Publication No. W E. Torque converter Transmission 8FLWN TDN Model PRINTED IN JAPAN 0612 E

Transcription

1 Publication No. W E 02 Torque converter Transmission Model 8FLWN TDN c2006 PRINTED IN JAPAN 0612 E

2 Foreword Foreword This repair manual gives the disassembly and reassembly procedures for torque converters and transmissions used in rough terrain cranes. The models covered are listed below. Before starting to repair these units, check the model code given on the model plate on the unit. Use this manual in conjunction with the relevant parts catalog, service manual and other reference materials and make proper preparations. 1. Applicable Crane Model The table below shows the relationship between the crane models and the models of torque converter and transmission used. Model Crane Torque converter Transmission TR-450XL-4 TR-500XL-4 ( ) TR-500XL-4 (540409, ) 8FLWN A 8FLWN B TDN G TDN H WARNING Exposed parts of the torque converter and transmission can cause burns. Never touch until they are cooled down enough. Rotating parts of the torque converter and transmission can cause severe injury. Keep away from rotating parts during operation. Handling of manual locking device Use the manual locking device only when neither the MDT (multiplex data transmitter ) system nor the emergency transmission switch is effective. Do not touch the manual locking device when the engine is running. The manual locking device is intended to manually switch the solenoid valves mounted on the transmission. When once operate the manual locking device, always return it to original position. If the solenoid valve is left manually locked, the vehicle will move as soon as the engine starts, leading to an injury. Eyes on the body cases of the torque converter and transmission are provided to hang themselves only. Before lifting the torque converter or transmission, always remove the accessories including the pump, propeller shafts, flexible joints and motors from the main unit, otherwise the eyes can be damaged due to excessive loads, leading to an injury. [NOTICE] There is a case that the appearance and so on differ from the parts for this crane. Although there is not so much difference in functions and disassembly procedures, make sure of the serial number of this crane and the part sales unit described in the parts catalog before starting disassembling operations. Please note that, for product Improvement, some changes may have been incorporated in the machine that are not covered in this manual. 1 W E

3 Foreword 2. Contents Foreword Applicable Crane Model Contents... 2 Structure Torque converter Torque converter unit sectional view Torque converter external view Torque converter Transmission Transmission sectional view Transmission external view Housing group F2/R clutch shaft group F1/F3 clutch shaft group High/Low clutch shaft group Output shaft group Steering pump / speedometer group Clutch pressure main relief valve group High/Low clutch pressure regulator valve froup Range clutch pressure regulator valve group Range selector valve group Valve assy Function Torque converter Converter unit Principle of power transmission through torque converter Pump drive system Oil circulating circuit Lockup clutch pressure regulator valve Transmission Outline Valve assy Theory of valve operation When in Neutral When gear is shifted Clutches Hydraulic circuit Troubleshooting Output remains low Non - power transmission Abnormal rise of oil temperature Too - high clutch pressure and torque converter pressure Too - low clutch pressure and torque converter pressure Noise Speed range can not be switched over Lockup can not be performed, or can not be canceled...41 Disassembly Torque converter Disassembly of torque converter Disassembly of converter main section Disassembly of charging pump drive sections Disassembly of steering pump drive sections Disassembly of PTO clutch section Transmission Transmission Shifter case assy (2-wheel/4-wheel selector) Disassembly of steering pump/speedometer group Disassembly of clutch pack group Disassembly of output shaft group...59 Checks Torque converter Check items Transmission Check items W E

4 Foreword Reassembly Torque converter the oil seals, O-rings, packings and copper packings with new parts Reinstalling the oil seal rings Reassembling converter internal components Reassembling the PTO clutch Application of liquid packing Shim adjustment points and bolt tightening torques Checks Transmission the oil seals, O-rings, packings and copper packings with new parts Reassembling the clutch Reinstalling the oil seal rings Greasing Application of liquid packing Shim adjustment points and tightening torques Oil Recommended oil Oil change procedure Removing oil Refilling Test Checking operating conditions Hydraulic pressure measurement Stall test Maintenance standard Overhaul interval Replacing intervals of parts Part replacing standard Torque converter Transmission W E

5 Structure Structure 1.Torque converter 1.1 Torque converter sectional view This torque converter is a 3-element, 1-stage, 2-phase unit, composed of an impeller vane wheel, a turbine vane wheel, and a stator vane wheel. The unit also incorporates a lock-up clutch. Input plate Lockup clutch Free wheel inner race Z42 PTO clutch Input guide Z35 Lock-up clutch oil pressure regulator valve Turbine shaft Ass'y Z46 Z41 Output flange Output shaft Front cover Cover wheel Turbine wheel Ass'y Impeller wheel Stator wheel Stator wheel Free wheel cam, Free wheel roller Z49 Z54 Charging pump Power-take-off for steering pump IW J06E 4 W E

6 Structure 1.2 Torque converter external view 5 W E

7 Structure 1.3 Torque converter 6 W E

8 Structure 1.Hexagon socket head bolt 47.Dowel pin 98.Output flange 145.Bolt 2.Washer 48.Inner race 99.O-ring 146.Dowel pin 3.Input plate 49.Dowel pin 100.Washer 147.plug 4.Spacer 50.Drive gear 101.Spring washer 148.Bolt 5.Input guide 51.Hexagon socket head bolt 102.Bolt 149.Tapered roller bearing 6.O-ring 52.Oil seal ring 103.Ball bearing 150.Hexagon socket head bolt 7.Ball bearing 53.Stator holder 104.P gear 8.Front housing 54.Hexagon socket head bolt 105.Spline hub 9.O-ring 55.Seal race 106.Ball bearing 10.Bolt 56.Hexagon socket head bolt 108.O-ring 11.Cover 57.Oil seal ring 109.Plate 12.Cover 58.Tapered roller bearing 110.Hexagon socket head bolt 13.Bolt 59.Tubine shaft assy 111.O-ring 14.Front cover 60.Tapered roller bearing 112.Ball bearing 15.Bolt 61.Oil seal ring 113.P gear 16.Spring washer 62.Tapered roller bearing 114.Spline hub 17.Oil seal 63.Thrust washer 115.Ball bearing 18.Oil seal ring 64.Ball bearing 116.Retainer ring 19.Oil seal ring 65.Snap ring 117.Packing 20.Clutch piston 66.Gear 118.Pump assy 21.Fiber plate 70.Snap ring 119.Stud 22.Back plate 71.Washer 120.Nut 23.Cover wheel 72.Spring 121.Shim 24.plug 73.Snap ring 122.Packing 25.Oil seal ring 74.Back plate 123.Supply cover assy 26.Snap ring 75.Fiber plate 124.Bolt 27.Washer 76.Steel plate 125.Steel ball 28.O-ring 77.Fiber plate 126.Plug 29.O-ring retainer 78.Piston assy 127.plug 30.Snap ring 79.Oil seal ring 128.Solenoid valve 31.Turbine wheel assy 80.Oil seal ring 129.Piston 32.Snap ring 81.Clutch shaft assy 130.Spring 33.Side washer 82.Taperd roller bearing 131.Spring 34.Snap ring 83.Oil seal ring 132.Spring 35.Stator wheel 86.Shim 133.Stopper 36.Free wheel cam 87.Packin 134.Packing 37.Leaf spring 88.Plate 135.Cover 38.Roller 89.Bolt 136.Bolt 39.Side washer 90.O-ring 137.Converter housing 40.Impeller hub 91.Tapered roller bearing 138.Plug 41.Impeller wheel 92.Gear B 139.O-ring 42.Bolt 93.Shim 140.O-ring 43.Spring washer 94.Packin 141.Band 44.Washer 95.Seal carrier 142.Hexagon socket head bolt 45.Washer 96.Bolt 143.Rear cover assy 46.Angular contact bearing 97.Oil seal 144.Bolt 7 W E

9 Structure 2. Transmission 2.1 Transmission sectional view Input shaft Z31 F2 Z41 R Z31 A B C Z50 D Z41 E F1 Z31 F Z63 Z41 G Z31 H F3 Z61 J K Z80 Low High Output shaft Rear Z61 Output shaft Front M L Z47 Z23 Z5 2-WD / 4-WD switching mechanism Z88 IW J13E 8 W E

10 Structure Speedometer gear IW J15E Strainer IW J17E Emergency steering drive IW J16E 9 W E

11 Structure 2.2 Transmission external view 10 W E

12 Structure 2.3 Housing group 11 W E

13 Structure 1.Housing assy 23.Bolt 45.Switch 67.Bolt 2.Housing cover 24.Cover 46.packing 68.Bolt 3.breather 25.Packing 47.Supply cover 69.O-ring 4.Elbow 26.Spring 48.Dowel pin 70.Adapter 5.Drain plug 27.Spring 49.Bolt 71.O-ring 6.Copper packing 28.Shifter fork 50.Bolt 72.Pipe 7.Oil level gauge 29.Shifter shaft 51.Steel ball 73.Hexagon socket head bolt 8.O-ring 30.O-ring 52.Spring 74.Strainer 9.Pickup sensor 31.Piston 53.Copper packing 75.O-ring 10.Dowel pin 32.O-ring 54.Hexagon socket plug 76.Cover 11.Bolt 33.Nut 55.O-ring 77.Packing 12.Hexagon socket head bolt 34.Sleeve 56.O-ring 78.Bolt 13.Bolt 35.O-ring 57.Filter element 79.Slector valve assy 14.Packing 36.Cover 58.Rubber washer 80.Solenoid valve assy 15.Seal carrier 37.Bolt 59.Washer 81.Clutch pressure regulator 16.Oil seal 38.Oil seal 60.Spring valve assy 17.Oil seal 39.Oil seal 61.Filter case 82.High/Low selector valve assy 18.Bolt 40.Bolt 62.Seal washer 83.Solenoid valve assy 19.Oil seal 41.Hexagon socket head bolt 63.Bolt 84.Main relief valve assy 20.Shroud 42.Shifter case 64.Band 21.Bolt 43.Packing 65.Spacer 22.Dowel pin 44.Copper packing 66.Packing 12 W E

14 Structure 2.4 F2/R clutch shaft group 91.Bolt 99.Snap ring 107.Spring 115.Gear C 92.Spring washer 100.Gear A 108.Clutch piston 116.Washer 93.Washer 101.Snap ring 109.Oil seal ring 117.Tapered roller bearing 94.O-ring 102.Back plate 110.Oil seal ring 118.Shim 95.Input flange 103.Fiber plate 111.Clutch shaft assy 119.Oil seal ring 96.Tapered roller bearing 104.Fiber plate 112.Seal carrier 97.Washer 105.Steel plate 113.Oil seal ring 98.Ball bearing 106.Snap ring 114.Clutch piston 13 W E

15 Structure 2.5 F1/F3 clutch shaft group 131.Tapered roller bearing 138.Snap ring 145.Clutch piston 152.Gear F 132.Washer 139.Back plate 146.Oil seal ring 153.Ball bearing 133.Thrust washer 140.Fiber plate 147.Oil seal ring 154.Snap ring 134.Thrust needle 141.Fiber plate 148.Clutch shaft assy 155.Spacer 135.Thrust washer 142.Steel plate 149.Seal carrier 156.Shim 136.Needle bearing 143.Snap ring 150.Oil seal ring 157.Oil seal ring 137.Gear D 144.Spring 151.Clutch pin 14 W E

16 Structure 2.6 High/Low clutch shaft group 161.Bolt 167.Snap ring 173.Steel plate 179.Clutch shaft assy 162.Spring washer 168.Gear H 174.Snap ring 180.Gear K 163.Washer 169.Snap ring 175.Spring 181.Washer 164.Tapered roller bearing 170.Back plate 176.Clutch piston 182.Tapered roller bearing 165.Gear G 171.Fiber plate 177.Oil seal ring 183.Shim 166.Ball bearing 172.Fiber plate 178.Oil seal ring 184.Oil seal ring 15 W E

17 Structure 2.7 Output shaft group 191.drive shaft 197.Needle bearing 203.Snap ring 209.Output flange 192.Ball bearing 198.Snap ring 204.Gear L 210.O-ring 193.Snap ring 199.Snap ring 205.Output Shaft 211.Washer 194.Washer 200.Roller bearing 206.Ball bearing 212.Spring washer 195.Retainer ring 201.Snap ring 207.Seal race 213.Bolt 196.Slide sleeve 202.Spacer 208.Oil seal ring 16 W E

18 Structure 2.8 Steering pump / speedometer group 221.O-ring 226.Bushing 231.Bolt 236.Gear assy 222.Bushing 227.Plug 232.Ball bearing 237.Shroud 223.Oil seal 228.Copper packing 233.Washer 238.Bolt 224.Bushing 229.Speedometer casing 234.Snap ring 225.Gear 230.Packing 235.Ball bearing 17 W E

19 Structure 2.9 Clutch pressure Main relief valve group 245.Valve body 249.Spring 253.Spring 257.Bolt 246.Piston 250.Outer piston 254.Packing 258.Bolt 247.Spring 251.Spring 255.Cover 259.Hexagon socket head bolt 248.Inner piston 252.Spring 256.Bolt 260.Packing 18 W E

20 Structure 2.10 High/Low clutch pressure regulator valve group 265.Valve body 273.Valve body 281.Spring 289.Piston 266.packing 274.Packing 282.Spring 290.Stopper 267.Bolt 275.Bolt 283.Spool 291.Spring 268.Bolt 276.Bolt 284.Spring 292.Spring 269.Bolt 277.Nut 285.Spool 293.Spring 270.Bolt 278.Bracket 286.Spring 294.Packing 271.Bolt 279.Bolt 287.Spring 295.Cover 272.Solenoid valve 280.Piston 288.Spool 296.Bolt 19 W E

21 Structure 2.11 Range clutch pressure regulator valve group 301.Valve body 306.Cover 311.Spool 316.Piston 302.Packing 307.Packing 312.Stopper 317.Cover 303.Bolt 308.Hexagon socket head bolt 313.Spring 318.packing 304.Bolt 309.Spring 314.Spring 319.Bolt 305.Bolt 310.Spring 315.Spring 20 W E

22 Structure 2.12 Range selector valve group 325.Valve body 330.Cover 336.Hexagon socket head bolt 341.Bolt 326.Packing 331.Hexagon socket head bolt 337.Hexagon socket head bolt 342.Bracket 327.Spool 332.Hexagon socket head bolt 338.Valve body 343.Bolt 328.Spring 334.Spacer 339.Packing 344.Bolt 329.Packing 335.Packing 340.Solenoid valve 345.Nut 21 W E

23 Structure 2.13 Valve assy 1. Clutch pressure main relief valve group Bleeding valve From torque converter charging pump Clutch pressure main relief valve To torque converter Cold oil relief valve IW J18E 2. High/Low clutch pressure regulator valve assy Lubrication pressure relief valve Low selector valve Hi selector valve Orifice D Orifice C Flow valve Accumulator valve IW J19E 22 W E

24 Structure 3. Range clutch pressure regulator valve assy Flow valve Orifice B Orifice A Accumulator valve IW J20E 4. Range selector valve assy R selector valve F1 selector valve F2 selector valve F3 selector valve IW J21E 23 W E

25 Structure 5. Solenoid valve assy R solenoid valve F1 solenoid valve F2 solenoid valve F3 solenoid valve IW J22E 6. Solenoid valve assy Low solenoid valve Hi solenoid valve IW J23E 24 W E

26 Function Function 1. Torque converter 1.1 Converter unit 1. The periphery of the impeller wheel is bolted to the cover wheel,and the latter is fixed to the engine flywheel via the front cover and the input plate. The bore of the impeller wheel is supported, via an angular contact bearing,by the freewheel inner race. 2. The engine drive motion is directly transmitted to the impeller wheel, which transmits the motion to the turbine wheel assembly through the working fluid,but,while the lockup clutch is ON,the engine motion is directly transmitted from the cover wheel, via the lockup clutch,to the turbine wheel assembly. 3. The turbine wheel asseembly is splined to one end of the turbine shaft. There is a gear on the other end of the turbine shaft.the gear is in mesh with the output gear, transmitting power to the flange splined to the output shaft after one-stage speed reduction. 4. The stator wheel is fixed to the converter housing via the freewheel cam,freewheel roller,freewheel inner race and the stator holder. 5. The stator wheel serves to raise the turbine torque above the input torque by adding the reaction torque,generated by the working fluid returning from the turbine wheel assembly to the impeller wheel,to the impeller wheel. 6. The stator wheel idles during high-speed operation to maintain the transmission efficiency at a high level. 1.2 Principle of power transmission through torque converter 1. Fluid clutches, transmitting rotational power by means of fluid, are classified into two major categories. 2. The fluid coupling, and the torque converter. Their main components are shown below. Torque converter Fluid coupling T P T P S P:Pump (impeller) wheel T:Turbine wheel S:Stator wheel IW J01E 3. Fluid coupling are fluid clutches consisting only of pumps and turbines, and they convey rotational motion just as a wind wheel installed face to face with an electric fan is driven by the fan. 4. When the pump is driven by an engine, the fluid starts to rotate around the shaft, and is driven outwavd by centrifugal force. 5. With the pump provided with radial vanes, oil flows out from the periphery of the vane wheel of the impeller, and flows into the periphery area of the turbine wheel which is installed face to face with the imperller. 6. From the periphery area of the turbine, the oil flows towards the center area along the turbine blades, exerting rotational force to the blades, and eventually, returns to the pump through the center area. 25 W E

27 Function Rotational motion 9. When the pump and the turbine run at a large speed difference, that is, when starting the turbine from standstill, and when climbing an uphill. Pump (impeller) Spiral motion Turbine IW J02E 10. With a torque converter, a stator wheel is placed between the turbine outlet and the pump inlet, to improve the transmission efficiency under heavy loads. 7. In this way, the oil motion resulting from the rotational motion around the shaft driven by the pump and the centrifugal motion, is a circulating spiral motion. 8. Since oil, the transmission medium, must be continuously used within the sealed space in a fluid coupling, the transmission efficiency is low and large input torque is required to drive the turbine. 11.In the fluid coupling, the oil return flow from the turbine to the pump is in the direction to detard the pump rotation at the impeller vane inlet, but in a torque converter, the return oil flow is turned around by the stator wheel into the direction of pushing the impeller blades forward, redulting in the improvement of efficiency under heavy loads, and even results in the transmission of larger torque than the input torque to the turbine. Fluid flowing opposite to pump rotation Pump Turbine Pump Fluid coupling Pump Turbine Detarding pump rotation IW J03E Stator Pump Turbine Stator Pump Torque converter Fluid flowing to push pump forward Pump Turbine Same direction as pump rotation IW J04E 26 W E

28 Function 12.The stator is so designed that it can be either left free to be directed by the flow of oil discharged from the turbine outlet, or fixed to guide the return oil into the direction to improve the converter efficiency. 13.when the load is small, such as in cruising at high speeds, the speeds of the impeller and the turbine are not much different. 14.As this condition is approached, the discharge oil from the turbine outlet changes flow direction towards the rotating direction, and eventually, it starts to hit the rear side of the stator blades. Fixed stator Running stator Fixed stator Running stator IW J05E 15.When this happens, the stator impedes the oil flow, and the efficiency of the converter is reduced. To prevent this, the stators of torque converters are provided with a one-way clutch allowing the stators to freely run to follow the oil flow, when the stator blades are pushed from the rear side. 16.This means that the stator is locked in one direction to amplify torque, and in the opposite direction, it moves free to make the converter operate as a fluid coupling under light load conditions. 27 W E

29 Function Power transmission route Z35 Z35 Z46 Z41 Z46 Z41 Torque converter Look-up IW J07E 1.3 Pump drive system 1. The converter housing is provided with three power take-off : the main pump drive PTO clutch, the steering pump drive, and the charging pump drive, and the charging pump drive, and they are driven by the drive gear bolted to the impeller wheel. PTO clutch Charging pump drive 4. The steel ball serves to eliminate the possibility of faulty clutch actuation by the residual oil in the clutch shaft and the piston under centrifugal force during the time of clutch disengagement. 5. As shown, the steel ball opens the relief port in the center under centrifugal force to allow the oil to flow to the outside. Neutral Operating Drive gear Output flange Drive gear Steering pump drive IW J08E Clutch piston 2. The sokenoid valve switches the hydraulic oil to the oil passage in the shaft leading to the clutch piston, and the oil pushes the piston to engage the fiber plates and the steel plates to create the PTO ON state to drive the pumps. 3. The clutch piston is provided with a steel ball in the oil passage connecting the working side and outsids. IW J09E 1.4 Oil circulating circuit 1. The torque converter oil is drawn by the charging pump from the transmission oil tank through a strainer. The oil is then forced into the torque converter after passing through the clutch pressure main relief valve and cold oil relief valve. 28 W E

30 Function 2. The oil flowing into the converter passes through the space between the turbine shaft and the free wheel innner race, and flows into the converter circuit from between the stator wheel and the turbine wheel. 3. After being used for power transmission, the oil, now high in temperature, flows out of the converter circuit through the space between the stator wheel and the impeller wheel, and via the grooves in the free wheel inner race and in the stator holder, flows out of the converter housing. 4. Befor the outlet of the converter housing, there is a port through which a part of the oil is directed to the PTO clutch to lubricate it. 5. This oil is cooled in the oil cooler, and after being adjusted in pressure by the lubrication oil relief valve, circulates to various parts of the transmission for their lubrication, before returning to the oil tank. 1.5 Lockup clutch pressure regulator valve 1. Directed to the lockup solenoid valve is the pressure whose level has been regulated by the clutch pressure main relif valve on the transmission side. 2. The solenoid valve operates under control of an external controller (multipl data transmitter) which outputs a command signal to the valve when the pickup sensor output pulse rate increases as transmission input shaft speed increase and reaches a predetermined speed. 3. The pressure is now directed to the lockup clutch pressure regulator valve to be adjusted to a certain high pressure level and the pressure thus increased is applied to the lockup clutch. 4. This allows the transmission to be driven directly by the engine. Accumulator piston Orifice a A Check valve A A-A IW J10E 29 W E

31 Function 5. When the solenoid valve is energized, the oil flows through orifice a and pushes the accumulator piston. Since the pressure increases only gradually at a specific rate, the accumulator piston causes the clutch to engage gently, thus minimizing shocks. 6. Once the clutch has engaged and the pressure built up to a certain level, port 1 opens, letting the hydraulic pressure increase immediately to the loclup pressure. 7. When the solenoid valve is deenergized, the pressure in the clutch port is quickly releases through check valve 2, so that the clutch is disengaged. Lockup cluch solenoid valve a 2 1 Accumulator valve Lockup clutch IW J11E 30 W E

32 Function Function 2. Transmission 2.1 Outline 1.This transmission consists of four hydraulic wet multi-disc type clutches (for gear combination selection and forward-reverse drive switching), reduction gears, shafts and a hydraulic system. 2. Multi-disk clutches F2 (2nd forward) and R (reverse) are monted on clutch shaft 1, and F1 (1st forward) and F3 (3rd forward) on clutch shaft 2. Input shaft Clutch shaft 1 Output shaft Clutch shaft 2 Clutch shaft 3 A D G H L (F2) (F3) B E (R) (F1) (Low) (High) C F (C) J K M 3. Engagement of each clutch transfers the power as shown in the tables below. The output shaft is equipped with a 2-wheel/4-wheel drive selector a high/low speed selector. 4-WD Rear 2-WD Front IW J12E High speed 2-wheel drive Gear combination 1st Forward B, E, D, G,H,L 2st Forward B, E, F, J, K, M 3st Forward A, D, G, K, M 4st Forward B, E, D, G, K, M Reverse C, J, K, M Low speed 2-wheel and 4-wheel drive 1st Forward 2st Forward 3st Forward 4st Forward Reverse Gear combination B, E, F, J, H, L B, E, D, G, H, L B, E, F, J, K, M A, D, G, K, M C, J, H, L 31 W E

33 Function 2.2 Valve assy The valve assy consists of clutch pressure main relief valve assy, High/Low clutch presseure regulator valve assy, range clutch presseure regulator valve assy, range switching valve assy, and solenoid valve assy. Each of these component valves is constructed and has functions as follows. Name Constitution Function Clutch pressure main relief valve This valve adjust the pressure to the clutch main pressure level. Clutch pressure main relief valve assy High/Low clutch pressure regulator valve assy Range clutch pressure regulator valve assy Range selection valve assy Solenoid valve assy Air bleeder valve Cold oil relief valve Accumulator valve Flow valve High selector valve Low selector valve Lubrication pressure relief valve Accumulator valve Flow valve F1 seliction valve F2 seliction valve F3 seliction valve R seliction valve Solenoid valve When the torque converter starts, this valve discharges the air into the pump discharge port. This valve prevents the torque converter insid pressure from rising to an abnormally high level due to high oil viscosity when it is cold. This valve maintains the High/Low clutch pressure. After the clutch pressure has been increased, this valve allows the clutch pressure to be raised to a predetermined level. This valve operates by using the pressure resulting from switching action of the High solenoid valve as a pilot pressure to direct the oil to the High clutch This valve operates by using the pressure resulting from switching action of the Low solenoid valve as a pilot pressure to direct the oil to the Low clutch This valve prevents an excessive increase of lubricating oil pressure. This valve maintains the range clutch pressure. After the clutch pressure has been increased, this valve allows the clutch pressure to be raised to a predetermined level. This valve operates by using the pressure resulting from switching action of the F1 solenoid valve as a pilot pressure to direct the oil to the F1 clutch This valve operates by using the pressure resulting from switching action of the F2 solenoid valve as a pilot pressure to direct the oil to the F2 clutch This valve operates by using the pressure resulting from switching action of the F3 solenoid valve as a pilot pressure to direct the oil to the F3 clutch This valve operates by using the pressure resulting from switching action of the R solenoid valve as a pilot pressure to direct the oil to the R clutch Each solenoid valve operates in response to a command from the controller and leads pressure to the corresponding selector valves. 32 W E

34 Function 2.3 Theory of valve operation The following table shows the status of each solenoid valve for each gear position. Mode High Low Gear position 1st 2nd 3rd 4th Rev 1st 2nd 3rd 4th Rev F1 Solenoid valve OFF ON OFF OFF OFF ON OFF OFF ON OFF F2 Solenoid valve OFF OFF ON OFF OFF OFF ON OFF OFF OFF F3 Solenoid valve ON OFF OFF ON OFF OFF OFF ON OFF OFF R Solenoid valve OFF OFF OFF OFF ON OFF OFF OFF OFF ON High Solenoid valve OFF ON ON ON ON OFF OFF OFF ON OFF Low Solenoid valve ON OFF OFF OFF OFF ON ON ON OFF ON [NOTICE] In the above table, ON indicates that the associated valve is energized (activated) and OFF indicates that the valve is deenergized (deactivated). 2.4 When in Neutral In the neutral position, all the solenoid valves are in the OFF state, which means that there are no pressure in the pilot circuit 1 through 6 and that the range clutch port 7 and High-Low clutch port 8 are blocked by the R selector and Low selector valve. The pressure at the clutch port 7,8 is, therefore, retained in the accumulator, being ready for next clutch selection. Orifice A Accumulator valve Flow valve Orifice B Pressure gauge φ1 F3 SOL 2 1 F2 SOL F2 F3 F1 SOL F2 F3 3 Selector valve 4 R F1 From clutch pressure main relief valve R SOL Low SOL R Orifice C F1 Accumulator valve Flow valve 8 High Low Orifice D 5 High SOL 6 High Low IW J24E 33 W E

35 Function 2.5 When gear is shifted [NOTICE] The explanation of gearshift is represented by a one for the shift from N (neutral) to D (drive). 1. By a command from the external controller the F3 solenoid valve and Low solenoid valve is energized. 2. Passing through the opened valve, the hydraulic oil flows to the pilot circuit 1 and the pressure established in this circuit causes the F3 selector valve to open the range clutch port 7 to the F3 clutch port. 3. At the same time, the pressure retained in the accumulator valve is released into the clutch port to establish the pressure in the port. 4. Once the predetermined pressure has been established in the port, the oil flowing through the orifices A and B gradually pushes the accumulator piston with a pressure that increases in an optimum gradient to engage the clutch. This gradual increase of pressure reduces shock that occur when the clutch engages. 5. When the clutch has engaged and the predetermined pressure level has been reached, the flow valve switches the oil passage, allowing the pressure to increase instantly to the level necessary for maintaining the clutch engaged. 6. The pressurized oil passed through the Low solenoid valve is led to the Low selector valve via pilot circuit 5, then the Low selector valve connects High-Low clutch port 8 and Low clutch port. 7. The pressurized oil in the accumulator is released into the clutch port and fills the clutch port up. 8. The oil filled the clutch port pushes gradually accumulator piston, engages the clutch under the given rising characteristic, then relief the engaging schock. 9. When the clutch engagement finishes and the pressure reaches to the required level, the flow valve switched increases instantaneously the oil pressure by the required clutch pressure. Orifice A Accumulator valve Flow valve Orifice B Pressure gauge φ1 F3 SOL 2 1 F2 SOL F2 F3 F1 SOL F2 F3 3 Selection valve 4 R F1 From clutch pressure main relief valve R SOL Low SOL R Orifice C F1 Accumulator valve Flow valve 8 High Low Orifice D 5 High SOL 6 High Low IW J25E 34 W E

36 Function 2.6 clutches 1. Each of these clutches comprises a clutch piston, steel plates, and fiber plates, as shown. 2. Clutch pressure supplied through the solenoid valve flows, via the housing cover, supply cover, and passage in the clutch shaft assy, into the oil chamber of the clutch carrier. 3. The oil in the chamber pushes the clutch piston to press the steel plates and the fiber plates together, overcoming the pressure of the return spring. 4. In this way the torque of the clutch shaft assy is transmitted to the reduction gear. Clutch piston Steel plate Fiber plate Clutch shaft assembly (Input shaft) Z31 Z41 B Z31 To R clutch To F2 clutch クラッチシャフト Ass'y F2 R Lubrication A C Supply cover Clutch shaft assembly Z50 D F3 Z41 E F1 Z31 F To F1 clutch To F3 clutch Lubrication Clutch shaft assembly Z41 G Z31 H J Z61 Z63 K To High clutch To Low clutch Low High Lubrication Z80 Z47 IW J26E 35 W E

37 Lockup clutch SOL PTO clutch SOL Lockup clutch PTO clutch T/C Charging pump Torque converter Lockup clutch accumulator valve Thermo. sensor G 3/8 G 1 G 1 Oil cooler G 1 G 1 G 1 G 1 Filter G 3/8 Lubricating oil relief valve Transmission Cold oil relief valve Clutch pressure main relief valve F3 SOL F2 SOL F1 SOL R SOL Low SOL High SOL ACC ACC F2 R Orifice A To accumulator valve for range valve F3 2nd 3rd selector valve Hifg/Lo accumulator valve Flow valve F1 Rev 1st High selector valve Orifice C Flow valve High Low selector valve selector valve Low selector valve IW J29E Orifice B Φ 1 Orifce C Orifice D Pressure gauge Function 2.7 Hydraulic circuit selector G 3/8 G 3/8 Orifice a Breather G 1-1/4 G 1-1/4 G 1-1/4 G 1-1/4 36 W E

38 Troubleshooting Troubleshooting 1. Output remains low. Engine Fault area and cause Engine speed is abnormal. Torque converter oil Insufficient oil Wrong oil Air in oil Blocked oil filter Correction Measure engine speed during neutral and during stall, and adjust or repair engine if speed is faulty. (See the sub-section for stall test.) Add oil with specified oil. Tighten fittings and joints in hydraulic circuit. Clean or replace filter. Torque converter Torque converter Damage in stator freewheel Stator wheel seizure Measure stall speed, and if very low, replace the freewheel inner race, freewheel cam and rollers. (See the sub-section for stall test) Measure oil temperture rise under no load, and if abnormally high, replace the freewheel inner race, freewheel cam and rollers. Damage or contact of vane wheel Check torque converter oil for aluminum powder, and if found, replace vane wheel. Transmission Charging pump Faulty pump Insufficient oil Add oil Use of unspecified oil with specified oil. Torque converter oil Drop of torque converter pressure Check toque converter pressure, and adjust. causing bubbles Water mixed in oil Check oil cooler and replace entire oil. Clutch pressure drop due to spring setting or break Valve assy Valve seized open or repair Clogged orifices Clean and wash Damaged seal rings on shaft end and clutch pressure Clutch area Clutch plate slipping due to low clutch pressure Measure pressure Worn or damaged clutch plates Clutch piston malfunction or repair Shassis parts Breake Brake remains on Incomplete unbraking Check electric and air circuits in brake system. Check and adjust 37 W E

39 Troubleshooting 2. Non- power transmission Fault area and cause Correction Torque converter Damaged input plate Insufficient oil Worn shaft and spline Damaged gear Faulty charging pump Add oil Transmission Troque converter oil Insufficient oil Add oil Clutch Output shaft Solenoid valve Valve assy Worn or damaged clutch plates Clutch plate seizure Wear in clutch shaft splines Clutch pressure drop due to faulty oil seal rings at clutch shaft ends and on clutch piston. Worn shaft spline Domaged gear Broken solenoid wire Malfunction of spool Clutch pressure drop due to setting or broken springs. Valve seized open Blocked orifice Repair or replace Repair or replace Wash and clean Electric circuit for solenoid control Faulty switch and relay Disconnected or broken wires Repair according to circuit diagram. Repair according to circuit diagram. Chassis parts Propeller shafts and universal joints Damged 38 W E

40 Troubleshooting 3. Abnormal rise of oil temperature Torque converter Fault area and cause Correction Check stall speed, and replace stator assy if Faulty stator wheel below specified speed. (See the sub-section for stall test) Troque converter If torque converter oil contains aluminum Fauling vane wheel powder, etc., replace vane wheel. Worn or seized bearings Correct or replace. Improper oil volume Check oil level. Troque converter oil Improper oil quality with specified oil. Air in oil Tighten pipe fittings. Water in oil Check cooler, and replace entire oil. Excessive piping Bent or folded hoses Correct or replace. resistance Blocked oil cooler Wash or replace. Seized clutch plates Transmission Clutch drags Worn or seized bearings Clutch piston malfunction Repair or replace Low clutch pressure Check Instruments Faulty instruments Too- high clutch pressure and torque converter pressure Fault area and cause Correction Torque converter Bent or damaged discharge pipes, or blocked oil cooler Repair or replace Too high oil viscosity (cold season) Use of unspecified oil Heat oil when ambient temperature is below zero. with specified oil. Transmission Valve assy Valve malfunction due to damage, dust, etc. Repair or replace 39 W E

41 Troubleshooting 5. Too- low clutch pressure and torque converter pressure Fault area and cause Correction Torque converter Insufficient oil Use of unspecified oil Worn or damaged charging pump Worn oil seal rings or O-rings Blocked oil filter Set or broken springs Add oil with specified oil Clean or replace Transmission Valve assy Clutch Valve seized open Blocked orifices Faulty seal rings at shaft ends and on clutch piston Correct or replace Wash and clean 6. Noise Fault area and cause Correction Torque converter Transmission Broken input plate Damaged or worn bearings Damaged gears Fouling vane wheel Loose or broken bolts, rivets Worn splines Faulty pumps Clutch seizure, dragging Bearing seizure or wear Damaged gears Worn splines Loose or broken bolts Repair or replace Repair or replace Chassis parts Damaged universal joints Other parts Check brake and differential areas. 40 W E

42 Troubleshooting 7. Speed range can not be switched over Transmission Fault area and cause Clutch plate seizure Solenoid valve malfunction Damaged gears Correction Repair or replace Electric circuit for solenoid switching Faulty switches, relays Disconnected or broken wires Repair by referring to circuit diagram. Repair by referring to circuit diagram. 8. Lockup cannot be effected, or cannot be canceled. Fault area and cause Correction Torque converter Worn or damaged clutch plates Faulty oil seal rings on turbine shaft Faulty O-rings on input shaft Faulty seal rings on clutch piston Transmission Lockup pressure reducing valve Solenoid valve Lockup reducing valve piston malfunction Repair or replace Lockup solenoid malfunction Excessive leak from lockup solenoid valve Repair or replace Electric circuit Faulty multipe data transmitter unit Faulty pickup sensor Blown fuse Disconnected or broken wire Repair by referring to circuit diagram. 41 W E

43 Disassembly Disassembly 1. Torque converter Hex. socket head bolt Spacer [NOTICE] The following parts should not be disassembled. 1) Charging pump 2) Clutch shaft assy (clutch shaft and clutch carrier are shrunken fit) 3) Turbine wheel assy (riveted) 4) PTO clutch piston ( steel ball, plug) 5) Drive-in plug Place removed parts in order, and tag them with mounting position. 1.1 Disassembly of torque converter 1. Remove plug on the right side (as viewed from the output shaft) of the converter housing, remove plug on cover wheel through the opened plug hold on the converter housing, and drain the converter circuit. Washer Input shaft Input guide IW J32E 3. Lay the converter, the input side up. Unscerw bolts, and by utilizing the therded extraction holes, remove front housing. Remove O-ring and oil seal from front housing. Bolt O-ring Front housing Converter housing Plug Oil seal IW J33E IW J31E 4. Remove snap ring, and remove washer. 2. Unscrew hexagon socket head bolts, and remove washer, input plate, spacer and input guide. Snap ring Washer IW J34E 42 W E

44 Disassembly 5. Place the converter on wood blocks, with the input side down, resting the rim of the housing on the blocks. Unscrew bolt, spring washer and washer,and remove output flange. Bolt Output flange Spring washer Washer 7. Unscrew bolts and hexagon socket head bolt, and remove the lockup clutch pressure regulator valve. Remove shims. Bolt Hexagon socket head bolt Lockup clutch pressure regulator valve Shim IW J37E 8. Unscrew bolts and plate. Remove shims. Front cover Wood block Bolt Plate IW J35E Shim 6. Unscrew bolts, and remove seal carrier by prying the recesses in the seal carrier. Remove shim. Bolt Seal carrier IW J38E Shim IW J36E 43 W E

45 Disassembly 9. Remove hexagon socket head bolt, and plate. Remove shim and o-ring. 11.Remove gear B (output shaft), and remove turbine shaft Hexagon socket head bolt Plate Turbine shaft assy Gear B O-ring IW J41E IW J39E 12.Unscrew nuts, and remove pump assy. 10.Unscerw bolts, and remove rear cover by utilzing the theraded extraction holes. Remove PTO clutch section as a whole. Pump assy Nut Bolt Rear cover PTO clutch section IW J42E IW J40E 44 W E

46 Disassembly 13.Unscrew hexagon socket head bolts. With a wood board inserted under the converter and with housing slightly lifted, lightly tap the end surface of seal race, until the internal converter section comes off, down on the board. Hex. socket head bolt Converter housing Tapered roller bearing Gear B Tapered roller beating (large size) IW J45E Seal race 1.2 Disassembly of converter main section 1. Unscrew hexagon socket head bolts, and remove seal race. Hexagon socket head bolt Wood block Seal race IW J43E 14.Remove oil seal rings, and tapered roller bearings from turbine shaft assy. Oil seal ring Tapered roller bearing Turbine shaft assy IW J46E 2. Unscrew bolts; utilizing the threaded extraction holes, separate impeller wheel from cover wheel; remove turbine wheel assy. Bolt Impeller wheel Tapered rolleer bearing Oil seal ring IW J44E 15.Remove tapered roller bearing (large size), from gear B (output shaft). Turbine wheel assy Cover wheel IW J47E 45 W E

47 Disassembly 3. Unscerw bolts; utilizing the threaded extracrion holes, remove front cover. Remove clutch piston from the front cover. 6. Remove snap ring, and remove side washer and pin. Remove stator wheel and free wheel cam. Rollers and leaf springs will come off then. Front cover Bolt Stator wheel Snap ring Side washer Pin Clutch piston Free wheel cam Rollr, Leaf spring IW J48E 4. Remove oil seal rings from front cover and clutch piston. Impeller wheel IW J51E Oil seal ring Front cover Clutch piston Oil seal ring IW J49E 7. After removing side washer and pin, remove snapring. With wood blocks inserted under impeller wheel, remove free wheel inner race by tapping its input-side end. Washer Side washer Pin Snap ring 5. Remove fiber plate and back plate from cover wheel. Fiber plate Back plate Impeller wheel Free wheel Inner race Wood block Cover wheel IW J52E IW J50E 46 W E

48 Disassembly 8. Unscrew hexagon socket head bolts, and remove drive gear. Rmove angular contact bearing and impeller hub tapping the angular cortact bearing. Hexagon socket head bolt Drive gear Disassembling stick P gear Converter housing Angular bearing Boll bearing Spline hub IW J55E Impeller hub Impeller wheel IW J53E 2. Remove P gear and ball bearing out of converter housing. 9. After removing oil seal ring, unscrew hexagon socket head bols, and separate free wheel inner race from stator holder. P gear Boll bearing Converter housing Hexagon socket head bolt Stator holder IW J56E Oil seal ring Free wheel inner race IW J54E 1.3 Disassembly of charging pump drive sections 1. Insert a disassembling stick into the disassembling hole (Φ11) inside the converter housing. Remove spline hub and ball bearing, rotating P gear and tapping the end of the spline hub with the disassembling stick. 47 W E

49 Disassembly 1.4 Disassembly of steering pump drive sections 1. Insert a disassembling stick into the disassembling hole (Φ11) inside the converter housing. Remove retaining ring, and spline hub and ball bearing, rotating P gear and tapping the end of the spline hub with the disassembling stick. 1.5 Disassembly of PTO clutch section 1. Remove oil seal ring, and tapered roller bearing. Oil seal ring Tapered roller bearing Disassembling stick P gear Converter housing IW J59E Spline hub Boll bearing Retaining ring IW J57E 2. Remove tapered roller bearing, P gear, thrust washer, ball bearing and snapring from shaft. Tapered roller bearing 2. Remove P gear and ball bearing out of the converter housing. P gear Thrust washer Ball bearing P gear Ball bearing Converter housing Snap ring Ball bearing IW J58E IW J60E 48 W E

50 Disassembly 3. Remove snap ring, and remove back plates, fiber plates and steel plates. 5. Withdraw piston assy. Remove oil seal rings from the piston assy and the clutch assy. Steel plate Snap ring Back plate Fiber plate Steel plate Fiber plate Steel plate Fiber plate Piston assy Oil seal ring Oil seal ring Clutch shaft assy IW J63E IW J61E 4. Remove snap ring, and remove washer and spring. CAUTION When removing the snap ring, take care to prevent the ring from being thrown out by the spring force. Snap ring Spring IW J62E 49 W E

51 Disassembly 2. Transmission 2. Unscrew bolt, and remove input flange. [NOTICE] The following parts shall not be disassembled. 1) Drive plug, piping and steel bolls in housing. 2) Clutch shaft and clutch carrier (shrink fit). 3) Output shaft, gear M, and gear P (shrink fit) 4) Needle roller bearing in the bore of output shaft. 5) Drive plugs and steel balls in valves. Place removed parts in order, and tag them with mounting position. Bolt Input flange 2.1 Transmission 1. Remove the valves, the strainer and other external attachments. IW J81E 3. Remove the bolts and hexagon socket head bolts. Remove the shifter case (2WD-4WD selector assy) by screwing a bolt into the threaded hole provided for disassembly. Hexagon socket head bolt Bolt Snap ring Shifter cace IW J82E 50 W E

52 Disassembly 4. Place the transmission on wooden blocks with the front output end upward. 6. Unscrew bolts and hexagon socket head bolt, and remove clutch pressure main relief assy. 5. Unscrew bolt, and remove output flange. Bolt 7. Unscrew bolts, and remove bracket and solenoid valve assy. Output flange IW J84E 51 W E

53 Disassembly 8. Unscrew bolts, and remove bracket and solenoid valve assy. 10.Unscrew hexagon socket head bolt, and remove range selector valve assy. Hexagon socket head bolt Valve body 9. Unscrew hexagon socket head bolt, and remove spacer. IW J89E 11.Unscrew bolt, and remove High/Low clutch pressure regulator valve assy. 52 W E

54 Disassembly 12.Unscrew bolt, and remove spacer. Bolt 14.Remove the bolts, and screw a bolt into the threaded hole in the seal carrier to remove the carrier. Spacer Bolt Seal carrier Bolt IW J91E 13.Remove the bolts and hexagon socket head bolts. Remove the cover and range clutch pressure regulator valve assy. IW J93E [NOTICE] If the shaft group components and supply cover are not replaced, put marks on all shims so that they can be replaced correctly at the time of reassembly. 15.Remove the bolts, and screw a bolt into the threaded hole in the supply cover to remove the carrier. Bolt Supply cover IW J94E [NOTICE] Tapping the output shaft end surface, remove the housing cover. Do not remove the emergency steering pump from the housing. 53 W E

55 Disassembly 16.Remove the bolts and the hexagon socket head bolts. Remobe the housing cover screwing bolts into the threaded hole for disassembly. High/Low Clutch pack group Output shaft group Hexagon socket head bolt Bolt Housing cover Shroud Bolt Emargency steering pump group IW J95E IW J97E 17.Remove pipe,adapter and O-ring. O-ring Adapter O-ring 19.Using the lifting jig, remove the F2-R and F1-F3 clutch pack groups simultaneously out of the housing. F1,F3 Clutch pack group pipe O-ring Adapter O-ring F2,R Clutch pack group lifting jib IW J96E 18.Remove the shroud mounting bolts. Using the lifting jib, remove the High/Low clutch pack group, output shaft group, and shroud together out of the housing. IW J98E 54 W E

56 Disassembly 20.Remove snap ring, and remove roller bearing. Snap ring Spring Roller bearing Slide sleeve IW J99E Shifter case Retainer ring Shifter fork 2.2 Shifter case assy (2-wheel/4-wheel selector) Washer Shifter case Slide sleeve Drive gear Shifter fork IW J101E Shaft 2. Remove snap ring; then remove ball bearing. Cover Piston IW J100E Snap ring 1. Remove springs, silde sleeve and shifter fork. Remove retainer ring; then remove drive shaft from shifter case by tapping the shaft end. Ball bearing Shaft case IW J102E 55 W E

57 Disassembly 3. Unscrew bolt, and remove cover; then remove O-ring. Bolt 2.3 Disassembly of steering pump/speedometer group Gear Cover Case O-ring Gear assy Shroud IW J103E IW J105E 4. Unscrew nuts, and remove piston, O-ring, and shifter shaft. 1. Remobe bolt, then remove shroud, and remove snap ring and washer. Nut Piston O-ring O-ring Bolt Shroud Shifter shaft IW J104E Washer Snap ring IW J106E 56 W E

58 Disassembly 2. Remove gear assy by tapping its end; remove bolt, then remove casing. Case 2.4 Disassembly of clutch pack group [NOTICE] In this sub-section, the F1, F3 clutch pack group is used as an example in describing disassembling processes. Bolt Gear assy IW J107E Remove plug and copper packing, and remove bushing, oil seal, and O-ring ,134, IW J Remove oil seal ring. Applying a bearing puller to gear F(C), remove tapered roller bearing and spacer. Oil seal ring Tapered roller bearing Spacer Gear C IW J110E 57 W E

59 Disassembly 2. Remove snap ring, and remove back plate, fiber plates, and steel plates. Snap ring Back plate Fiber plate Steel plate Fiber plate 5. Aplyin a bearing puller to gear D, remove tapered roller bearing, washer, thrust washers, thrust needles, and needle bearinng. Teperd roller bearing Washer Thrust washer Thrust needle Thrust washer Needle bearing Fiber plate Gear D IW J111E Thrust washer Thrust needle Thrust washer 3.Remove snap ring, and remove spring. CAUTION Remove snap ring, taking care to prevent the ring from being thrown out by spring. IW J113E 4. Remove clutch piston, and snap ring, and seal carrier. Then remove oil seal ring. Snap ring Spring 6. Remove snap ring, and remove back plate, fiber plates, and steel plates. Snap ring Back plate Fiber plate Clutch piston Oil seal ring Snap ring Seal carrier Oil seal ring Steel plate Fiber plate Fiber plate IW J112E IW J114E 58 W E