Publication No. W E. Service Manual. Torque converter Transmission RF16C-76E3 RF16M-77H8. Model TADANO LTD.

Transcription

1 Publication No. W E Service Manual 01 Torque converter Transmission Model RF16C-76E3 RF16M-77H8 TADANO LTD.

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, the models of torque converters, and transmissions used. Crane Torque converter Transmission GR-160N-1 RF16C-76E3 RF16M-77H8 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. 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 transmission PTO clutch assy Solenoid valve assy Tightening torque table Transmission Transmission sectional view Transmission external view Transmission assy Hydraulic clutch assy (F2 5, R1 2) Hydraulic clutch assy (F3 6, F1 4) Hydraulic clutch assy (High, Low) Solenoid valve assy (High-Low selector) Solenoid valve assy (F-R speed selector) Tightening torque table Function Torque converter Torque converter Operating principle of power transmission by torque converter Main pressure regulating valve Torque converter inlet relief valve PTO clutch Lock-up system Transmission General Control valve assy Forward-reverse selector valve assy High/Low selector valve assy Modulating valve Clutch line pressure diagram Solenoid valves at various gear shift positions wheel/4-wheel drive selector Clutch Hydraulic system Hydraulic circuit diagram...38 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...43 Disassembly Torque converter Transmission Transmission assy Hydraulic clutch Solenoid valve assy (High/Low selector)...55 Reassembly Torque converter Transmission...56 Oil Recommended oil Oil changing procedure Draining oil Oil filling W E

4 Foreword Test Operational check Oil pressure measurement Stall test Maintenance standards Overhaul interval Replacement interval of important parts Part replacement standards 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. PTO driven gear PTO clutch Converter housing Drive shaft Input plate Drive gear Front cover Stator support Input guide Coupling Turbine shaft Charging pump Lock-up piston Lock-up clutch Drive shaft Turbine Stator Pump (impeller) Driven gear Drive shaft Driven gear Steering pump mounting portion 4 W E

6 Structure 1.2 Torque converter external view Filler port (M30 1.5) Main pressure check port (Rc1/8) Air breather PTO pump mounting flange Rotating direction From line filter (G3/4) Torque converter inlet pressure check port (Rc1/4) Lock-up pressure check port (Rc1/4) Solenoid valve (Lock-up) Rotating direction Torque converter outlet pressure check port (Rc1/4) Oil temperature sensor Solenoid valve (PTO) A Charging pump PTO pressure check port (Rc1/4) To cooler (G3/4) Delivery port (G3/4) To line filter Suction port (G1) From transmission Identification Rotating direction Steering pump mounting flange suction filter mark Output shaft Torque converter drain (G1-1/4) To control valve (G1/2) Bypass drain (G3/4) Main pressure regulating valve Torque converter inlet relief valve Input shaft View A 5 W E

7 Structure 1.3 Torque converter exploded view 1. Torque converter circuit 6. Bolt 18. Rivet 28. Mark band 2. Torque converter transmission 7. Hexagon socket head plug 20. Plug 29. Mark band 3. Hydraulic clutch assy 8. Spring washer 22. O-ring 30. Mark band 4. Solenoid valve assy 9. O-ring 26. Mark band 31. Flange bolt 5. Gear pump assy 17. Name plate 27. Mark band 6 W E

8 Structure 1.4 Converter circuit 1. Impeller assy 11. Inner race 21. Thrust needle bearing 33. Plug 2. Turbine assy 12. Piston 22. Support 34. Disc assy 3. Wheel stator assy 13. Pressure plate 23. Snap ring 35. Snap ring 4. Front cover assy 14. Washer 24. O-ring 36. Thrust washer 5. Input guide 15. Ball bearing 25. O-ring 37. Thrust washer 6. Input plate 16. Ball bearing 26. O-ring 39. Spacer 7. Outer race 17. Thrust needle bearing 27. D-shaped ring 40. Flange bolt 8. One-way clutch 18. Thrust washer 28. D-shaped ring 9. Clutch retainer A 19. Snap ring 29. Flange bolt 10. Clutch retainer B 20. Snap ring 30. Flange bolt 7 W E

9 Structure 1.5 Torque converter transmission 1. Housing 18. Seal ring 34. Flange 53. Plug 2. Cover 19. Snap ring 35. O-ring 54. Plug 3. Oil seal 20. Washer 36. Washer 55. Plug 4. Gear assy 21. Ball bearing 37. Bolt 56. O-ring 5. Snap ring 22. Ball bearing 40. Oil seal 59. Pressure spring 6. Turbine shaft 23. Snap ring 41. Oil seal 60. Piston 7. Ball bearing 24. Washer 42. Snap ring 61. Pressure spring 8. Seal ring 25. Snap ring 43. Washer 62. Pressure spring 9. Stator support assy 26. O-ring 44. Shim 63. Piston 10. Gear (P) 27. Ball bearing 45. Shim 64. Breather 11. Gear (R) 28. Ball bearing 46. O-ring 65. Plug 12. Shaft (S) 29. Washer 47. Flange bolt 66. O-ring 13. Shaft (C) 30. Gasket 49. Adapter 71. Plug 14. Seal ring 31. Washer 50. O-ring 72. Piston 15. Snap ring 32. Snap ring 51. Cover 73. Spring 16. Flange bolt 33. Spacer 52. Bolt 74. Spring 8 W E

10 Structure 75. Stopper 76. Cover 77. Gasket 78. Hexagon socket head bolt 79. Temperature sensor 9 W E

11 Structure 1.6 PTO clutch assy 1. Shaft assy 6. Disc assy 11. Snap ring 16. Ball bearing 2. Seal ring 7. Back plate 12. Gear (N) 17. Ball bearing 3. Seal ring 8. Snap ring 13. Snap ring 18. Snap ring 4. Piston 9. Spring 14. Ball bearing 19. Seal ring 5. Drive plate 10. Washer 15. Thrust washer 20. Snap ring 21. Cap 10 W E

12 Structure 1.7 Solenoid valve assy 1. Body 2. Gasket 3. Solenoid valve 4. Choke 11 W E

13 Structure 1.8 Tightening torque table Part No. Part name Standard Tightening torque Maximum limit N m kgf m N m kgf m Bolt Hexagon socket head bolt Plug Flange bolt Flange bolt Flange bolt Plug Flange bolt Flange bolt Bolt Flange bolt Bolt Plug Plug Plug Breather Plug Plug Plug Hexagon socket head bolt Temperature sensor Solenoid valve Choke W E

14 Structure 2. Transmission 2.1 Transmission sectional view Transmission housing Input coupling (F1, F4, F3, F6) Clutch shaft Housing cover (F2, F5, R1, R2) Clutch shaft Front housing (High, Low) Clutch shaft (Rear) Output coupling Speedometer drive gear (Front) Output coupling To rear axle To front axle Speedometer driven gear 4-wheel drive detection switch Output shaft Shifter rod (for 2-wheel/4-wheel drive selection) Sleeve (for 2-wheel/4-wheel drive selection) 13 W E

15 Structure 2.2 Transmission external view F2 clutch oil pressure check port (RC1/8) R clutch oil pressure check port (RC1/8) F1 clutch oil pressure check port (RC1/8) F3 clutch oil pressure check port (RC1/8) Pressure sensor View A A Lubricating oil pressure check port (Rc1/8) Pickup sensor Identification mark Emergency steering pump flange B Speedometer check port Input shaft rotating direction Air breather Lubricating oil pressure check port (Rc3/8) Solenoid valve (for High) From cooler (G3/4) From main pressure regulating valve (G1/2) 4-wheel drive selection detection switch (ON at 4-wheel drive) Identification mark Solenoid valve (for R) Solenoid valve (for F2) 2/4-wheel drive selection port (Rc1/4) (Air in for 2-wheel drive) High clutch oil pressure check port (RC1/8) Low clutch oil pressure check port (RC1/8) Solenoid valve (for Low) Air cylinder (for 2/4-wheel drive selection) Oil level gauge From bypass drain (G3/4) From torque converter drain (G1-1/4) View B Solenoid valve (for F1) Solenoid valve (for F3) Identification mark Rotating direction at forward traveling To charging pump ( 30) Drain plug (M24 1.5) 14 W E

16 Structure 2.3 Transmission assy 15 W E

17 Structure 16 W E

18 Structure 1. Hydraulic clutch assy 47. Shroud 93. Bolt 139. Snap ring 2. Hydraulic clutch assy 48. Plate 94. Bolt 140. Ball bearing 3. Hydraulic clutch assy 49. Spacer 95. Bolt 141. Mark band 4. Control valve assy Bolt 142. Mark band 5. Solenoid valve assy Mark band 6. Transmission housing 52. Ball bearing Mark band 7. Gasket 53. Spring 99. Spring washer 145. Mark band 8. Housing cover 54. Gasket 100. Flange bolt 146. Mark band 9. Gasket 55. Shift bar 101. Bolt 147. Mark band 10. Front housing 56. Shift fork 102. Bolt 148. Mark band 11. Flange 57. Spring pin 103. Bolt 149. Oil seal Washer 104. Bolt Gear assy L 59. Spring 105. Bolt 151. Coin filter 14. Shaft assy 60. Cover Shaft 61. O-ring 107. Nut 16. Flange 62. Piston 108. Spring washer 17. Sleeve (B) 63. O-ring 109. Nut 18. Oil seal 64. Collar 110. Pressure sensor 19. O-ring 65. Washer 111. O-ring 20. Washer 66. U packing Bolt 67. Bolt 113. Bracket O-ring 114. Bracket 23. Parallel pin Plug 24. Gear (W) Plug 25. Shaft 71. Speedometer case 117. Plug 26. Cover 72. Collar 118. Hexagon socket head bolt 27. Gasket 73. Snap ring Cover 74. Speedometer drive gear Gasket (C) 75. Ball Speedometer driven gear 122. Gasket Speedometer bushing Breather Clip 33. Oil seal 79. Hexagon socket set screw Oil seal 80. Oil seal Cover (D) 81. Strainer assy Gasket (D) 82. Gasket Ball bearing Ball bearing 84. Subplate Switch 85. Gasket 131. Model plate 40. Seal washer Rivet 41. Sensor 87. Plug O-ring Snap ring 89. Oil gauge 135. Spring 44. Snap ring Spring 45. Needle bearing Piston 46. Snap ring 92. Bolt 138. Stopper 17 W E

19 Structure 2.4 Hydraulic clutch assy (F2 5, R1 2) 1. Shaft assy 7. Disc assy 13. Gear (F) 19. Snap ring 2. Seal ring 8. Back plate Ball bearing Snap ring 15. Ball bearing 21. Snap ring 4. Piston assy 10. Thrust washer 16. Gear (D) 22. Ball bearing 5. Seal ring 11. Spring 17. Thrust washer 23. Seal ring 6. Drive plate 12. Roller bearing 18. Snap ring 24. Collar 25. Conical plate 18 W E

20 Structure 2.5 Hydraulic clutch assy (F3 6, F1 4) 1. Shaft assy 8. Back plate 15. Ball bearing 22. Thrust washer 2. Seal ring 9. Snap ring 16. Gear (C) 23. Seal ring Washer 17. Collar 24. Ball bearing 4. Piston assy 11. Spring 18. Snap ring 25. Conical plate 5. Seal ring 12. Roller bearing 19. Snap ring 6. Drive plate 13. Gear (F) 20. Ball bearing 7. Disc assy 14. Washer 21. Snap ring 19 W E

21 Structure 2.6 Hydraulic clutch assy (High, Low) 1. Shaft assy 9. Snap ring 17. Washer 25. Gear (E) 2. Seal ring 10. Washer 18. Snap ring 26. Thrust washer Spring 19. Snap ring 27. Thrust needle bearing 4. Piston assy 12. Ball bearing 20. Ball bearing 28. Needle bearing 5. Seal ring 13. Gear (I) 21. Snap ring 29. Needle bearing 6. Drive plate 14. Washer Conical plate 7. Disc assy 15. Ball bearing 23. Seal ring 31. Back plate Gear (K) 24. Snap ring 20 W E

22 Structure 2.7 Solenoid valve assy (High-Low selector) 1. Valve body 5. Spool 9. Gasket (C) 13. Bolt 2. Gasket (A) 6. Washer 10. Solenoid valve 14. Spring washer 3. Valve body (B) 7. Spring 11. Special bolt 15. Spring washer 4. Gasket (B) 8. Cover (C) 12. Bolt 16. Choke 21 W E

23 Structure 2.8 Solenoid valve assy (F-R speed selector) 1. Valve body Solenoid valve 25. Bolt 2. Speed selector valve Gasket (A) 26. Spring washer Piston 19. Cover (B) Speed selector valve 13. Stopper 20. Gasket (B) 28. Gasket (D) 5. Pressure spring 14. Pressure spring 21. Cover (C) 29. Pressure spring 6. Spool 15. Pressure spring 22. Gasket (C) 30. Pressure spring 7. Pressure spring 16. Cover (A) 23. Bolt 31. Choke 8. Spool bracket 24. Spring washer 32. Hexagon socket head bolt W E

24 Structure 2.9 Tightening torque table Part No. Part name Standard Tightening torque Maximum limit N m kgf m N m kgf m Bolt Breather Switch Sensor Bolt Hexagon socket set screw Plug (Drain) Oil gauge Bolt Bolt Bolt Bolt Bolt Flange bolt Bolt Bolt Bolt Bolt Bolt Bolt Pressure sensor Plug Plug Plug Hexagon socket head bolt Special bolt Bolt Bolt Choke Bolt Bolt Choke Hexagon socket head bolt 23 W E

25 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 the turbine shaft by their splines. The power is transmitted from the other side of the turbine shaft to the output flange that is connected with splines. 4. The stator wheel is supported by the freewheel (one-way clutch) unit on the stator support assy. For the stator support, its flange is fixed to 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 トルクコンバータ converter P: Pump (impeller) wheel T: Turbine wheel S: Stator wheel フルード Fluid ( 流体 coupling ) カップリング T P T P S IW J 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 回転流 ポンプ Pump ( インペラ (impeller) ) Vortex うず巻流 flow タービン Turbine IW J W E

26 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 ポンプ回転と反対方向に opposite to the pump rotation. 流体が向かう ポンプ Pump タービン Turbine ポンプ Pump フルードカップリング Fluid coupling Pump ポンプ タービン Turbine The oil flow disturbs ポンプの回転を邪魔する the pump rotation. IW J019 Stator ステータ Pump ポンプ Turbine タービン Stator ステータ Pump ポンプ トルクコンバータ Torque converter The ポンプ回転を後押しする oil flows in the direction to 方向に流体が向かう help the pump to rotate. Pump ポンプ タービン Turbine The oil flows in the same direction ポンプ回転と同方向 as the pump. IW J W E

27 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 pump (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. ステータ固定 Stator locked ステータ固定 Stator locked ステータ空転 Stator freewheeling Stator ステータ空転 freewheeling IW J As described above, the relationship among efficiency, torque ratio and speed ratio can be illustrated as below. Clutch クラッチポイント point Works コンバータ範囲 as converter フルードカップリング範囲 Works as fluid coupling ステータ固定 Stator locked 空転 Stator freewheeling Torque トルク比 ratio トルク Torque 2 60 Efficiency 効率 % % 40 Pump ポンプトルク torque Torque converter トルコンレンジ range 1 20 カップリングレンジ Coupling range 回転比 Speed ratio IW J W E

28 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-element, single stage, two-phase type. 27 W E

29 Function 1.3 Main pressure regulating valve 1. This valve adjusts the pressure of the oil delivered from the charging pump to the constant predetermined pressure MPa { kgf/cm 2 }, and supplies the oil to the PTO clutch, lock-up clutch and transmission control valve. 1.4 Torque converter inlet relief valve 1. This valve prevents the pressure inside the torque converter from exceeding the specified pressure 0.7 MPa {7 kgf/cm 2 }. Main pressure regulating valve piston Torque converter inlet relief valve 1.6 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. 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. 1.5 PTO clutch Lock-up accumulator 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). ピックアップセンサ 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. Drive plate Disc Clutch piston ピックアップセンサ用ギヤ Pickup sensor gear IW J 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. Solenoid valve for lock-up clutch 28 W E

30 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), etc. 2. There are six multi-plate clutches, namely Forward 1 st and 4 th (F1 F4), Forward 2 nd and 5 th (F2 F5), Forward 3 rd and 6 th (F3 F6), Reverse (R1 R2), High range (High) and Low range (Low). By controlling combination of the engagement of these clutches, the vehicle can run one of the driving modes from six speeds in forward or two speeds in reverse. 3. By selectively actuating clutches, power is transmitted by the gear train listed as follows. The output shaft at the rear of the vehicle is equipped with a 2-wheel/4-wheel drive selector. Gear combination Forward 1 st G3, G9, G8, G11 Forward 2 nd G2, G5, G4, G1, G7, G8, G11 Forward 3 rd G1, G7, G8, G11 Forward 4 th G3, G9, G10, G12 Forward 5 th G2, G5, G4, G1, G7, G10, G12 Forward 6 th G1, G7, G10, G12 Reverse 1 st G2, G5, G6, G9, G8, G11 Reverse 2 nd G2, G5, G6, G9, G10, G12 29 W E

31 Function Input coupling (F3, F6, F1, F4) Clutch shaft (F2, F5, R1, R2) Clutch shaft (High, Low) Clutch shaft (Rear) Output coupling (Front) Output coupling Output shaft Sleeve (for 2-wheel/4-wheel drive selection) 30 W E

32 Function 2.2 Control valve assy 1. The control valve assy consists of the forward-reverse selector valve assy and Hi-Low selector valve assy to control the engagement/disengagement of the transmission clutches to select one of the six forward speeds and two reverse speeds by changing the flow of pressure oil from the charging pump. Transmission hydraulic circuit diagram Forward-reverse selector valve assy Orifice Accumulator Orifice Modulating valve Hydraulic clutch From charging pump Hydraulic valve Hydraulic clutch Hydraulic valve (F1) Hydraulic valve (F2) Orifice Accumulator (in transmission) Hydraulic clutch High/Low selector valve assy Hydraulic valve (High-Low) 31 W E

33 Function 2.3 Forward-reverse selector valve assy 1. This valve controls the forward 1 st and 4 th clutch, forward 2 nd and 5 th clutch, forward 3 rd and 6 th and reverse clutch. It consists of four solenoid valves (F1), (F2), (F3) and (R), a modulating valve and an accumulator to reduce shocks at clutch engagement, and hydraulic valves. 2. Pressure oil from the charging pump flows through the orifice into the modulating valve. 3. When the gear shift position is in neutral, the pressure oil in the modulating valve flows through the orifice in the spool and flows right into the hydraulic valves (F3), (F2) and (F3), then flows into the solenoid valve (R). Accumulator Modulating valve 4. The pressure oil in the modulating valve also flows into the accumulator built in the transmission to charge the accumulator. 5. When the accumulator is fully charged, the spool of the modulating valve is pushed to the left by the pressure oil. Then the pressure oil from the charging pump flows directly into the hydraulic valve (F3) together with the circuit passing the orifice of the spool. Hydraulic valve (F1) Hydraulic valve (F3) Hydraulic valve (F2) 6. When the gear shift position is at the 3 rd speed, the spool of hydraulic valve (F3) is pushed to the right by the pressure oil from the solenoid valve (F3). Then the pressure oil in the modulating valve flows into the clutch (F3) through the hydraulic valve (F3). 32 W E

34 Function 2.4 High/Low selector valve assy 1. This valve consists of the solenoid valve, hydraulic valve, etc. to control the engagement/disengagement of the High/Low clutch. The accumulator is built in the transmission. 2. The pressure oil from the charging pump flows through the orifice into the hydraulic valve (High/Low), and also charges the accumulator. 3. In case that the gear shift position is at the 3 rd speed, the solenoid valve (Low) is energized, and the pressure oil in the solenoid valve (Low) flows into the hydraulic valve (High/Low). 4. The spool is pressed to High side, and the pressure oil of the charging pump is supplied to Low clutch. P D L AC H D D Hydraulic ハイドロバルブ valve (High/Low) / Low) IW J Modulating valve 1. When the gear shift position is in neutral, pressure oil from the charging pump flows through the orifice of the valve inlet into the modulating valve, flows through the orifice in the spool, and then flows right into the hydraulic valves (F3), (F1), and (F2) and the solenoid valve (R). 2. The pressure oil of the modulating valve also flows into the accumulator to charge the accumulator. directly into the hydraulic valves (F3), (F1) and (F2) together with the circuit passing the orifice of the spool. 4. At the moment when the solenoid valve (F3) is energized and switched, pressure oil flows into the hydraulic valve (F3) and the spool in the hydraulic valve (F3) shifts right, causing pressure oil to flow in the circuit among the modulating valve, the hydraulic valve and the clutch (F3). This makes the pressure drop. 5. As a result, the spool of the modulating valve shifts right by the spring, and the circuit passing the orifice of the spool only remains for the pressure oil to flow to the F3 clutch. 6. The oil charged in the accumulator flows through the modulating valve and the hydraulic valve (F3) into the clutch (F3), and prevent the time lag for connecting the clutch. 7. Immediately before the clutch pressure begins to rise as the transmission clutch piston pushes the clutch plates, the pressure built in accumulator is completely released. And then, the pressure oil makes the accumulator charged with oil and the clutch line pressure gradually increases. 8. Under this condition, the clutch discs and drive plates are in half-clutch state (sliding with each other), softening the shocks at the time of clutch engagement. 9. When the accumulator is fully charged, the clutch line pressure reaches the predetermined pressure and pressure becomes the same everywhere in the circuit. 10. The spool of the modulating valve shifts left, and the pressure oil of the charging pump flows into the hydraulic valve (F3) and the clutch (F3) not passing the orifice of the spool. 3. When the accumulator is fully charged, pressure becomes the same everywhere in the circuit. At that time, the spool of the modulating valve is pushed to the left, and the pressure oil flows 33 W E

35 Function 2.6 Clutch line pressure diagram The diagram below shows the clutch line pressure rising process Oil 油圧 pressure Time 時間 IW J040 1: Immediately after solenoid valve switching 2: Clutch in half-clutch state 3: Clutch fully engaged 2.7 Solenoid valves at various gear shift positions SOL F1 SOL F2 SOL F3 SOL R SOL Low SOL High F1 ON OFF OFF OFF ON OFF F2 OFF ON OFF OFF ON OFF F3 OFF OFF ON OFF ON OFF F4 ON OFF OFF OFF OFF ON F5 OFF ON OFF OFF OFF ON F6 OFF OFF ON OFF OFF ON R1 OFF OFF OFF ON ON OFF R2 OFF OFF OFF ON OFF ON N OFF OFF OFF OFF OFF OFF 34 W E

36 Function wheel/4-wheel drive selector 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. This changes the drive mode from 4-wheel drive to 2-wheel drive. A switch is provided to detect the 4-wheel drive position. Output coupling (Rear) To rear axle To front axle Sleeve Shift fork Piston Air 4-wheel drive detection switch 35 W E

37 Function 2.9 Clutch 1. The clutch is composed of a clutch piston, drive plates and disks. The shaft supporting the clutches has internal passages for clutch operating oil and lubricating oil. 2. The disk 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 disks. 5. The clutch piston is equipped with a steel ball in the oil passage leading to the atmosphere to prevent an erroneous operation of the clutch. 6. 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 eventually engages the clutch, even when the valves do not direct oil to push the piston to engage the clutch. 7. The steel ball is designed to prevent this unwanted clutch engagement. The centrifugal force moves steel ball radially and makes the pinhole open, allowing the remaining oil in the oil chamber between the clutch drum and clutch piston to flow out to the atmosphere. Disc Drive plate Return spring To clutch piston Lubricating oil To clutch piston Back plate Clutch drum Clutch piston 36 W E

38 Function 2.10 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 converter housing via the line filter. 2. The oil adjusted to the predetermined MPa { kgf/cm 2 } 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 modulating valve of the control valve assy mounted on the transmission. 3. After flowing through the modulating valve, 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: 0.7 MPa {7 kgf/cm 2 }) 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 into the transmission. After lubricating the transmission clutches and bearings, etc., the oil returns to the oil tank. 37 W E

39 Function 2.11 Hydraulic circuit diagram Torque converter assy Torque converter inlet relief valve Main pressure regulating valve Line filter Charging pump Bypass drain Torque Torque converter drain drain Transmission assy Cooler Lock-up accumulator Forward-reverse selector valve assy Filter Lock-up valve PTO valve High/Low selector valve assy PTO clutch Filter Strainer Hydraulic circuit diagram Hydraulic clutch Hydraulic clutch Hydraulic clutch 38 W E

40 Troubleshooting Troubleshooting 1. Power cannot be transmitted. Engine Torque converter Transmission Fault area and cause Engine does not rotate normally. Hydraulic system Mechanical parts Hydraulic system Mechanical parts Insufficient oil Faulty charging pump Damaged piston or spring of inlet relief valve or main pressure regulating valve Damaged input plate Broken input plate mounting bolts Damaged shaft or gear Insufficient oil Faulty operation of spools in control valve assy (modulating valve, hydraulic 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 disks Correction 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. Check and replace. Repair or replace. Repair or replace. 39 W E

41 Troubleshooting 2. Power drops. (Speed cannot increase.) Engine Torque converter Transmission Fault area and cause Engine does not rotate normally. Hydraulic system Mechanical parts Insufficient oil Oil with air mixed to the charging pump. Clogged line filter Decreased charging pump delivery rate Damaged piston or spring of main pressure regulating valve Damaged piston or spring of inlet relief valve or main pressure regulating valve 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 damaged. Seized or damaged bearing. Insufficient oil Faulty operation of spools in control valve assy (modulating valve, hydraulic valve) Damaged seal ring Clogged strainer Use of wrong (unspecified) oil Oil with air mixed to the charging pump. Seized clutch Correction 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. Check and replace. Hydraulic system Clean or replace. Use specified oil. Inspect joints and gaskets. Mechanical parts Seized or damaged bearing 40 W E

42 Troubleshooting 3. Oil temperature rises abnormally. Torque converter Transmission Fault area and cause Excessive or insufficient oil Adjust oil quantity. Hydraulic Seized charging pump Check and replace. system Faulty oil cooler Repair or replace. Clogged line filter Clean or replace. Vane wheels touch each other. Check and replace. Mechanical Seized PTO clutch parts Seized or damaged bearing Excessive or insufficient oil Adjust oil quantity. Hydraulic Clogged hydraulic line Check and replace. system Clogged strainer Clean or replace. Mechanical Seized clutch parts Seized or damaged bearing Correction 4. Unusual noise is heard. Torque converter Transmission Fault area and cause Correction Hydraulic Faulty charging pump Check and replace. system Oil with air mixed to the charging pump. Inspect joints and gaskets. Damaged input plate Damaged gear or spline Mechanical Damaged bearing parts Vane wheels touch each other. Check and replace. Damaged damper spring in turbine wheel Hydraulic system Insufficient oil (cavitation) Supply oil. Damaged gear or spline Mechanical Damaged bearing parts Seized clutch Gear noise Low air pressure Increase air pressure by running engine. when Sleeve and gear (or spline) out of engagement Change selector switch again. 2-wheel/4-whe el drive Shift position not in neutral Set shift position to neutral. selector shifted Vehicle not completely stopped Stop vehicle completely. 41 W E

43 Troubleshooting 5. There exists drag torque. Transmission Fault area and cause Correction Faulty operation of check ball in clutch piston Check and replace. Faulty operation of spool in control valve assy Check and replace. Hydraulic (hydraulic valve) system Clogged drain line in solenoid valve or hydraulic Check and replace. valve Mechanical Seized clutch parts Damaged clutch return spring 6. Clutches do not properly work. Fault area and cause Damaged clutch seal ring Correction Transmission Hydraulic system Mechanical parts Faulty operation of check ball in clutch piston Clogged hydraulic circuits like modulating valve, hydraulic valve or solenoid valve, etc. Worn clutch drive plates and disks Check and replace. Check and clean. 7. Shocks are felt when clutches are changed. Fault area and cause Correction Transmission Hydraulic system Faulty operation of accumulator piston in control valve assy Faulty operation of modulating valve spool in control valve assy Check and replace. Check and replace. 8. Shift between 2-wheel and 4-wheel drives cannot be achieved. Transmission Fault area and cause Air cylinder Air leakage due to damaged piston packing Replace packing. Mechanical parts Damaged shifter fork Damaged shifter fork return spring Correction 42 W E

44 Troubleshooting 9. Shift between High and Low speeds cannot be achieved. Transmission Hydraulic system Mechanical parts Fault area and cause Insufficient oil Faulty operation of spools in High/Low selector valve assy 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 disks Supply oil. Check and replace. Repair or replace. Repair or replace. Correction 43 W E

45 Disassembly Disassembly 3. Remove input guide and O-ring. 1. Torque converter [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, and place them by order. インプットガイド Input guide OO-ring リング 1. Remove flange bolts (M10, 12 pcs.), and remove washers and input plate assy. IW J024 Washer ワッシャボルト Bolt インプット Input plate assy プレートAss'y 4. Remove seal ring from the end of turbine shaft, and remove snap ring fixing turbine shaft assy and remove washers and shim. ワッシャ Washer スナップリング Snap ring シールリング Seal ring シム Shim タービンシャフト Turbine shaft IW J029 IW J Remove flange 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. コンバータハウジング Converter housing ボルト Bolt カバー Cover Front cover Plug Plug IW J W E

46 Disassembly 6. Using a sling and eye bolts, pull out converter circuit and cover as a unit from housing. 吊りボルト Sling and eye bolt コンバータサーキット Converter circuit 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. 吊りボルト Sling and eye bolt Cover カバー OO-ring リング IW J Remove snap ring fixing PTO drive gear, and remove gears and cover. Remove O-ring from cover. Snap スナップリング ring O-ring Oリングギヤ Gear カバー Cover IW J Remove flange bolts (M8, 24 pcs.) fixing front cover to impeller assy. ボルト Bolt フロントカバー Front cover IW J 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. スラストニードル Thrust needle Thrust スラストワッシャ washer ベアリング bearing Thrust スラストワッシャ washer ワンウェイ One-way クラッチ clutch Snap スナップリング ring リテーナ retainer B B アウターレース Outer race ワンウェイクラッチ One-way clutch インナレース Inner race Stator ステータワンウェイ One-way Thrust クラッチ clutch washer スラストリテーナ retainer A A ワッシャ インペラ Impeller A'ssy assy Thrust スラスト needle ニードル bearing ベアリング IW J035 インペラ Impeller Ass'y assy IW J W E

47 Disassembly 11. Remove snap ring from the end of turbine hub, and pull turbine assy out of front cover assy. (If it is difficult to remove, carefully tap the end of turbine hub with a plastic hammer.) 14. Remove flange bolts (M10, 2pcs.), and remove charging pump and gasket. Gasket タービン Turbine assy A'ssy スナップリング Snap ring ボールベアリング Ball bearing Charging pump Bolt スナップリング Snap ring フロントカバー Front cover assy A'ssy IW J Remove bolts (M10, 2 pcs.) and spring washer, and remove solenoid valve assy and gasket. 12. Remove snap ring of front cover, and remove pressure plate, disc, piston and D-shaped rings from front cover. Spring washer Gasket スナップリング Snap ring プレッシャプレート Pressure plate Bolt Solenoid valve assy ディスク Disc ピストン Piston D-shaped Dリング ring フロントカバー Front cover IW J Remove bolt (M16, 1pc), washer and O-ring, and pull out flange. フランジ Flange OO-ring リング ボルト Bolt ワッシャ Washer IW J W E

48 Disassembly 16. Remove hexagon socket head bolts (M10, 8 pcs.), and remove adapter and O-ring. 19. Pull out turbine shaft, and remove the spacer. Bolt ボルトアダプタ Adapter Oリング O-ring タービンシャフト Turbine shaft スペーサ Spacer IW J Remove snap rings retaining PTO gears, and remove washer and gear. IW J027 Gear 17. Remove PTO clutch. (If it is difficult to remove, carefully tap the shaft end from inside housing.) Snap ring PTO クラッチ clutch Washer IW J Remove flange bolts (M10, 6 pcs.), pull out stator support. ステータサポート Stator support 21. Remove snap rings retaining PTO bearings and remove washer. Washer Bolt ボルト IW J029 Snap ring 47 W E

49 Disassembly 22. Pull out PTO shafts and bearings as a unit. (If it is difficult to remove, carefully tap the shaft end from inside housing.) 25. Remove snap ring holding back plate and piston. スナップリング Snap ring Back バックプレート plate Shaft Piston ピストン IW J Remove plug of each valve (2 places) and O-ring, and pull out pressure spring and piston. 26. Remove snap ring holding return spring with a special tool. スナップリング Snap ring プレッシャスプリング Pressure spring Piston ピストン プラグ Plug OO-ring リング Special 特殊治具 tool IW J034 IW J Remove snap ring, and pull out ball bearing, thrust washer, and PTO driven gear from PTO clutch. 27. Pull out back plate, discs, drive plates, washer, return spring, piston and seal ring. Back バックプレート plate Snap スナップリング ring Thrust スラストワッシャ washer PTO driven ドリブンギヤ gear Drive ドライブ plate プレート ディスク Disc Washer ワッシャ Return リターンspring スプリング Piston ピストン Ball bearing ボールベアリング IW J050 Seal シールリング ring IW J W E

50 Disassembly 28. Remove flange bolts (M8, 4 pcs.) from lock-up accumulator, and remove cover and gasket. Bolt ボルト Cover カバーガスケット Gasket IW J Pull out springs, stopper and piston. ピストン Piston スプリング Spring Stopper ストッパ IW J Remove solenoids from solenoid valve. Solenoid ソレノイド IW J W E

51 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, and place them by order. 4. Remove bolts (M10, 8pcs.) and spring washer, and remove 2-wheel/4-wheel drive selector cover on shaft using tapped extractor from housing. Remove gasket and springs (2pcs.). Spring washer Bolt Cover Gasket Shaft 2.1 Transmission assy 1. Remove bolt (M16, 1pc) and washer. Remove input flange and O-ring. ボルト Bolt Washer ワッシャ Oリング O-ring フランジ Flange Spring 5. Remove bolts (M10, 2pcs.) and spring washer, and remove cover from the top of 2-wheel/4-wheel drive selector air cylinder and O-ring. IW J Remove bolt (M16, 1pc) and washer. Remove output flange (front) and O-ring. Cover O-ring Bolt Spring washer フランジ Flange O-ring Oリング ボルト Bolt Washer ワッシャ 3. Unbend washer. Remove bolt (M16, 1pc) and washer. Remove output flange (rear) and O-ring. Washer O-ring Flange Bolt IW J35 6. Remove bolt (M8, 1pc) and washer inside air cylinder, and remove piston. ボルト Bolt Washer ワッシャピストン Piston 50 W E IW J061

52 Disassembly 7. Pull out shift fork, sleeve, and needle bearing, and remove O-ring. 10. Remove hexagon socket head bolts (M8, 6pcs.), and remove subplate and gasket from front cover. Sleeve Needle bearing ボルト Bolt ガスケット Gasket Shift fork O-ring サブプレート Subplate Front cover フロントカバー IW J Remove snap ring retaining bearing, and pull out shaft from each bearing. 11. Remove bolts (M8, 6pcs.) and spring washer, and remove solenoid valve assy (High-Low selector) and gasket from front housing. スナップリング Snap ring Solenoid valve assy Gasket シャフト Shaft Spring washer IW J Remove bolts (M8, 10pcs.) and spring washer, and remove solenoid valve assy (F-R speed selector) and gasket from front housing. Solenoid valve assy Bolt 12. Remove screw (M8) from speedometer case of output shaft (front), and pull out speedometer driven gear. Gasket Screw Speedometer driven gear Spring washer Bolt 51 W E

53 Disassembly 13. Remove bolts (M10, 4pcs.) and spring washer, and remove cover and gasket from housing. ガスケット Gasket カバー Cover ボルト Bolt 16. Remove snap rings that position shaft end bearings to housing cover. If it is difficult to remove, carefully tap shaft ends from behind housing. Spring スプリング washer ワッシャ スナップリング Snap ring G1 IW Pull out speedometer gear and steel ball. IW J091 スチールボール Steel ball 17. Remove bolts (M10, 15pcs.) and spring washer fixing housing cover. スピードメータギヤ Speedometer gear ハウジングカバー Housing cover IW J042 スプリングワッシャ Spring washer 15. Remove bolts (M10, 24pcs.), and remove front housing and gasket from housing cover. スプリングワッシャ Spring washer ボルト Bolt IW J44 Bolt ボルトフロントハウジング Front housing ガスケット Gasket 18. Using tapped extractor and a sling and eye bolts, remove housing cover and gasket from housing. Sling 吊りボルト and eye bolt ハウジングカバー Housing cover ガスケット Gasket ハウジング Housing IW J094 IW J W E

54 Disassembly 19. Pull out valve pistons, springs and stoppers from housing. Spring 22. Using a sling and eye bolts and a special tool, pull out hydraulic clutch (High/Low) assy and output shaft. Then, pull out hydraulic clutch (F2 5, R1 2) assy and hydraulic clutch (R3 6, F1 4) assy in this order. Valve piston Stopper 20. Remove flange bolts (M8, 3pcs.), and remove plate from shroud. Bolt ボルト Plate プレート Shroud シュラウド Hydraulic 油圧クラッチ clutch (High/Low) (High/Low) assy Ass'y 油圧クラッチ油圧クラッチ Hydraulic clutch (R3 6, Hydraulic clutch F1 4) assy (F2 5, R1 2) 5,R1 assy 2) (F3 6,F1 4) Ass'y Ass'y IW J Hydraulic clutch IW J Remove snap ring fixing ball bearing and housing, and pull out output shaft. [NOTICE] As the basic disassembling procedure is common to all hydraulic clutches, the following description on hydraulic clutch (F2 5, R1 2) assy can be applied to others. 出力軸 Output shaft IW J049 スナップリング Snap ring IW J W E

55 Disassembly 1. Remove seal rings (3 pcs.) from the shaft end, and remove snap ring and washer. Seal シールリング ring スナップリング Snap ring ワッシャ Washer ドライブプレート Drive plate Snap スナップリング ring Conical コニカルプレート plate Back バックプレート plate Disc ディスク IW J Using a puller, pull out ball bearing, and remove collar. Ball ボールベアリング bearing Collar カラー IW J Remove snap ring holding return spring with a special tool. Snap スナップリング ring IW J051 特殊治具 Special tool 3. In addition, pull out gear using a puller, and remove leaving thrust washer and snap ring. Gear ギヤ IW J086 Thrust スラストワッシャ washer Snap スナップリング ring IW J Using minus driver, remove snap ring holding back plate, and remove conical plate, back plate, discs and drive plates in this order. 6. Take out thrust washer, return spring, thrust washers and piston. スラストワッシャ Thrust washer リターンスプリング Return spring Thrust スラストワッシャ washer Piston ピストン IW J Disassemble the clutch on the other side in the same manner. 54 W E

56 Disassembly 2.3 Solenoid valve assy (High/Low selector) 1. Remove solenoid (1pc). ソレノイドバルブ Solenoid valve Ass'y assy Solenoid ソレノイド IW J Remove bolts (M8, 2pcs.) and spring washer, and remove valve body and gasket. Bolt ボルト Spring スプリングワッシャ washer Valve バルブボディ body Gasket ガスケット IW J Remove bolts (M6, 4pcs.) and spring washer, remove covers and gaskets, then pull out spool, springs and washers. ボルト Bolt スプリングワッシャ Spring washer Spring スプリング Washer ワッシャ スプリングワッシャ Spring washer スプール Spool ボルト Bolt ワッシャ Washer スプリング Spring Gasket ガスケット Cover カバー IW J Disassemble solenoid valve assy (front/rear selector) in the same manner. 55 W E

57 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 with clean oil and remove foreign material from them totally. Especially carefully clean oil grooves and oil passages. But it is not necessary to wash O-rings, D-shaped rings, oil seals, disks and gaskets. 2. Replace O-rings, D-shaped rings, oil seals and gaskets with new ones. 3. Torque converter inlet relief valve and the main pressure regulating valve are built in the housing. After cleaning them, apply genuine oil to them before installing them. 4. Tighten bolts to the specified torque. (Refer to 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 threadlockers 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. 1/3-1/2 of the space volume. 8. Adjust shim thickness at the turbine shaft end to keep a clearance of mm. 2. Transmission 1. Wash disassembled parts with clean oil and remove foreign material from them totally. Especially carefully clean oil grooves and oil passages. But it is not necessary to wash O-rings, D-shaped rings, oil seals, disks and gaskets. 2. Replace O-rings, D-shaped rings, oil seals and gaskets with new ones. 3. Wash parts (spools and pistons) of control valve that are built in the housing, and apply genuine oil to them before installing them. 4. Tighten bolts to the specified torque. (Refer to 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 threadlockers 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. 1/3-1/2 of the space volume. Pack the space between oil seals in tandem at the output flange with the grease to approx. 1/3 of the volume. 8. Before installing O-rings and U-shaped packing, 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. 9. At the end of reassembly operation, make sure that all sliding parts can move smoothly. 56 W E

58 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. 2. Shift the gear shift lever to 'N' and set the PTO to 'OFF'. With the engine running at idle (at approx. 700 rpm), gradually add oil. 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'. [NOTICE] Check the oil level when the oil temperature is approx. 50 C. Total oil quantity: Oil filler port (M30 x 1.5) approx. 25 L Recommended oils Manufacturer Brand name Mobil Mobil ATF Oil changing procedure 2.1 Draining oil [NOTICE] Drain oil from the torque converter turbine wheel after removing the plug on the side of the front cover assy. (Approx. 6 L) 1. Remove the drain plug at the bottom of the transmission and drain the oil from the transmission and torque converter. Oil level range 2.2 Oil filling [NOTICE] Pour oil carefully not allowing dusts, water, etc. to enter. Either insufficient or excessive oil may cause troubles. Drain plug (M24 x 1.5) Oil level gauge 1. While the engine does not run, remove the oil filler plug from the torque converter, and pour oil. (Approx. 6 L) 57 W E

59 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 1. Start the engine, and drive the torque converter at various speeds from low to high, and make sure that: No unusual noise No abnormal vibration No oil leakage [NOTICE] Set the transmission clutch to 'N' for a no load condition. 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 No oil leakage [NOTICE] When checking conditions, be sure to drive the tires in the 4-wheel drive mode. 3. Read the clutch pressure displayed on the multi-display device on the crane, and measure the torque converter inlet pressure and torque converter outlet pressure by pressure gauges connected to the torque converter inlet/outlet pressure check ports. 4. When measuring the individual clutch pressures, PTO clutch pressure and lubricating oil pressure, install 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. [NOTICE] When checking conditions, be sure to drive the tires in the 4-wheel drive mode. Standard pressure table Oil temperature for measurement: 70 to 80 C Item Torque converter inlet pressure Torque converter outlet pressure Clutch pressure Transmission lubricating oil pressure 3. Stall test Standard valve MPa {kgf/cm 2 } 700rpm 2500rpm 0.13 or higher {1.3 or higher} { } { } {3-7} {1.5-4} { } { } 2. Oil pressure measurement 1. Run the torque converter to raise the torque converter oil temperature to approx. 50 C. 2. Start the engine, and measure the clutch pressure, torque converter inlet pressure and torque converter outlet pressure at the idling speed (700 rpm) and at the maximum speed (2500 rpm) of the engine. Keep the gear shift lever at neutral (N). (When measuring the lock-up clutch pressure, keep it at 2nd or shift to 'D'.) 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 run it more than 30 seconds. And do not perform this test when the oil temperature is above 90 C. [NOTICE] Be sure to perform this test in the 4-wheel drive mode. 58 W E

60 Test 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: "3 rd " 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 GR-160N-1: approx min W E

61 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. Replace 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. Replacement interval of important parts Time Parts Oil seal O-ring Gasket Copper gasket Oil seal ring Seal ring race surface Sintered plate Stator freewheel Oil seal sliding surface Clutch piston sliding surface Bushing bore Bearings Spring At first overhaul Replace all parts. Inspect the condition At second overhaul and later Replace all parts at overhaul. Replace all parts at 2nd and 4th overhauls. Replace parts exceeding its wear limit. Replace parts exceeding its wear limit. Replace flat springs if defective. Replace parts exceeding its wear limit. 3. Part replacement standards Class Description Applicable parts Part name A B C D Parts that should be replaced with new ones whenever they are removed at overhauls, inspections and cleanings. Parts that tend to wear out relatively quickly, and need frequent replacement at overhauls 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. Gaskets Rubber parts Seal rings Clutch plates Bearings Race surface of seal rings Gears Shafts Gasket, O-ring, copper gasket, oil seal Oil seal ring, snap ring, fiber plate, steel plate Bearing, bushing, parts for freewheel set, seal race Various gears, clutch shaft, turbine shaft, flange 60 W E

62 Maintenance standards 3.1 Torque converter Check item Standard valve (mm) Use limit A B Clearance between torque converter inlet relief piston (2-60) and housing bore (A - B) Clearance between main pressure regulating IW J115 valve piston (2-63) and housing bore (A - B) A: Housing bore ID B: Piston OD Clearance between lock-up accumulator piston (2-72) and housing bore (A - B) A C B IW J116 A: Free length B: Installed length C: Spring force when installed Torque converter inlet relief valve spring (2-59) Main pressure regulating valve spring (large) (2-61) (small) (2-62) PTO clutch return spring (3-9) Accumulator spring (large) (2-73) (small) (2-74) Free length (A) Installed length (B) Force when installed (C) 141N {14.4kgf} 127N {13.0kgf} Free length (A) Installed length (B) Force when installed (C) 84N {8.6kgf} 76N {7.7kgf} Free length (A) Installed length (B) Force when installed (C) 0N {0kgf} 0N {0kgf} Free length (A) Installed length (B) Force when installed (C) 320N {32.7kgf} 288N {29.4kgf} Free length (A) Installed length (B) Force when installed (C) 137N {13.9kgf} 123N {12.5kgf} Free length (A) Installed length (B) Force when installed (C) 54N {5.5kgf} 48N {4.9kgf} PTO clutch disc (3-6) thickness A PTO clutch drive plate (3-5) thickness IW J119 A: Clearance for clutch disengagement Clearance for PTO clutch disengagement (A) Lock-up clutch disk (1-34) thickness W E

63 Maintenance standards Oil seal (mm) Impeller assy Check item Standard value Use limit Peripheral surface of impeller assy (1-1) that contacts oil seal (2-3) Output coupling Peripheral surface of output coupling (2-34) that contacts oil seal (2-40), (2-41) Seal ring (mm) Check item Standard value Use limit Teflon ring B A IW J117 C D IW A: Radial thickness B: Axial width C: Inside dia. D: Groove width At the input guide side end of turbine shaft At middle of turbine shaft At stator support Seal ring (2-14) Area of input guide (1-5) on which seal ring slides Groove width where seal ring is installed Seal ring (2-8) Area of stator support (2-9) on which seal ring slides Groove width where seal ring is installed Seal ring (2-18) Area of impeller assy (1-1) on which seal ring slides Radial thickness (A) Axial width (B) Inside dia. (C) Groove width (D) Radial thickness (A) Axial width (B) Inside dia. (C) Groove width (D) Radial thickness (A) Axial width (B) Inside dia. (C) Groove width where seal ring is installed Groove width (D) W E

64 Maintenance standards Check item At end of PTO clutch drive shaft Seal ring (3-19) Area of adapter (2-49) on which seal ring slides Groove width where seal ring is installed Radial thickness (A) Axial width (B) Inside dia. (C) Groove width (D) Standard value Use limit Teflon ring B A IW J117 At middle of PTO clutch drive shaft Seal ring (3-3) Area of PTO clutch piston (3-4) on which seal ring slides Radial thickness (A) Axial width (B) Inside dia. (C) C D IW A: Radial thickness B: Axial width C: Inside dia. D: Groove width At PTO clutch piston Groove width where seal ring is installed Seal ring (3-2) Area of shaft assy (3-1) on which seal ring slides Groove width where seal ring is installed Groove width (D) Radial thickness (A) Axial width (B) Inside dia. (C) Groove width (D) W E

65 Maintenance standards 3.2 Transmission (mm) Check item Standard value Use limit A Clearance between hydraulic valve (F1), (F2) spool (4-4) and valve body bore (A - C) B C IW J120 A: Housing bore ID B: Piston OD C: Spool OD Clearance between hydraulic valve (F3) spool (4-2) and valve body bore (A - C) Clearance between modulating valve spool (4-6) and valve body bore (A - C) Clearance between F1, F2, F3, R accumulator piston (4-12) and valve body bore (A - B) Clearance between hydraulic valve (High/Low) spool (5-5) and valve body bore (A - C) Clearance between High/Low accumulator piston (137) and housing bore (A - B) 2-wheel/4-wheel drive selector air cylinder return spring (large) (53) (small) (59) Free length (A) Installed length (B) Force when installed (C) 49N {5.0kgf} 44N {4.5kgf} Free length (A) Installed length (B) Force when installed (C) 98N {10kgf} 88N {9kgf} A C B IW J116 A: Free length B: Installed length C: Spring force when installed Hydraulic valve (F1), (F2) and (F3) spool return spring (4-5) Modulating valve spool return spring (large) (4-7) (small) (4-29) Free length (A) Installed length (B) Force when installed (C) 57N {5.8kgf} 51N {5.2kgf} Free length (A) Installed length (B) Force when installed (C) 31N {3.2kgf} 28N {2.8kgf} Free length (A) Installed length (B) Force when installed (C) 19N {1.9kgf} 17N {1.7kgf} 64 W E

66 Maintenance standards A C B IW J116 A: Free length B: Installed length C: Spring force when installed F1, F2, F3, R accumulator spring F1, F2, F3, R accumulator spring Check item (small) (4-15) (large) (4-14) Hydraulic valve (High/Low) spool return spring (5-7) High/Low accumulator spring (small) (136) (large) (135) Standard value Use limit Free length (A) (mm) Installed length (B) N 56N Force when installed (C) {6.3kgf} {5.7 kgf} Free length (A) Installed length (B) Force when installed (C) 124N {12.7kgf} 112N {11.4 kgf} Free length (A) Installed length (B) Force when installed (C) 29N {3.0kgf} 26N {2.7 kgf} Free length (A) Installed length (B) Force when installed (C) 49N {5.0kgf} 44N {4.5 kgf} Free length (A) Installed length (B) Force when installed (C) 63N {6.4kgf} 57N {5.8kgf} A IW J121 A: Clearance for clutch disengagement F1, F2, F3, R clutch High/Low clutch Disc (1-7), (2-7) thickness Drive plate (1-6), (2-6) thickness Clearance for disengagement (A) Disc (3-7) thickness Drive plate (3-6) thickness Clearance for disengagement (A) W E

67 Maintenance standards Clutch return spring A C B IW J116 A: Free length B: Installed length C: Spring force when installed Check item Standard value Use limit F1, F2, F3, R Free length (A) clutch return Installed length (B) spring (1-11), (2-11) 1157N 1042N Force when installed (C) {118kgf} {106kgf} High/Low clutch return spring (3-11) Free length (A) Installed length (B) Force when installed (C) 1863N {190kgf} (mm) 1677N {171kgf} Oil seal (mm) Check item Standard value Use limit Input coupling Peripheral surface of input coupling (11) that contacts oil seal (18), (149) Output coupling Peripheral surface of output coupling (16) that contacts oil seal (33), (34) (front wheel side, rear wheel side) Speedometer driven gear Peripheral surface of speedometer driven gear (76) that contacts oil seal (80) W E