is called Half Pressure.
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KT4036
T/C Inside Pressure is calculated with T/C Inlet and Outlet Pressure Sensor as an average.
Inside Pressur e
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KT4036
Therefore, by sensing T/C internal pressure and give a higher current to proportional solenoid of ECMV to win the T/C internal pressure.
P1 : T/C Internal Pressure P2 : L/U Half Pressure a : Inflated Pressure P2 = P1 + a
T/C Inside Pressure is calculated with T/C Inlet and Outlet Pressure Sensor as an average. Slide 19 KT4036
(11) Harness cover Material was changed to woven braid to increase the durability ECMV type was changed from large ECMV Small ECMV
(9) To reduce Power Loss and Fuel consumption 1) Flow Change Valve with Tandem Pump 2) Main pressure Switching Valve 3) T/M Lubrication Flow change valve
(11) Unifying the T/M Oil with Retarder Oil T/M Oil Pan became large
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KT4036
(3) Clutch Disk Durability improvement Material - Ray flex G525 2) Number of discs increased High : 4 5 discs 3rd : 3 4 discs
(1) Reverse Grade ability increased Reverse speed is RL and RH RL Reduction Gear Ratio 3.934 5.244 Single Reverse planetary Gear was applied to increase the efficiency
(4) Coupling size up #12 #14 to match increased ENG Max torque
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<HD785-7>
Relief valve ( L )
Relief valve ( H )
When ENG Rev, is low or Oil Temp is low
T/M
(A>B)
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KT4036
When the solenoid (1) is disengaged, no oil flow to chamber A. Then spring (3) pushes the flow change valve(2) to the left. Then all oil from pump (B ) and (C) flow into T/M through main relief Valve( 4).
B C
When the solenoid T/C (1) is engaged, Oil flow to chamber A. and pushes the flow change valve(2) to B the right. Then oil from pump (B) flows to T/M through main relief valve and oil from pump (C ) bypassed and flows to torque converter.
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KT4036
According to the using Shift Range, Main Relief Pressure Will be changed
T/C
T/M Main Relief Pressure
T/C
T/M Pump
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KT4036
When the solenoid (1) isn't energized, no oil pressure works in chamber A. Force of pressure in chamber B and spring force is balanced. Normal setting of main Relief Pressure.
When the solenoid (1) is energized, Oil pressure works in chamber A. So force of pressure of chamber A works main relief valve (3) to the left. So force of pressure in chamber B balanced by spring force decrease.
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Speed range
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REDUCES POWER LOSS due to Viscous drag inside free clutch packs!
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Side View
Drain
Drain
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Solenoid OFF
Engagement
Normal Lubrication Flow (Solenoid OFF) Speed Range F1-F5, R1, R2 Reduce Lubrication Flow ( Solenoid ON )(15%down) Speed Range F6,F7
To Relief Valve ( 4 )
REDUCES POWER LOSS due to Viscous drag inside free clutch packs!
When the solenoid (1) isn't energized, no oil pressure works in chamber A, because by connecting to drain port. So spool (2) is pushed to the right by force of spring (3).
When the solenoid (1) is energized, Oil pressure works in chamber A in chamber A. So spool (2) is pushed to the left; so lubrication flow will be squeezed. As the result, amount of oil flow to relief valve (4) increased, so Lubrication Oil flow to T/M inside will be reduced.
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KT4036
Clutch Idle Rotation Loss (Whole Idling Clutch ) Except engaged Clutch, other ones are Idle Rotation under the condition of oil between Disks and Plates. This is the time of generating Hydraulic Loss.
Ring Seal Loss (Whole Ring Seals ) Ring Seals are moving under pressure of Lubrication or Clutch Oil Pressure, so generate Hydraulic Loss.
Gears Chewing Loss (Whole Chewing Gears ) Power Line Gears generate mechanical Loss
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REDUCES POWER LOSS due to Viscous drag inside free clutch packs!
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ECMV (R Clutch) ECMV (3rd Clutch) ECMV (2nd Clutch) ECMV (1st Clutch)
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HD785-7
HD785-5
Application : HD465-7,HD325-7
Application : HD325-6,HD785-5,HD1500-5,WA1200,D575,D475,D375
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Rotary clutch
4th Revolution Clutch
Bleed OFF
Body of Revolution
Bleed off has a role when Clutch is OFF, because of revolution Clutch is rotating all the time, if oil is remaining in the clutch port this will act as centrifugal force and moves piston to the right direction and push disk, as the result, unnecessary torque will be created ( Clutch Slipping ). So, when Clutch is OFF, Clutch port oil will be drained for preventing the centrifugal force from 2- 1 drilled hole. On the other hand, when Clutch is ON, oil is leaked all the time.
Revolution Ring seal is sealing oil as moving from fixed oil circuit inside T/M to revolving clutch. Therefore, Oil is leaking from this Ring Seal all the time.
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Single Planetary
HD785-7
HD785-5
Double Planetary
The reason of current gear train dose not make large reverse gear ratio.
HD785-5
1.
2.
It will work by reducing the teeth number of Sun Gear and increase the teeth number of Ring gear theoretically, but if increasing the teeth number of Ring Gear, disc size will be large and it is necessary to increase the disc size on 3rd, Rev, 2nd, 1st at the same time. Unnecessary cost. Double planetary gear set like -5 is less efficient. By locating R Clutch at the rear-most position of T/M, Only R-disc Size Up will become enough. It is possible to apply single planetary gear set and efficiency is increased about 6%.
HD785-7 Slide 37
1. 2.
KT4036
Bearing damage
There may be damage to the transmission and other parts of the power line.
Because there will be lack of lubrication oil due to down E/G speed.
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Last chance filter does NOT have any scheduled PM time! Judge by method of visual inspection as shown at right! Slide 39 KT4036
EXIT
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