RF80C-76G9 RF80M-77K5

Transcription

1 Publication No. W E 01 Torque converter Transmission Model RF80C-76G9 RF80M-77K5

2 Foreword Foreword This service 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, the models of torque converters, and transmissions used. Model Crane Torque converter Transmission GR-1000XL-2 GR-800EX-2 GR-750XL-2 GR-600EX-2 RF80C-76G9 RF80M-77K3 WARNING Never touch the body cases during operation and immediately after operation. Touching the body can cause burns. Never get close to rotating parts of the body during operation. You can be caught in the rotating parts, resulting in an injury. Never operate the manual lock device on the tip of the solenoid valve when the engine is running. When once operating the manual lock device while the engine is not running, always return it to the original state. If the manual lock device is operated or left in operation while the engine is running, the vehicle can start and cause an injury. Eyes on the body cases are provided to hang themselves only. Before lifting, 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. Crane model Applicable serial No. GR-1000XL GR-800EX GR-750XL GR-600EX [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 sectional view Torque converter external view Torque converter exploded view Converter circuit Torque converter mission PTO clutch assy Tightening torque table Transmission Transmission sectional view Transmission external view Transmission assy Hydraulic clutch assy (F2, R) Hydraulic clutch assy (F3, F1) Tightening torque table Function Torque converter Torque converter Operating principle of power transmission by torque converter PTO clutch Lock-up system Transmission General Main pressure regulating valve Torque converter inlet relief valve Control valve assy Clutch line pressure diagram Solenoid valves at various gear shift positions Lubricating oil flow control valve wheel/ 4-wheel drive selection High/Low range selection Clutch Hydraulic system Hydraulic circuit diagram Troubleshooting Power cannot be transmitted Power drops. (Speed cannot increase.) Oil temperature rises abnormally Unusual noise is heard There exists drag torque Clutches do not properly work Shocks are felt when clutches are changed Shift between 2-wheel and 4-wheel drives cannot be achieved Shift between High and Low speeds cannot be achieved Disassembly Torque converter Transmission Transmission assy Hydraulic clutch Counter shaft Output shaft Reassembly Torque converter Transmission Oil Recommended oil Oil changing procedure Draining oil (Installed state) Oil filling Test Operational check Pressure measurement Stall test Maintenance standards Overhaul interval ment interval of important parts Part replacement standards Torque converter Transmission Torque Converter Circuit W E

4 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. 3 W E

5 Structure 1.2 Torque converter external view 4 W E

6 Structure 1.3 Torque converter exploded view 1. Converter circuit 5. Gear pump assy 13. Bolt 29. Washer 2. Torque converter mission 7. O-ring 24. Band mark 30. Washer assy 8. Gasket 26. Band mark 3. PTO clutch assy 11. Bolt 27. Clip 4. Solenoid valve assy 12. Bolt 28. Plate 5 W E

7 Structure 1.4 Converter circuit 1. Impeller assy 11. Inner race 21. Thrust needle bearing 31. Plug 2. Turbine assy 12. Piston 22. Support 32. Disc 3. Stator wheel 13. Pressure plate 23. Snap ring 33. Snap ring 4. Front cover 14. Washer 24. O-ring 34. Thrust washer 5. Input guide 15. Ball bearing 25. O-ring 35. Thrust washer 6. Input plate assy 16. Ball bearing 26. O-ring Outer race 17. Thrust needle bearing 27. D-shaped ring One-way clutch 18. Thrust washer 28. D-shaped ring 38. Washer 9. One-way clutch retainer A 19. Snap ring 29. Bolt 39. Washer 10. One-way clutch retainer B 20. Snap ring 30. Bolt 6 W E

8 Structure 1.5 Torque converter mission 1. Housing 2. Cover 3. Oil seal 4. Cover 5. Gasket 6. Gear (N) 7. Snap ring 8. Turbine shaft 9. Stator support 10. Ball bearing 11. Seal ring 12. Seal ring 13. Seal ring 14. Shaft assy 15. Gear (Q) 16. Shaft (S) 17. Shaft (C) 18. Washer 19. Ball bearing 20. Ball bearing 21. Snap ring 22. Snap ring 23. Washer 26. Washer 27. Snap ring 28. Ball bearing 29. Ball bearing 30. Washer 31. Snap ring 32. Flange 33. O-ring 34. Washer 35. Bolt 36. Oil seal 37. Oil seal 38. Snap ring 39. Washer 40. Shim 41. Shim 42. O-ring 43. Piston 44. Spring 45. Spring 46. Spring 47. Stopper 48. Cover 49. Gasket 50. Plug 51. O-ring 52. Cover 53. Coin filter (small filter) 54. O-ring 55. Pin 56. Temperature sensor 57. Magnetic plug 58. Bolt (with washer) 61. Bolt 62. Bolt 64. Plug 65. Bolt 66. Gear (M) 67. Spacer (C) 68. Washer 69. Washer 70. Choke 71. Bolt 7 W E

9 Structure 1.6 PTO clutch assy 1. Shaft assy 7. Back plate 13. Snap ring 19. Seal ring 2. Seal ring 8. Snap ring 14. Ball bearing 20. Snap ring 3. Seal ring 9. Spring 15. Thrust washer 21. Cap 4. Piston assy 10. Washer 16. Ball bearing 5. Drive plate Ball bearing 6. Disc 12. Gear (p) 18. Snap ring 8 W E

10 Structure 1.7 Tightening torque table Part No. Part name Standard Tightening torque Maximum limit N m ft-lbf N m ft-lbf Bolt Bolt Bolt Bolt Bolt Plug Bolt Plug Temperature sensor Magnetic plug Bolt (with washer) Bolt Bolt Plug Bolt Choke Bolt Conversion table Torque, moment N-cm N-m kgf-cm kgf-m foot-pound, ft-lbf inch-pound, in-lbf W E

11 Structure 2. Transmission 2.1 Transmission sectional view 10 W E

12 Structure 2.2 Transmission external view 11 W E

13 Structure 2.3 Transmission assy 12 W E

14 Structure 13 W E

15 Structure 14 W E

16 Structure 1. Clutch pack 2. Clutch pack 3. Solenoid valve 4. Transmission housing 5. Gasket 6. Housing cover 7. Gasket 8. Front housing 9. Shaft assy 10. Solenoid valve 11. Flange 12. Shaft assy 13. Gear (K) 14. Gear (U) 15. Shaft 16. Flange 17. Sleeve (B) 18. Oil seal 19. Oil seal 20. O-ring 21. Washer 22. Bolt 23. Pin 24. Gear (W) 25. Shaft 26. Speedometer case 27. Gasket 28. Cover 29. Gasket 30. Cover 31. Gasket 32. Cover 33. Oil seal 34. Oil seal 35. Cover (C) 36. Gasket (C) 37. Ball bearing 38. Ball bearing 39. Switch 40. Seal washer 41. Sensor 42. Snap ring 43. Snap ring 44. Needle bearing 45. Shroud 46. Plate 47. Ball bearing 48. Spacer 49. Spring 50. Spring 51. Shift bar 52. Shift fork 53. Spring pin 54. Washer 55. Cover 56. O-ring 57. Piston 58. O-ring 59. Collar 60. Packing 61. Bolt 62. Washer 63. O-ring 64. Cover 65. Gasket 66. Rotor 67. Steel ball 68. Snap ring 69. Ball bearing 70. Snap ring 71. Washer 72. Sensor 73. Bolt 76. Strainer assy 77. Gasket 79. Oil gauge 80. Pipe 81. Plug 82. O-ring 83. Piston 84. Pressure spring 85. Pressure spring 86. Piston 87. Spring 88. Piston 89. Spring 90. Spring 91. Spring 92. Stopper 93. Coin filter (small filter) 94. O-ring 95. Bolt 96. Plate 100. Spring 102. Plug 104. Breather 108. Bracket 110. Shroud 111. Joint 112. O-ring 113. Pressure sensor 114. O-ring 115. O-ring 116. Gasket 117. Bolt 118. Bolt 119. Bolt 120. Bolt 121. Bolt 122. Bolt 123. Bolt 124. Bolt 125. Bolt 126. Bolt 127. Bolt 130. Hexagon socket head bolt 131. Nut 132. Plug 133. Plug 134. Plug 135. Plug 137. Mark band (0) 138. Mark band (1) 139. Mark band (2) 140. Mark band (3) 142. Mark band (5) 143. Mark band 144. Mark band 151. Snap ring 152. Choke 153. Gear (H) 154. Gear 155. Washer 156. Ball bearing 157. Washer 158. Snap ring 159. Roller bearing 160. Thrust washer 161. Snap ring 162. Ball bearing 163. Washer 164. Snap ring 165. Gear (I) 166. Ball bearing 167. Snap ring 168. Sleeve (A) 169. Shift fork 170. Shift bar 171. Bolt 172. Nut 173. Wire 174. Adapter 175. O-ring 177. Spring 178. Cover 179. Collar 180. Seal washer 181. Bolt 182. Spacer 183. Cover 184. O-ring 185. Bolt 186. Ball bearing 187. Bolt 188. Switch 190. Plate 191. Caution plate 192. Choke 193. Washer 194. Bolt 195. Spring washer 196. Spring washer 197. Bolt 198. Washer 199. Clip 201. Bolt 15 W E

17 Structure 2.4 Hydraulic clutch assy (F2, R) 1. Shaft assy 9. Snap ring 17. Spacer (A) 25. Snap ring 2. Seal ring 10. Thrust washer 18. Roller bearing 26. Needle bearing 3. Piston assy 11. Spring 19. Ball bearing 27. Thrust washer 4. Seal ring 12. Snap ring 20. Washer 28. Snap ring 5. Drive plate 13. Gear (F) 21. Snap ring 29. Washer 6. Disc 14. Ball bearing 22. Seal ring 51. Disc kit 7. Back plate 15. Snap ring 23. Spacer (B) 8. Conical plate 16. Gear (C) 24. Thrust washer 16 W E

18 Structure 2.5 Hydraulic clutch assy (F3, F1) 1. Shaft assy 11. Spring 19. Ball bearing 26. Collar 2. Seal ring 12. Snap ring 20. Washer 27. Thrust bearing 3. Piston assy 13. Gear (F) 21. Snap ring 51. Disc kit 4. Seal ring 14. Needle bearing 22. Ball bearing 8. Conical plate 16. Gear 23. Seal ring 9. Snap ring 17. Ball bearing 24. Thrust washer 10. Thrust washer 18. Snap ring 25. Snap ring 17 W E

19 Structure 2.6 Tightening torque table Part No. Part name Standard Tightening torque Maximum limit N m ft-lbf N m ft-lbf Bolt Switch Sensor Bolt Bolt Oil gauge Plug Bolt Plug Breather Pressure sensor Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Hexagon socket head bolt Nut Plug Plug Plug Plug Choke Nut Bolt Hexagon socket head bolt Bolt Switch Choke Bolt Bolt Bolt W E

20 Structure Conversion table Torque, moment N-cm N-m kgf-cm kgf-m foot-pound, ft-lbf inch-pound, in-lbf W E

21 Function Function 1. Torque converter 1.1 Torque converter 1. The periphery of the impeller wheel is connected to the engine flywheel through the front cover, input guide and input plate. The inner bore of the impeller wheel is supported by the ball bearing on the stator support assy. 2. Usually the driving power from the engine is transmitted to the impeller wheel, then to the turbine wheel by using torque converter oil as a medium. But when the lock-up conditions are met and the lock-up clutch is engaged, the lock-up clutch directly transmits the power from the front cover to the turbine wheel assy without the help of torque converter oil. 3. The turbine wheel assy is connected to one end of the turbine shaft by their splines. 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 supported through the freewheel (one way clutch) with the stator support. The flange of the stator support is fixed on the converter housing with bolts. 5. The stator wheel adds reaction torque, which is generated when torque converter oil returns from the turbine wheel assy to the impeller wheel, to the turbine torque, thus increasing the turbine torque compared to the input torque. 6. The stator wheel can free wheel when the speed ratio between the impeller wheel and the turbine wheel is high. Although this cannot increase torque, high transmission efficiency can be achieved. 1.2 Operating principle of power transmission by torque converter 1. The fluid clutch that transmits power by means of fluid is classified into two major categories. 2. One is the fluid coupling, and the other is the torque converter. They consist of the following main components as shown below. Torque converter Fluid coupling T P T P S P: Pump (impeller) wheel T: Turbine wheel S: Stator wheel IW J017E 3. The fluid coupling consists only of a pump (impeller) and a turbine, and it transmits rotational motion just like a windmill placed in front of an electric fan. 4. When the pump (impeller) is driven by an engine, the fluid (oil) starts to rotate around the shaft, and is driven outward by the centrifugal force. 5. As the pump (impeller) has radial vanes, oil flows out from the periphery of the vanes and flows into the periphery of the turbine placed face-to-face with the pump (impeller). 6. The oil flows towards the center of the turbine along the turbine blades while transmitting rotational force to the turbine. The oil eventually returns to the center of the pump (impeller). Rotating flow Pump (impeller) Vortex flow Turbine IW J018E 20 W E

22 Function 7. In this way, firstly the rotating flow around the shaft is generated by the rotating pump (impeller), and secondly the resulting centrifugal force induces vortex flow circulating between the pump (impeller) and turbine. 8. The fluid coupling has to continuously use oil as the transmission medium within a sealed space. 9. When the speed difference between the pump (impeller) and turbine is large under heavily loaded conditions like startup or hill climbing, the transmission efficiency is low and large input torque from the pump (impeller) is required to drive the turbine. 10.As a measure to improve the transmission efficiency under heavy loads, the torque converter is invented by placing a stator wheel between the turbine outlet and the pump (impeller) inlet. 11.In the fluid coupling, the returning oil from the turbine to the pump (impeller) flows in the direction to retard the pump rotation at the impeller vane inlet. 12.On the other hand, in case of the torque converter, the returning oil is redirected by the stator wheel to the direction to push the impeller blades forward. This results in improved efficiency under heavy loads and larger turbine torque than the input torque. The oil flows in the direction opposite to the pump rotation. Pump Turbine Pump Fluid coupling Pump Turbine The oil flow disturbs the pump rotation. IW J W E

23 Function 13.The stator can either freewheel or be locked according to the direction of the discharged oil flow from the turbine outlet, thus improving the torque converter efficiency. 14.Under light load conditions like when cruising at high speed, the speed difference between the impeller and turbine is small. 15.As this condition is approached, the direction of the discharged oil flow from the turbine outlet changes toward the direction to allow the stator wheel to freewheel. Eventually the discharge oil hits against the back of the stator blades. 16.In this condition, the stator blades greatly disturb the smooth oil flow and drop the efficiency. To prevent this unfavorable condition, a one-way clutch is provided to the stator wheel of the torque converter so that the stator wheel can freely rotate when the stator blades are pushed from the back by oil flow. 17.With the one-way clutch, the stator wheel is locked in one direction to get amplified torque. And in the opposite direction, it can freewheel to make the torque converter work as a fluid coupling under light load conditions. Stator locked Stator locked Stator freewheeling Stator freewheeling IW J021E 18.As described above, the relationship among efficiency, torque ratio and speed ratio can be illustrated as below. Works as converter Clutch point Works as fluid coupling 5 Stator locked Stator freewheeling 100 Torque ratio 4 80 Torque Efficiency % Pump torque Torque converter range Coupling range Speed ratio IW J022E 22 W E

24 Function 19.When the speed ratio is low, the stator wheel is locked and amplifies torque. So the efficiency rises as the speed ratio becomes higher with its peak at the speed ratio around 0.6. After that the efficiency starts to drop. 20.Once the speed ratio reaches the clutch point, the stator wheel starts to freewheel without amplifying torque as now it functions as a fluid coupling. And the efficiency starts to increase linearly with the speed ratio. 21.The functioning ranges such as torque converter range and fluid coupling range are called 'phases'. The number of turbine wheels is counted by 'stages', and each kind of vane wheel is called an 'element'. 22.Then the torque converter explained in this document is a three-elements, single stage, two-phases type. 1.3 PTO clutch 2. When the lock-up conditions are met, the external control unit (MDT) sends a signal to energize the solenoid valve, making pressure oil from the charging pump lead to the lock-up clutch and the accumulator. 3.The accumulator causes the lock-up clutch pressure to rise gradually in order to lessen shocks at locking up. 4. When the lock-up clutch is provided with pressure oil, the power from the engine is transmitted directly to the turbine shaft without passing through the torque converter. This can improve the transmission efficiency and fuel consumption rate. 5. The pickup sensor built in the transmission housing detects the rotational speed of the pickup sensor gear, corresponding to the vehicle speed, and sends it to the external control unit (MDT). Pickup sensor 1. When the solenoid valve is switched, the pressure oil flows through the oil passage in the shaft, pushes the clutch piston and makes the drive plates and discs securely contact one another. This makes the PTO engaged. Pickup sensor gear IW J027E 6. The pressure oil from the charging pump is connected to the port P of the solenoid valve for lock-up. Once the solenoid valve is energized, the pressure oil will be sent from the port P to the lock-up clutch via the port A. 1.4 Lock-up system 1. The lock-up system consists of a solenoid valve, a pickup sensor, a lock-up accumulator and a lock-up clutch. 23 W E

25 Function 2. Transmission 2.1 General 1. This transmission consists of hydraulic wet multi-plate clutches (for selecting speeds and forward/reverse drive directions), reduction gears, shafts, hydraulic units, air cylinder (for selecting 2-wheel/4-wheel drive modes and High/Low ranges), etc. 2. There are four multi-plate clutches, namely Forward 1 st (F1), Forward 2 nd (F2), Forward 3 rd (F3), Reverse (R). By controlling combination of the engagement of these clutches, the vehicle can run one of the driving modes from three speeds in forward or one speed in reverse of high range and from three speeds in forward or one speed in reverse of low range. 3. By selectively actuating clutches, power is transmitted by the gear train listed below. The output shaft at the rear of the vehicle is equipped with a 2-wheel/4-wheel drive selection and the output shaft at the front with a High/ Low range selection. Clutch Forward 1st Forward 2nd Forward 3rd Reverse Forward 1st Forward 2nd Forward 3rd Reverse High/Low selection High Low Gear combination G2, G5, G6, G9, G10, G12 G1, G4, G7, G10, G12 G2, G5, G4, G7, G10, G12 G3, G9, G10, G12 G2, G5, G6, G9, G8, G11 G1, G4, G7, G8, G11 G2, G5, G4, G7, G8, G11 G3, G9, G8, G Main pressure regulating valve 1. This valve adjusts the pressure of the oil delivered from the charging pump to the constant predetermined pressure MPa { psi}, and supplies the oil to the PTO clutch, lock-up clutch and transmission control valve. 2.3 Torque converter inlet relief valve 1. This valve prevents the pressure inside the torque converter from exceeding the specified pressure 0.7 MPa {101.5psi}. 24 W E

26 Function 2.4 Control valve assy The control valve assy consists of the forward-reverse selector valve assy and accumulator to control the engagement/ disengagement of the transmission clutches to select one of the three forward speeds and one reverse speed by changing the flow of pressure oil from the charging pump. 1. Clutch pressure is controlled with two 2-position solenoid valves (A, B), one 3-position solenoid valve (C), and one accumulator. Pressure oil from the charging pump controls the F1, F2, F3, and R clutches with the solenoid valves (A, B, C). 2. Pressure oil from the charging pump is directed, through the orifice, to the solenoid valves A, B, and C. 3. When the gear shift position is in neutral, the pressure oil from the charging pump is blocked with the spool in the solenoid valve C. 4.The pressure oil also is directed into the accumulator in the speed control circuit, and used to accumulate the accumulator. 5. When the gear shift position is at the 1 st (F1) speed, the solenoid valve B is energized and the pressure oil is directed to F1 clutch via the a-port. 25 W E

27 Function 2.5 Clutch line pressure diagram The diagram below shows the clutch line pressure rising process Lubricating oil flow control valve 1. This valve regulates the pressure oil flowing from the cooler to a predetermined pressure MPa { psi} before supplying it to clutches and bearings. Oil pressure Piston From oil cooler Time IW J040E Lubricating valve section IW E014 1: Immediately after solenoid switching 2: Clutch in half-clutch state 3: Clutch fully engaged 2.6 Solenoid valves at various gear shift positions SOL A SOL B SOL C-a SOL C-b Lo-F1 OFF ON OFF OFF Lo-F2 OFF OFF ON OFF Lo-F3 ON OFF OFF OFF Hi-F1 OFF ON OFF OFF Hi-F2 OFF OFF ON OFF Hi-F3 ON OFF OFF OFF Lo-R OFF OFF OFF ON Hi-R OFF OFF OFF ON N OFF OFF OFF OFF 26 W E

28 Function wheel/ 4-wheel drive selection 1. This selector is actuated by an air cylinder. 2. The pressurized air from the air tank pushes the piston and the shifter fork, mechanically connected to the piston, to move the sleeve (for 2-wheel/4-wheel drive selection). This changes the drive mode from 4-wheel drive to 2-wheel drive. A switch is provided to detect the 2/4-wheel drive position. 27 W E

29 Function 2.9 High/Low range selection 1. This selector is actuated by an air cylinder. 2. The pressurized air from the air tank pushes the piston and the shifter fork, mechanically connected to the piston, to move the sleeve (for High/Low range selection). This changes the drive mode from High range to Low range. A switch is provided to detect the Low range position. 28 W E

30 Function 2.10 Clutch 1. The clutch is composed of a clutch piston, drive plates and discs. The shaft supporting the clutches has internal passages for clutch operating oil and lubricating oil. 2. The disc has a paper type surface for better wear resistance and improved smoothness at the time of engagement. The drive plate is made of special steel for durability, wear resistance and secure engagement. 3. The pressure oil from the hydraulic valve enters the shaft from its end and flows through the internal passage to the space between the clutch drum and the clutch piston. 4. The pressure oil pushes the clutch piston against the return spring force to firmly engage the drive plates and discs. 6. The clutch piston is equipped with a steel ball to prevent an erroneous operation of the clutch. 7. As the clutch drum and clutch piston rotates at high speed, the oil remaining between the clutch drum and piston is pressurized by centrifugal force and could push the clutch piston and engage the clutch, even when the valves do not direct oil to push the piston to engage the clutch. 8. The steel ball is designed to prevent this unwanted clutch engagement. The centrifugal force moves the steel ball radically and makes the drain passage open, allowing the remaining oil in the oil chamber between the clutch drum and clutch piston to flow out inside the transmission case. 5. Therefore, the torque of clutch shaft assy is transmitted to the deceleration gear. 29 W E

31 Function 2.11 Hydraulic system 1. Oil in the oil tank at the bottom of the transmission is pumped up by the charging pump through the strainer, and flows to the main pressure regulating valve built in the transmission housing via the line filter. 2. The oil adjusted to the predetermined MPa { psi} by the main pressure regulating valve is provided to the PTO clutch solenoid valve and the lock-up clutch solenoid valve. The oil also flows to the control valve assy mounted on the transmission. 3. Flowing to the transmission, the pressure oil then flows to the hydraulic valves. When the hydraulic valves receive pilot pressure from the solenoid valves, the pressure oil is directed to the transmission clutches through selected oil passages. 4. The oil vented by the main pressure regulating valve is adjusted by the torque converter inlet relief valve (pressure setting: 0.7MPa {101.5psi}) and supplied to the torque converter. The oil enters the converter circuit through the path between the impeller wheel and the stator wheel. 5. The oil heated by transmitting power is discharged to the outside through the path between the turbine wheel and the stator wheel. Then the oil flows out of the converter housing and enters the oil cooler. After being cooled by the cooler, the oil flows to the lubricating oil flow control valve (pressure setting: MPa { psi}) mounted in the transmission. 6. The oil from the lubricating oil flow control valve lubricates the transmission clutches, bearings, etc. and returns to the oil tank. 30 W E

32 Function 2.12 Hydraulic circuit diagram 31 W E

33 Troubleshooting Troubleshooting 1. Power cannot be transmitted. Engine Torque converter Transmission Fault and cause Engine does not rotate normally. Hydraulic system Mechanical parts Hydraulic system Mechanical parts Insufficient oil Faulty charging pump Damaged input plate Broken input plate mounting bolts Damaged shaft or gear Insufficient oil Damaged piston or spring of inlet relief valve or main pressure regulating valve Faulty operation of solenoid valve Damaged seal ring Damaged shaft or gear Damaged spline Damaged clutch drum Damaged snap ring for back plate Damaged clutch drive plates or discs Measures Measure the engine speed with the transmission shifted to neutral and under a stall condition. If the speed is not within the specified limits, adjust or repair the engine. Supply oil. Repair or replace Supply oil. Repair or replace Repair or replace 32 W E

34 Troubleshooting 2. Power drops. (Speed cannot increase.) Engine Torque converter Transmission Fault and cause Engine does not rotate normally. Hydraulic system Mechanical parts Hydraulic system Mechanical parts Insufficient oil Oil with air mixed in it entered charging pump. Clogged line filter Decreased charging pump delivery rate Faulty operation of solenoid valve for lock-up clutch Damaged seal ring or O-ring Use of wrong (unspecified) oil Vane wheels are damaged or interfering with each other. One-way clutch is faulty. Lock-up clutch disc is worn or damage. Bearing is binding or damaged. Insufficient oil Damaged piston or spring of main pressure regulating valve Damaged piston or spring of inlet relief valve or main pressure regulating valve Damaged seal ring Clogged strainer Use of wrong (unspecified) oil Oil with air mixed in it entered charging pump. Seized clutch Seized or damaged bearing Measures Measure the engine speed with the transmission shifted to neutral and under a stall condition. If the speed is not within the specified limits, adjust or repair the engine. Supply oil. Inspect joints and gaskets. Clean or replace Check and replace Check and replace Use specified oil. Check and replace Supply oil. Clean or replace Use specified oil. Inspect joints and gaskets. 33 W E

35 Troubleshooting 3. Oil temperature rises abnormally. Fault and cause Measures Torque converter Hydraulic system Mechanical parts Excessive or insufficient oil Seized charging pump Faulty oil cooler Clogged line filter Vane wheels touch each other. Seized PTO clutch Seized or damaged bearing Excessive or insufficient oil Adjust oil quantity. Check and replace Repair or replace Clean or replace Check and replace Adjust oil quantity. Transmission Hydraulic system Mechanical parts Clogged hydraulic line Damaged lubricating oil flow control valve (damaged spring) Clogged strainer Seized clutch Seized or damaged bearing Check and replace Clean or replace 4. Unusual noise is heard. Torque converter Transmission Hydraulic system Mechanical parts Hydraulic system Mechanical parts Gear noise when 2-wheel/4-wheel drive selector shifted Fault and cause Faulty charging pump Oil with air mixed in it entered charging pump. Damaged input plate Damaged gear or spline Damaged bearing Vane wheels touch each other. Damaged damper spring in turbine wheel Insufficient oil (cavitation) Damaged gear or spline Damaged bearing Seized clutch Low air pressure Sleeve and gear (or spline) out of engagement Shift position not in neutral Vehicle not completely stopped Measures Check and replace Inspect joints and gaskets. Check and replace Supply oil. Increase air pressure by running engine. Change selector switch again. Set shift position to neutral. Stop vehicle completely. 34 W E

36 Troubleshooting 5. There exists drag torque. Fault and cause Measures Transmission Hydraulic system Mechanical parts Faulty operation of check ball in clutch piston Clogged drain line in solenoid valve or hydraulic valve Seized clutch Damaged clutch return spring Check and replace Check and replace 6. Clutches do not properly work. Fault and cause Damaged clutch seal ring Measures Transmission Hydraulic system Mechanical parts Faulty operation of check ball in clutch piston Clogged hydraulic circuits like modulating valve, hydraulic valve or solenoid valve Worn-out clutch drive plates and discs Check and replace Check and clean 7. Shocks are felt when clutches are changed. Fault and cause Measures Transmission Hydraulic system Faulty operation of accumulator piston for speed selector valve Faulty operation of accumulator piston for High/Low selector valve Check and replace Check and replace 8. Shift between 2-wheel and 4-wheel drives cannot be achieved. Fault and cause Measures Transmission Air cylinder Air leakage due to damaged piston packing packing. Mechanical parts Damaged shifter fork Damaged shifter fork return spring 35 W E

37 Troubleshooting 9. Shift between High and Low speeds cannot be achieved. Fault and cause Measures Transmission Air cylinder Air leakage due to damaged piston packing packing. Mechanical parts Damaged shifter fork Damaged shifter fork return spring 36 W E

38 Disassembly Disassembly 1. Torque converter 3. Remove input guide and O-ring. [NOTICE] Thoroughly clean the outside before starting disassembly. Disassemble the torque converter on a clear surface. Note the installation positions of disassembled parts by putting tags on them for later reassembly. 1. Remove bolts (M10, 12 pcs.), and remove plain washers, washer and input plate assy. 4. Remove seal ring from the end of turbine shaft, and remove snap ring, washers, and shims. Snap ring Washer Seal ring Shim Turbine shaft IW E Remove bolts (M8, 4pcs.) fixing cover on housing. 2. Remove two drain plugs (Rc 1/8) near the periphery of the front cover, and drain oil from the torque converter circuit. 37 W E

39 Disassembly 6. Using a sling and eye bolts, pull out converter circuit and cover as a unit from housing. 9. Using tapped extractor holes and a sling and eye bolts, remove front cover and turbine assy as a unit. Remove O-ring from front cover. 7. Remove snap ring fixing PTO drive gear, and remove gears and cover. Remove O-ring from cover. O-ring Oil seal Snap ring Gear Cover IW E Remove thrust washer, thrust needle bearing, thrust washer, One-way clutch retainer B, Snap ring, Outer race, One-way clutch, Inner race, Stator, One-way clutch retainer A, thrust washer, thrust needle bearing from impeller assy. Thrust needle bearing One-way clutch retainer B Outer race Thrust washer Thrust washer Snap ring One-way clutch 8. Remove bolts (M8, 24 pcs.) fixing front cover to impeller assy. Bolt Front cover Inner race One-way clutch retainer A Stator Thrust washer Impeller assy Thrust needle bearing IW E027 Impeller assy IW E W E

40 Disassembly 11.Remove snap ring from the end of turbine hub, and pull turbine assy out of front cover assy. (If difficult to remove, carefully tap the end of turbine hub with a plastic hammer.) 14.Remove bolts (M10, 2pcs.), and remove charging pump and gasket. Turbine assy Snap ring Ball bearing Snap ring Front cover assy IW E Remove bolts (M5, 4 pcs.), and remove solenoid valve assy (Lock-up/ PTO), o-rings (attached parts of solenoid valve assy), o-ring, and coin filter (small filter). 12.Remove snap ring, and remove pressure plate, disc, piston and D-shaped rings from front cover. Snap ring Pressure plate Disc Piston D-shaped ring 16.Remove bolts (M10, 10 pcs.), and remove cover and gasket. Front cover IW E Remove bolt (M16), washer and O-ring, and pull out flange. Flange O-ring Bolt Washer IW E W E

41 Disassembly 17.Remove PTO clutch. (If difficult to remove, carefully tap the shaft end from inside housing.) 20.Remove O-ring in the steering pump mounting portion. 18.Pull out output shaft with bearings, spacer and gear. (If difficult to remove, carefully tap the shaft end from inside housing.) 21.Remove snap rings retaining PTO gears, and remove washer and gear. 19.Pull out turbine shaft. (If difficult to remove, carefully tap the shaft end from inside housing.) 22.Remove snap rings retaining PTO bearings and remove washer. Turbine shaft IW E W E

42 Disassembly 23.Pull out shaft with bearings. (If difficult to remove, carefully tap the shaft end from inside housing.) 26.Remove snap ring holding back plate and pull out back plate, disc, and drive plate. 24.Remove bolts (M10, 6 pcs.), and pull out stator support. Bolt 27.Remove snap ring holding return spring with a special tool. Stator support IW E Pull out ball bearing, thrust washer, and gear (P) from PTO clutch. 28.Pull out washer, return spring, piston, and seal ring. 41 W E

43 Disassembly 29.Remove bolts (M8, 4 pcs.) from lock-up accumulator valve, and remove cover and gasket. Bolt Cover Gasket IW E Take out springs, stopper and piston. Piston Spring Stopper IW E W E

44 Disassembly 2. Transmission [NOTICE] Thoroughly clean the outside before starting disassembly. Disassemble the transmission on a clear surface. Note the installation positions of disassembled parts by putting tags on them for later reassembly. 4. Remove bolts (M10, 8pcs.), and remove 2-wheel/4-wheel drive selector cover with shaft using tapped extractor holes from housing, and remove gasket and springs (2pcs). 2.1 Transmission assy 1. Remove bolt (M16), washer, and remove input flange with O-ring. 5. Remove bolts(m10, 2pcs.), and remove cover from the top of 2-wheel/4-wheel selector air cylinder with O-ring. 2. Remove bolt (M16), washer, and remove output flange (front) with O-ring, and remove spacer. 6. Remove bolt (M8) and washer inside air cylinder, and remove piston. 3. Unbend washer. Remove bolt (M16) and washer, and remove output flange (rear) with O-ring. Bolt Washer Piston IW E W E

45 Disassembly 7. Pull out shift fork, sleeve, and needle bearing, and remove O-ring. 10. Remove two solenoid valve assys (F1, F2/R) and o-rings (attached parts of solenoid valve assy). 8. Remove snap ring retaining bearing, and pull out shaft. Snap ring Shaft 11. Remove bolts (M10, 29pcs.) and hexagon socket head bolts (M8, 6pcs.), and remove front housing and gasket from housing cover. IW E Remove solenoid valve assy (F3), coin filter (small filter) and o-ring, and o-rings (attached parts of solenoid valve assy). 44 W E

46 Disassembly 12. Remove bolts (M10, 6pcs.), and remove cover 15.Remove bolts (M10, 21pcs.) fixing housing cover. and gasket from housing cover. 13. Remove snap rings that position shaft end bearings to housing cover. (If difficult to remove, carefully tap shaft ends from behind housing.) 16.Using tapped extractor holes and a sling and eye bolts, remove housing cover and gasket from housing. 17. At emergency steering pump mounting portion, remove bolts(m8, 3pcs.), remove shroud from housing cover. 14. Remove hexagon socket head bolt (M10, 4pcs.) and bolt (M10, 4pcs.), remove ball bearing, spacer and cover, remove o-rings. 45 W E

47 Disassembly 18. Remove snap ring retaining gear, and remove gear. 20.Remove snap ring, and remove rotor, ball, washer, and snap ring. 19. Remove bolts(m10, 5pcs.), and remove speedometer with shaft assy from housing cover, and remove gasket. 21.Remove snap ring, and pull out shaft assy from speedometer case. 22.Pull out valve pistons, springs and stoppers from housing. 46 W E

48 Disassembly 23. Remove plug with O-ring from front housing, and remove pressure spring and piston. 26.Using a sling and a special tool, pull out hydraulic clutch (F2, R) assy and hydraulic clutch (R3, F1) assy. 24. Remove bolts (M8, 3pcs.), and remove plate from shroud. 25.Using a sling and eye bolt, pull out counter shaft and output shaft. 47 W E

49 Disassembly 2.2 Hydraulic clutch [NOTICE] As the basic disassembling procedure is common to all hydraulic clutches, the following description on hydraulic clutch (F3, F1) assy can be applied to others. 3. In addition, remove snap ring and thrust washer, pull out gear assy using a puller, and remove thrust washer and snap ring. 4. Using minus driver, remove snap ring holding back plate, and remove conical plate, back plate, discs and drive plates. 1. Remove seal rings (3 pcs.) from the shaft end, and remove snap ring and washer. 2. Using a puller, pull out ball bearing, and remove washer. 5. Remove snap ring holding return spring with a special tool. Snap ring Special tool IW E W E

50 Disassembly 6.Take out thrust washer, return spring, thrust washers, piston and seal ring. 2.4 Output shaft 7.Disassemble the clutch on the other side in the same manner. 2.3 Counter shaft Do not disassemble gear shrinkage-fitted to shaft. 49 W E

51 Reassembly Reassembly [NOTICE] Perform reassembly operations in the reverse order of disassembly while paying attention to the following notes. 1. Torque converter 1. Wash disassembled parts in clean oil and remove foreign material from them. Especially carefully clean oil grooves and oil passages. But it is not necessary to wash O-rings, D-shaped rings, oil seals, discs and gaskets. 2. O-rings, D-shaped rings, oil seals and gaskets with new ones. 3. Tighten bolts to the specified torque. (See Tightening Torque Table.) 4. Wind sealing tape on threads before screwing taper pipe threaded parts. Be careful not to allow any fragments of sealing tape to enter hydraulic circuits. 5. Degrease threads before applying thread lockers to them. Be careful not to allow residual locking compound to enter hydraulic circuits. 6. When installing an oil seal, pack the space between lips with Albania Grease No. 2 or No. 3 to approx. one-third to a half of the space volume. 7. Adjust shim thickness at the turbine shaft end to keep a clearance of mm( in). 8. At the end of reassembly operation, make sure that all sliding parts can move smoothly. 2. Transmission 1. Wash disassembled parts in clean oil and remove foreign material from them. Especially carefully clean oil grooves and oil passages. But it is not necessary to wash O-rings, D-shaped rings, oil seals, discs and gaskets. 2. O-rings, D-shaped rings, oil seals and gaskets with new ones. 3. Wash parts (spools and pistons) of the main pressure regulating valve, torque converter inlet relief valve, the lubricating oil flow control valve and control valve that are built in the converter housing, and apply genuine oil to them before installing them. 4. Tighten bolts to the specified torque. (See Tightening Torque Table.) 5. Wind sealing tape on threads before screwing taper pipe threaded parts. Be careful not to allow any fragments of sealing tape to enter hydraulic circuits. 6. Degrease threads before applying thread lockers to them. Be careful not to allow residual locking compound to enter hydraulic circuits. 7. When installing an oil seal, pack the space between lips with Albania Grease No. 2 or No. 3 to approx. one-third to a half of the space volume. Pack the space between oil seals in tandem at the output flange with the grease to approx. one-third of the volume. 8. Before installing O-rings and U-shaped gaskets, apply thin coat of grease (Albania No. 2) to them to prevent any cuts and nicks. 9. At the end of reassembly operation, make sure that all sliding parts can move smoothly. 50 W E

52 Oil Oil 1. Recommended oil [NOTICE] Torque converter oil should have the following properties: Proper viscosity at high temperature Good fluidity at low temperature High oxidation stability Antifoaming tendency and lubricating property Be sure to use only the brands listed below for oil replenishment and change. Be careful to add only the same brand oil for replenishment. [NOTICE] Check the oil level when the oil temperature is approx. 50 C (122 F). Total oil quantity: approx. 35L (9.25 gal) 3. Run the engine for approx. five minutes, and add oil until the oil level stabilizes at the height between the center of the oil level gauge and 'H'. Recommended oils Manufacturer TADANO Genuine Brand TADANO Genuine Torque Converter Oil 2. Oil changing procedure 2.1 Draining oil (Installed state) 1. Remove the drain plug at the bottom of the transmission and drain the oil from the transmission. 2. Remove the drain plug at the bottom of the torque converter and drain the oil from the torque converter. [NOTICE] After take out the torque converter, drain oil from the converter turbine wheel by removing the plug on the side of the front cover assy. (Approx. 6.5L (1.72 gal)) 2.2 Oil filling [NOTICE] Pour oil while being careful not to allow dusts, water, etc. to enter. Either insufficient or excessive oil may cause troubles. 1. While the engine does not run, remove the oil filler plug from the torque converter, and pour oil. (Approx. 25L (6.61 gal)) 2. Shift the gear shift lever to 'N' and set the PTO to 'OFF'. With the engine idling (at approx. 700 min -1 ), gradually add oil. 51 W E

53 Test Test [NOTICE] When driving the tires for measurement and adjustment purposes with them lifted off the ground by extending outrigger jacks, make sure that the 4-wheel drive mode is selected. 1. Operational check [NOTICE] Set the transmission clutch to 'N' for a no load condition. 1. Drive the torque converter at various speeds from low to high, and make sure that: No unusual noise, No abnormal vibration, and No oil leakage. [NOTICE] When checking conditions, be sure to drive the tires in the 4-wheel drive mode. 2. Extend the outrigger jacks and shift the gear shift lever to 'N', 'D' and 'R', and change the engine speed from low to high at each shift position to make sure that: No unusual noise, No abnormal vibration, and No oil leakage. 2. Pressure measurement 1. Run the torque converter to raise the torque converter oil temperature to approx. 50 C (122 F). 2. Measure the clutch pressure, torque converter inlet pressure and torque converter outlet pressure at the idling speed (700 min -1 ) and at the rated speed (2500 min -1 ) of the engine. Keep the gear shift lever at neutral (N). (When checking the lock-up clutch pressure, keep it at 2 nd or D.) 3. Read the clutch pressure displayed on the Vehicle Information Display Screen for maintenance mode of the AML on the crane, and measure the torque converter inlet pressure and torque converter outlet pressure by pressure gauges connected to the torque converter oil pressure check ports (Rc 1/8). [NOTICE] When measuring the pressure, be sure to drive the tires in the 4-wheel drive mode. 4. When measuring the individual clutch pressures and lubricating oil pressure, connect pressure gauges to the respective pressure check ports, extend the outrigger jacks to lift the tires off the ground and measure the pressures by changing the gear shift lever. Standard pressure table Oil temperature for measurement: 75 to 85 C (167 to 176 F) Item Torque converter inlet pressure Torque converter outlet pressure Transmission clutch pressure PTO clutch pressure Lock-up clutch pressure Transmission lubricating oil pressure Standard valve MPa {kgf/cm 2 } (psi) 700min min {0.3} (4.35) or more {3-7} ( ) 700min min {0.2} (2.9) or more (*1) 1.9 {19.4} (275.5) { } ( ) min { } ( ) 700min min {13.3} (188.5) or more { } ( ) min { } ( ) 700min min { } ( ) (*1): Min. required pressure { } ( ) 52 W E

54 Test 3. Stall test CAUTION In the stalled condition, the torque converter produces the maximum torque. Be extremely careful not to allow the vehicle to move suddenly. As the torque converter generates much heat in the stalled condition, do not stall it more than 30 seconds. And do not perform this test when the oil temperature is above 90 C (194 F). [NOTICE] Be sure to perform this test in the 4-wheel drive mode. 1. Securely apply the parking brake and foot brake. 2. Set the switches and levers to the following conditions. PTO switch: "OFF" Gear shift lever: "2 nd " Drive speed select switch: "4-wheel HI" Service brake: "ON" 3. Fully push the accelerator pedal, and read the engine speed when it becomes stabilized. Standard maximum engine speed under stall condition: approx min -1 (reference). 53 W E

55 Maintenance standards Maintenance standards 1. Overhaul interval 1. It is recommended that an overhaul should be given every two years or 4,000 hours of operation, whichever comes first. 2. rubber parts such as oil seals and O-rings, gaskets and copper gaskets. 3. Check all disassembled parts by proper methods like visual inspection for cracks, flaws, unusual wear, corrosion, etc. If these defects are evident, replace or repair them. 4. If a part is worn over the 'part replacement standards' below, only itself or its pair or the entire set should be replaced. 2. ment interval of important parts Time Parts Oil seal O-ring Gasket Copper gasket Oil seal ring Seal ring race surface Disc Stator freewheel Oil seal sliding surface Clutch piston sliding surface Bushing bore Bearing Spring At first overhaul all parts. Inspect the condition. At second overhaul and later all parts at overhaul. all parts at 2 nd and 4 th overhauls. parts exceeding its wear limit. parts exceeding its wear limit. flat springs if defective. parts exceeding its wear limit. 3. Part replacement standards Class Description Applicable parts Part name Parts that should be replaced with new ones whenever they are Gaskets A Gasket, O-ring, copper gasket, oil seal removed at overhauls, Rubber parts inspections and cleanings. Parts that tend to wear out relatively quickly, and need Seal rings B Oil seal ring, snap ring, disc, drive plate frequent replacement at Clutch plates overhauls C D Parts that do not need to be replaced at every overhaul, but should be replaced if found defective. Parts that normally do not need to be replaced, but should be replaced only if found defective. Bearings Race surface of seal rings Gears Shafts Bearing, bushing, parts for freewheel set, seal race Various gears, clutch shaft, turbine shaft, flange 54 W E