sevice manaul tadano GR700E (PDF)

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					                                                                    Publication No.   W561-0101E




                   Service Manual
                   (Torque converter Transmission)
                                                             01
                                                     Torque converter
                                                     Transmission
                                                           RF80C-76F4
                                                     Model RF80M-77J0
                   W561-0101E




c
◯2006
PRINTED IN JAPAN
0612    E
                                                    Foreword


Foreword                                                                              WARNING
This repair manual gives the disassembly and                       Exposed parts of the torque converter and
reassembly procedures for torque converters and                   transmission can cause burns.
transmissions used in rough terrain cranes.                       Never touch until they are cooled down enough.
The models covered are listed below.
                                                                   Rotating parts of the torque converter and
Before starting to repair these units, check the model
                                                                  transmission can cause severe injury.
code given on the model plate on the unit.
                                                                  Keep away from rotating parts during operation.
Use this manual in conjunction with the relevant parts
catalog, service manual and other reference materials              Handling of manual locking device Use the
and make proper preparations.                                     manual locking device only when neither the
                                                                  MDT (multiplex data transmitter) system nor the
                                                                  emergency transmission switch is effective.
                                                                  Do not touch the manual locking device when the
1. Applicable crane model                                         engine is running.
The table below shows the relationship between the                The manual locking device is intended to
crane models, the models of torque converters, and                manually switch the solenoid valves mounted on
transmissions used.                                               the transmission.
                                                                  When once operate the manual locking device,
                                                                  always return it to original position.
                         Model                                    If the solenoid valve is left manually locked, the
     Crane         Torque converter      Transmission             vehicle will move as soon as the engine starts,
                                                                  leading to an injury.
 TR-600XXL-4
 TR-800XXL-4                                                       Eyes on the body cases of the torque converter
                      RF80C-76F4         RF80M-77J0
 GR-700EXL-1                                                      and transmission are provided to hang
 GR-550EX-1                                                       themselves only.
                                                                  Before lifting the torque converter or
[NOTICE]                                                          transmission, always remove the accessories
                                                                  including the pump, propeller shafts, flexible
  There is a case that the appearance and so on
                                                                  joints and motors from the main unit, otherwise
  differ from the parts for this crane. Although there is
                                                                  the eyes can be damaged due to excessive
  not so much difference in functions and                         loads, leading to an injury.
  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       W561-0101E
                                                                    Foreword


2. Contents                                                                           2.4    Control valve assy.....................................27
                                                                                      2.5    Forward-reverse selector valve assy ........27
                                                                                      2.6    Forward-reverse modulation .....................28
Foreword .................................................. 1                         2.7    Clutch line pressure diagram ....................29
                                                                                      2.8    Solenoid valves at various gear shift
1.    Applicable crane model ............................. 1                                     positions..............................................29
                                                                                      2.9    Lubricating oil flow control valve ...............29
2.    Contents .................................................... 2                 2.10   2-wheel/4-wheel drive selection................30
                                                                                      2.11   High/Low range selection..........................31
                                                                                      2.12   Clutch ........................................................32
Structure .................................................. 4                        2.13   Hydraulic system.......................................33
                                                                                      2.14   Hydraulic circuit diagram...........................34
1.    Torque converter ....................................... 4
     1.1   Torque converter sectional view................. 4
     1.2   Torque converter external view .................. 5                   Troubleshooting .....................................35
     1.3   Torque converter exploded view ................ 6                          1.Power cannot be transmitted. .........................35
     1.4   Converter circuit ......................................... 7              2.Power drops. (Speed cannot increase.)..........36
     1.5   Converter transmission .............................. 8                    3.Oil temperature rises abnormally. ...................37
     1.6   PTO clutch assy ......................................... 9                4.Unusual noise is heard....................................37
     1.7   Solenoid valve assy.................................. 10                   5.There exists drag torque. ................................38
     1.8   Tightening torque table............................. 11                    6.Clutches do not properly work. .......................38
                                                                                      7.Shocks are felt when clutches are changed. ..38
2.    Transmission ........................................... 12                     8.Shift between 2-wheel and 4-wheel drives
     2.1   Transmission sectional view..................... 12                                  cannot be achieved.............................38
     2.2   Transmission external view ...................... 13                       9.Shift between High and Low speeds
     2.3   Transmission assy.................................... 14                             cannot be achieved.............................39
     2.4   Hydraulic clutch assy (F2,R) .................... 18
     2.5   Hydraulic clutch assy (F3, F1).................. 19
     2.6   Solenoid valve assy                                                   Disassembly............................................40
               (F-R, speed selector) ......................... 20
     2.7   Tightening torque table............................. 21               1.    Torque converter ..................................... 40

                                                                                 2.    Transmission ........................................... 46
Function ................................................ 22                          2.1    Transmission assy ....................................46
                                                                                      2.2    Hydraulic clutch.........................................50
1.    Torque converter ..................................... 22                       2.3    Counter shaft ............................................52
     1.1   Torque converter ...................................... 22                 2.4    Output shaft ..............................................52
     1.2   Operating principle of power
              transmission by torque converter ....... 22
     1.3   PTO clutch................................................ 25         Reassembly.............................................53
     1.4   Lock-up system ........................................ 25
                                                                                 1.    Torque converter ..................................... 53
2.    Transmission ........................................... 26
     2.1   General..................................................... 26       2.    Transmission ........................................... 53
     2.2   Main pressure regulating valve ................ 26
     2.3   Torque converter inlet relief valve ............ 26


                                                                             2           W561-0101E
                                                                        Foreword


Oil              ................................................ 54

1.    Recommended oil.................................... 54

2.    Oil changing procedure............................ 54
     2.1   Draining oil (Installed state)...................... 54
     2.2   Oil filling .................................................... 54



Test             ................................................ 55

1.    Operational check.................................... 55

2.    Pressure measurement ........................... 55

3.    Stall test ................................................... 55



Maintenance standards ......................... 57

1.    Overhaul interval...................................... 57

2.    Replacement interval of important parts .. 57

3.    Part replacement standards..................... 57
     3.1   Torque converter ...................................... 58
     3.2   Transmission ............................................ 61




                                                                                 3   W561-0101E
                                      Structure


Structure
                                              This torque converter is a 3-element, 1-stage,
1. Torque converter                           2-phase unit, composed of an impeller vane wheel,
                                              a turbine vane wheel and a stator vane wheel.
1.1 Torque converter sectional view           The unit also incorporates a lock-up clutch.




                                          4       W561-0101E
                                     Structure

1.2 Torque converter external view




                                         5       W561-0101E
                                             Structure

1.3 Torque converter exploded view




1.Torque converter circuit    6.---              11.Flange bolt       24.Mark band
2.Torque converter            7.O-ring           12.Bolt              25.Mark band
  transmission assy           8.Gasket           13.Plug              26.Mark band
3.Hydraulic clutch assy       9.Name plate       22.Mark band         27.Clip
4.Solenoid valve assy        10.Rivet            23.Mark band         28.Bolt assy
5.Gear pump assy




                                                 6       W561-0101E
                                               Structure

1.4 Converter circuit




 1.Impeller assy        10.Clutch retainer B       19.Snap ring               28.D-shaped ring
 2.Turbine assy         11.Inner race              20.Snap ring               29.Flange bolt
 3.Wheel stator         12.Piston                  21.Thrust needle bearing   30.Flange bolt
 4.Front cover assy     13.Pressure plate          22.Support                 31.Plug
 5.Input guide          14.Washer                  23.Snap ring               32.Disc assy
 6.Input plate          15.Ball bearing            24.O-ring                  33.Snap ring
 7.Outer race           16.Ball bearing            25.O-ring                  34.Thrust washer
 8.One-way clutch       17.Thrust needle bearing   26.O-ring                  35.Thrust washer
 9.Clutch retainer A    18.Thrust washer           27.D-shaped ring           36.Plain washer



                                                   7       W561-0101E
                                          Structure

1.5 Converter transmission




 1.Housing              19.Ball bearing       37.Oil seal          55.Parallel pin
 2.Cover                20.Ball bearing       38.Snap ring         56.Temperature sensor
 3.Oil seal             21.Snap ring          39.Washer            57.Magnetic plug
 4.Cover                22.Snap ring          40.Shim              58.Washer bolt
 5.Gasket               23.Washer             41.Shim              59.Flange bolt
 6.Gear (N)             24.---                42.O-ring            60.Flange bolt
 7.Snap ring            25.---                43.Valve piston      61.Bolt
 8.Turbine shaft        26.Washer             44.Spring            62.Bolt
 9.Stator support       27.Snap ring          45.Spring            63.---
10.Ball bearing         28.Ball bearing       46.Spring            64.Plug
11.Seal ring            29.Ball bearing       47.Stopper           65.Bolt
12.Seal ring            30.Washer             48.Cover             66.Gear (M)
13.Seal ring            31.Snap ring          49.Gasket            67.Spacer (C)
14.Shaft                32.Flange             50.Plug
15.Gear (Q)             33.O-ring             51.O-ring
16.Shaft (S)            34.Washer             52.Cover
17.Shaft (C)            35.Bolt               53.Coin filter
18.Washer               36.Oil seal           54.Spacer

                                              8       W561-0101E
                                      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              10.Washer           16.Ball bearing
5.Drive plate         11.Snap ring        17.Ball bearing
6.Disc assy           12.Gear (p)         18.Snap ring


                                          9       W561-0101E
                                     Structure

1.7 Solenoid valve assy




1.Body                    2.Gasket        3.Solenoid valve    4.Choke




                                        10       W561-0101E
                                          Structure

1.8 Tightening torque table

                                                           Tightening torque
            Part
                              Part name            Standard             Maximum limit
            No.
                                               N・m            ft-lbf     N・m       ft-lbf
           1.3-11   Flange bolt                    58         42.8        74       54.6
           1.3-12   Bolt                           58         42.8        74       54.6
           1.3-13   Plug                          13           9.6        17       12.5
           1.4-29   Flange bolt                   31          22.9        37       27.3
           1.4-30   Flange bolt                   58          42.8        74       54.6
           1.4-31   Plug                           8           5.9        12        8.9
           1.5-35   Bolt                          177       130.6        236      174.1
           1.5-50   Plug                          93          68.6       123       90.7
           1.5-56   Temperature sensor             31         22.9        37       27.3
           1.5-57   Magnetic plug              58.5           43.1       78.5      57.9
           1.5-58   Bolt with washer              10           7.4        13        9.6
           1.5-59   Flange bolt                   31          22.9        37       27.3
           1.5-60   Flange bolt                   58          42.8        74       54.6
           1.5-61   Bolt                           58         42.8        74       54.6
           1.5-62   Bolt                           58         42.8        74       54.6
           1.5-64   Plug                           8           5.9        12        8.9
           1.5-65   Bolt                           31         22.9        37       27.3
            1.7-3   Solenoid valve body            18         13.3        23            17
            1.7-4   Choke                          7           5.2        10        7.4




                                             11         W561-0101E
                                  Structure


2. Transmission

2.1 Transmission sectional view




                                     12       W561-0101E
                                 Structure

2.2 Transmission external view




                                    13       W561-0101E
                        Structure

2.3 Transmission assy




                           14       W561-0101E
Structure




   15       W561-0101E
Structure




   16       W561-0101E
                                                         Structure

 1.Hydraulic clutch assy (F2,R)    50.Spring                      99.---                         148.---
 2.Hydraulic clutch assy (F3,F1)   51.Shift bar                   100.Pressure spring            149.---
 3.Control valve assy              52.Shift fork                  101.---                        150.---
 4.Transmission housing            53.Spring pin                  102.Plug                       151.Snap ring
 5.Gasket                          54.Washer                      103.---                        152.Choke
 6.Housing cover                   55.Cover                       104.Breather                   153.Gear (H)
 7.Gasket                          56.O-ring                      105.Coin filter                154.Gear (G)
 8.Front housing                   57.Piston                      106.---                        155.Washer
 9.Shaft assy                      58.O-ring                      107.Rivet                      156.Ball bearing
10.---                             59.Collar                      108.Bracket                    157.Washer
11.Flange (input coupling)         60.U packing                   109.---                        158.Retaining ring
12.Output shaft                    61.Bolt                        110.Shroud                     159.Roller bearing
13.Gear (K)                        62.Washer                      111.Joint (elbow)              160.Thrust washer
14.Gear (U)                        63.O-ring                      112.O-ring                     161.Retaining ring
15.Shaft                           64.Cover                       113.Pressure sensor            162.Ball bearing
16.Flange (output coupling)        65.Gasket                      114.O-ring                     163.Washer
17.Sleeve (B)                      66.Speedometer gear            115.O-ring                     164.Snap ring
18.Oil seal                        67.Ball                        116.Gasket                     165.Gear (I)
19.Oil seal                        68.Snap ring                   117.Bolt                       166.Ball bearing
20.O-ring                          69.Ball bearing                118.Bolt                       167.Snap ring
21.Washer                          70.Snap ring                   119.Bolt                       168.Sleeve (A)
22.Bolt                            71.Speedometer driven gear     120.Bolt                       169.Shift fork
23.Parallel pin                    72.Speedometer bushing         121.Bolt                       170. Shift bar
24.Gear (W)                        73.O-ring                      122.Bolt                       171. Bolt
25.Shaft                           74.Hexagon socket set screw    123.Bolt                       172. Nut
26.Speedometer case                75.Oil seal                    124.Bolt                       173.Wire
27.Gasket                          76.Strainer assy               125.Flange bolt                174.Adapter
28.Cover                           77.Gasket                      126.Flange bolt                175.O-ring
29.Gasket                          78.Flange                      127.Hexagon socket head bolt   176.---
30.Cover                           79.Oil gauge                   128.Hexagon socket head bolt   177.Spring
31.Gasket                          80.Pipe                        129.Hexagon socket head bolt   178.Cover
32.Cover                           81.Plug                        130.Hexagon socket head bolt   179.Coller
33.Oil seal                        82.O-ring                      131.Nut                        180.Seal washer
34.Oil seal                        83.Piston                      132.Plug                       181.Bolt
35.Cover (D)                       84.Pressure spring             133.Plug                       182.Spacer
36.Gasket (D)                      85.Pressure spring             134.Plug                       183.Cover
37.Ball bearing                    86.Piston                      135.Plug                       184.O-ring
38.Ball bearing                    87.pressure spring             136.---                        185.Bolt
39.Switch                          88.Valve piston                137.Mark band                  186.Ball bearing
40.Seal washer                     89.Spring                      138.Mark band                  187.Bolt
41.Sencer                          90.Spring                      139.Mark band                  188.Switch
42.Snap ring                       91.Spring                      140.Mark band                  189.Bolt
43.Snap ring                       92.Stopper                     141.Mark band
44.Needle bearing                  93.---                         142.Mark band
45.Shroud (A)                      94.---                         143.Mark band
46.Plate                           95.---                         144.Mark band
47.Ball bearing                    96.---                         145.---
48.Spacer                          97.---                         146.---
49.Spring                          98.---                         147.---


                                                                 17       W561-0101E
                                            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 assy             14.Ball bearing        22.Seal ring
 7.Back plate            15.Snap ring           23.Spacer (B)
 8. Conical plate        16.Gear (C)            24.Thrust washer


                                               18       W561-0101E
                                             Structure

2.5Hydraulic clutch assy (F3, F1)




1.Shaft assy             8.Conical plate         15.---               22.Ball bearing
2.Seal ring              9.Snap ring             16.Gear (D)          23.Seal ring
3.Piston assy            10.Thrust washer        17.---               24.Thrust washer
4.Seal ring              11.Spring               18.---               25.Snap ring
5.Drive plate            12.Snap ring            19.Ball bearing      26.Coller
6.Disc assy              13.Gear (F)             20.Washer            27.Thrust bearing
7.Back plate             14.Needle bearing       21.Snap ring


                                                19       W561-0101E
                                           Structure

2.6 Solenoid valve assy (F-R, speed selector)




 1.Valve body              6.Gasket (A)          11.Solenoid valve assy   16.Gasket (D)
 2.Range selector valve    7.Cover (B)           12.Clip                  17.Coin filter
 3.Speed selector valve    8.Gasket (B)          13.Washer
 4.Pressure spring         9.Cover (C)           14.Bolt
 5.Cover (A)              10.Gasket (C)          15.Bolt




                                                20       W561-0101E
                                                Structure

2.7 Tightening torque table

                                                             Tightening torque
            Part
                              Part name              Standard             Maximum limit
            No.
                                                   N・m          ft-lbf    N・m        ft-lbf
           2.3-22    Bolt                          183          135        236      174.1
           2.3-39    Switch                         21          15.5        25       18.4
           2.3-41    Sensor                         29          21.4        49       36.1
           2.3-61    Bolt                           16          11.8        20       14.8
           2.3-74    Hexagon socket set screw        7           5.2        10        7.4
           2.3-79    Oil gauge                       9           6.6        11        8.1
           2.3-81    Plug                           59          43.5        78       57.5
           2.3-102 Plug                             59          43.5        78       57.5
           2.3-104 Breather                         7.4          5.5        10        7.4
           2.3-113   Pressure sensor               16.7         12.3       24.5      18.1
           2.3-117   Bolt                           31          22.9        37       27.3
           2.3-118   Bolt                           31          22.9        37       27.3
           2.3-119   Bolt                           58          42.8        74       54.6
           2.3-120 Bolt                             58          42.8        74       54.6
           2.3-121 Bolt                             58          42.8        74       54.6
           2.3-122 Bolt                             58          42.8        74       54.6
           2.3-123 Bolt                             58          42.8        74       54.6
           2.3-124 Bolt                             58          42.8        74       54.6
           2.3-125 Flange bolt                      31          22.9        37       27.3
           2.3-126 Flange bolt                      31          22.9        37       27.3
           2.3-127 Hexagon socket head bolt         31          22.9        37       27.3
           2.3-128 Hexagon socket head bolt         31          22.9        37       27.3
           2.3-129 Hexagon socket head bolt         58          42.8        74       54.6
           2.3-130 Hexagon socket head bolt         58          42.8        74       54.6
           2.3-132 Plug                              8           5.9        12        8.9
           2.3-133 Plug                             13           9.6        17       12.5
           2.3-134 Plug                            20.5         15.1       28.5           21
           2.3-152 Choke                             7           5.2        10        7.4
           2.8-14    Bolt                           31          22.9        35       25.8
           2.8-15    Bolt                           12           8.9        15       11.1




                                                   21       W561-0101E
                                                   Function


Function                                                       1.2 Operating principle of power transmission by
                                                                         torque converter
1. Torque converter
                                                                1. The fluid clutch that transmits power by means of
1.1 Torque converter                                              fluid is classified into two major categories.

 1. The periphery of the impeller wheel is connected            2. One is the fluid coupling, and the other is the
   to the engine flywheel through the front cover,                 torque converter. They consist of the following
   input guide and input plate. The inner bore of the              main components as shown below.
   impeller wheel is supported by the ball bearing on
   the stator support assy.                                       Torque converter                  Fluid coupling

 2. Usually the driving power from the engine is
   transmitted to the impeller wheel, then to the
                                                                    T             P                T              P
   turbine wheel by using torque converter oil as a
   medium. But when the lock-up conditions are met
                                                                           S
   and the lock-up clutch is engaged, the lock-up
                                                                                                         IW561-0031J017E
   clutch directly transmits the power from the front
   cover to the turbine wheel assy without the help of
                                                                  P: Pump (impeller) wheel
   torque converter oil.
                                                                  T: Turbine wheel
 3. The turbine wheel assy is connected to one end of             S: Stator wheel
    the turbine shaft by their splines. There is a gear
                                                                3. The fluid coupling consists only of a pump
    on the other end of the turbine shaft. The gear is
                                                                  (impeller) and a turbine, and it transmits rotational
    in mesh with the output gear, transmitting power
                                                                  motion just like a windmill placed in front of an
    to the flange splined to the output shaft after
                                                                  electric fan.
    one-stage speed reduction.
                                                                4. When the pump (impeller) is driven by an engine,
 4. The stator wheel is supported through the
                                                                   the fluid (oil) starts to rotate around the shaft, and
   freewheel (one way clutch) with the stator support.
                                                                   is driven outward by the centrifugal force.
   The flange of the stator support is fixed on the
   converter housing with bolts.                                5. As the pump (impeller) has radial vanes, oil flows
                                                                  out from the periphery of the vanes and flows into
 5. The stator wheel adds reaction torque, which is
                                                                  the periphery of the turbine placed face-to-face
   generated when torque converter oil returns from
                                                                  with the pump (impeller).
   the turbine wheel assy to the impeller wheel, to
   the turbine torque, thus increasing the turbine              6. The oil flows towards the center of the turbine
   torque compared to the input torque.                           along the turbine blades while transmitting
                                                                  rotational force to the turbine. The oil eventually
 6. The stator wheel can free wheel when the speed
                                                                  returns to the center of the pump (impeller).
    ratio between the impeller wheel and the turbine
    wheel is high. Although this cannot increase                                        Rotating flow
    torque, high transmission efficiency can be
    achieved.




                                                                Pump (impeller)                                 Turbine
                                                                                           Vortex flow
                                                                                                            IW561-0031J018E




                                                          22        W561-0101E
                                                    Function


7. In this way, firstly the rotating flow around the          10.As a measure to improve the transmission
   shaft is generated by the rotating pump (impeller),          efficiency under heavy loads, the torque converter
   and secondly the resulting centrifugal force                 is invented by placing a stator wheel between the
   induces vortex flow circulating between the pump             turbine outlet and the pump (impeller) inlet.
   (impeller) and turbine.
                                                              11.In the fluid coupling, the returning oil from the
8. The fluid coupling has to continuously use oil as            turbine to the pump (impeller) flows in the
  the transmission medium within a sealed space.                direction to retard the pump rotation at the
                                                                impeller vane inlet.
9. When the speed difference between the pump
  (impeller) and turbine is large under heavily               12.On the other hand, in case of the torque
  loaded conditions like startup or hill climbing, the          converter, the returning oil is redirected by the
  transmission efficiency is low and large input                stator wheel to the direction to push the impeller
  torque from the pump (impeller) is required to                blades forward. This results in improved
  drive the turbine.                                            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.
                                                                                                  IW561-0031J019




                                                         23       W561-0101E
                                                      Function


13.The stator can either freewheel or be locked                  17.With the one-way clutch, the stator wheel is
  according to the direction of the discharged oil                   locked in one direction to get amplified torque.
  flow from the turbine outlet, thus improving the                   And in the opposite direction, it can freewheel to
  torque converter efficiency.                                       make the torque converter work as a fluid
                                                                     coupling under light load conditions.
14.Under light load conditions like when cruising at
  high speed, the speed difference between the                              Stator locked
  impeller and turbine is small.                                                            Stator
                                                                                            freewheeling
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.                     Stator locked                       Stator freewheeling
                                                                                                                  IW561-0031J021E

16.In this condition, the stator blades greatly disturb
  the smooth oil flow and drop the efficiency. To
                                                                 18.As described above, the relationship among
  prevent this unfavorable condition, a one-way
                                                                     efficiency, torque ratio and speed ratio can be
  clutch is provided to the stator wheel of the torque
                                                                     illustrated as below.
  converter so that the stator wheel can freely rotate
  when the stator blades are pushed from the back
  by oil flow.

                                                                                      Clutch point
                                  Works as converter                                      Works as fluid coupling
                                                     Stator locked
                                                                                      Stator freewheeling
                                       5                                                     100


                        Torque ratio
                                       4                                                     80



                                       3                                                     60
                                                                                                  Efficiency
                              Torque                                                                     %
                                       2                                                     40


                    Pump torque
                                       1                                                     20
        Torque converter range
                 Coupling range
                                       0       0.2         0.4        0.6       0.8         1.0

                                                          Speed ratio
                                                                                                      IW561-0031J022E




                                                           24         W561-0101E
                                                  Function


 19.When the speed ratio is low, the stator wheel is          2. When the lock-up conditions are met, the external
   locked and amplifies torque. So the efficiency               control unit (MDT) sends a signal to energize the
   rises as the speed ratio becomes higher with its             solenoid valve, making pressure oil from the
   peak at the speed ratio around 0.6. After that the           charging pump lead to the lock-up clutch and the
   efficiency starts to drop.                                   accumulator.

 20.Once the speed ratio reaches the clutch point,            3.The accumulator causes the lock-up clutch
   the stator wheel starts to freewheel without                 pressure to rise gradually in order to lessen
   amplifying torque as now it functions as a fluid             shocks at locking up.
   coupling. And the efficiency starts to increase
                                                              4. When the lock-up clutch is provided with pressure
   linearly with the speed ratio.
                                                                 oil, the power from the engine is transmitted
 21.The functioning ranges such as torque converter              directly to the turbine shaft without passing
   range and fluid coupling range are called 'phases'.           through the torque converter. This can improve
   The number of turbine wheels is counted by                    the transmission efficiency and fuel consumption
   'stages', and each kind of vane wheel is called an            rate.
   'element'.
                                                              5. The pickup sensor built in the transmission
 22.Then the torque converter explained in this                 housing detects the rotational speed of the pickup
   document is a three-elements, single stage,                  sensor gear, corresponding to the vehicle speed,
   two-phases type.                                             and sends it to the external control unit (MDT).

                                                                                       Pickup sensor
1.3 PTO clutch

 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 disks securely contact one another.
   This makes the PTO engaged.



                                                                         Pickup sensor gear     IW561-0031J027E



                                                              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.




                                                         25       W561-0101E
                                                   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 Hifg/Low
   ranges), etc.

 2. There are four multi-plate clutches, namely
   Forward 1st (F1), Forward 2nd (F2), Forward 3rd
   (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
                                                               2.2 Main pressure regulating valve
    transmitted by the gear train listed below. The
    output shaft at the rear of the vehicle is equipped         1. This valve adjusts the pressure of the oil delivered
    with a 2-wheel/4-wheel drive selection and High/              from the charging pump to the constant
    Low range selection.                                          predetermined pressure 2.1 - 2.45 MPa {304.5 –
                                                                  355.3 psi}, and supplies the oil to the PTO clutch,
             High/Low                                             lock-up clutch and transmission control valve.
   Clutch                     Gear combination
             selection
  Forward                                                      2.3 Torque converter inlet relief valve
    1st                  G2, G5, G6, G9, G10, G12
  Forward                                                       1. This valve prevents the pressure inside the torque
    2nd                  G1, G4, G7, G10, G12
                High                                              converter from exceeding the specified pressure
  Forward
                         G2, G5, G4, G7, G10, G12                 0.7 MPa {101.5psi}.
    3rd
  Reverse                G3, G9, G10, G12
  Forward
    1st                  G2, G5, G6, G9, G8, G11
  Forward
    2nd                  G1, G4, G7, G8, G11
                Low
  Forward
    3rd                  G2, G5, G4, G7, G8, G11
  Reverse                G3, G9, G8, G11




                                                          26        W561-0101E
                                                      Function

2.4 Control valve assy

 1. 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.




2.5 Forward-reverse selector valve assy

 1. This valve controls the forward 1st (F1) clutch,
    forward 2nd (F2) clutch, Forward 3rd (F3) and
    reverse (R) clutch. It consists of four solenoid
    valves (F1), (F2), (F3) and (R), a accumulator to
    reduce shocks at clutch engagement, hydraulic
    valves(F1), (F2), and (F3).

 2. Pressure oil from the charging pump flows
   through the orifice into the hydraulic valve(F3).

 3. When the gear shift position is in neutral, the
   pressure oil flows through the hydraulic valve (F3)
   and then through the hydraulic valve (F1), (F2)and
   then flows into the solenoid valve (R).


                                                         27      W561-0101E
                                                 Function


4. The pressure oil also flows into the accumulator to        2.6 Forward-reverse modulation
   charge the accumulator built in the transmission.
                                                               1. When the gear shift position is in neutral, pressure
                                         rd
5. When the gear shift position is at the 3 speed,               oil from the charging pump flows through the
  the solenoid valve (F3) is energized. The pressure             orifice into the hydraulic valve (F1) (F2)and (F3),
  oil flows through into the hydraulic valve (F3), and           and then flows into the solenoid valve (R).
  pushes the spool of hydraulic valve (F3) toward
                                                               2. Pressure oil also flows into the accumulator.
  the left, and then flows into the clutch (F3).
                                                                  Then the accumulator can remain
                                                                  pressure-accumulated.

                                                               3. At the moment when the solenoid valve (F3) is
                                                                 energized and switched, pressure oil flows into
                                                                 the hydraulic valve (F3), the spool in the hydraulic
                                                                 valve (F3) shifts left, causing pressure oil to flow in
                                                                 the circuit among the hydraulic valve and the
                                                                 clutch (F3). This makes the pressure drop.

                                                               4. This allows the oil accumulated in the accumulator
                                                                 to be discharged and supplied to the clutch (F3).
                                                                 This additional pressure oil flow to the clutch
                                                                 compensates for the delay in clutch engagement.

                                                               5. 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.

                                                               6. 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.

                                                               7. When the accumulator is fully charged, the clutch
                                                                 line pressure reaches the predetermined pressure
                                                                 and the pressure becomes the same everywhere
                                                                 in the circuit.




                                                         28        W561-0101E
                                                       Function

2.7 Clutch line pressure diagram                                  2.9 Lubricating oil flow control valve

   The diagram below shows the clutch line pressure                1. This valve regulates the pressure oil flowing from
   rising process.                                                   the cooler to a predetermined pressure 0.08 - 0.15
                                                                     MPa {11.6 – 21.8 psi} before supplying it to
                        1             2            3                 clutches and bearings.

                                                                                       Piston
                                                                                                  From oil cooler
  Oil
  pressure




                                                                          Lubricating valve section
                                                                                                        IW561-0081E014

                                   Time
                                           IW561-0031J040E



  1: Immediately after solenoid switching
  2: Clutch in half-clutch state
  3: Clutch fully engaged

2.8 Solenoid valves at various gear shift
          positions

         SOL     SOL     SOL       SOL    SOL     SOL
          F1      F2      F3        R     Low      Hi
  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




                                                             29        W561-0101E
                                                    Function

2.10 2-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 2-wheel drive to 4-wheel
    drive. A switch is provided to detect the 4-wheel
    drive position.




                                                        30     W561-0101E
                                                    Function

2.11 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.




                                                        31     W561-0101E
                                                    Function

2.12 Clutch
                                                             6. The clutch piston is equipped with a steel ball in
 1. The clutch is composed of a clutch piston, drive           the oil passage leading to the atmosphere to
   plates and disks. The shaft supporting the                  prevent an erroneous operation of the clutch.
   clutches has internal passages for clutch
   operating oil and lubricating oil.                        7. As the clutch drum and clutch piston rotates at
                                                               high speed, the oil remaining between the clutch
 2. The disk has a paper type surface for better wear          drum and piston is pressurized by centrifugal
    resistance and improved smoothness at the time             force and could push the clutch piston and
    of engagement. The drive plate is made of                  eventually engages the clutch, even when the
    special steel for durability, wear resistance and          valves do not direct oil to push the piston to
    secure engagement.                                         engage the clutch.

 3. The pressure oil from the hydraulic valve enters         8. The steel ball is designed to prevent this
   the shaft from its end and flows through the                 unwanted clutch engagement. The centrifugal
   internal passage to the space between the clutch             force moves steel ball radially and makes the
   drum and the clutch piston.                                  pinhole open, allowing the remaining oil in the oil
                                                                chamber between the clutch drum and clutch
 4. The pressure oil pushes the clutch piston against
                                                                piston to flow out to the atmosphere.
   the return spring force to firmly engage the drive
   plates and disks.

 5. Therefore, the torque of clutch shaft assy is
    transmitted to the deceleration gear.




                                                        32       W561-0101E
                                                     Function

2.13 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 2.1 - 2.45
    MPa {304.5 – 355.3psi} 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: 0.7 MPa {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: 0.08 - 0.15 MPa {11.6 –
    21.8psi}) 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.




                                                            33   W561-0101E
                                 Function

2.14 Hydraulic circuit diagram




                                    34      W561-0101E
                                                           Troubleshooting


Troubleshooting
1. Power cannot be transmitted.

                                       Fault area and cause                                            Correction
                                                                                      Measure the engine speed with the
                                                                                      transmission shifted to neutral and under
Engine




                   Engine does not rotate normally.                                   a stall condition. If the speed is not
                                                                                      within the specified limits, adjust or repair
                                                                                      the engine.
                                  Insufficient oil                                    Supply oil.
Torque converter




                   Hydraulic
                   system         Faulty charging pump                                Repair or replace.
                                  Damaged input plate                                 Replace.
                   Mechanical
                                  Broken input plate mounting bolts                   Replace.
                   parts
                                  Damaged shaft or gear                               Replace.
                                  Insufficient oil                                    Supply oil.
                                  Damaged piston or spring of inlet relief valve or
                                                                                      Replace.
                                  main pressure regulating valve
                   Hydraulic
                                  Faulty operation of spools in control valve assy
                   system                                                             Check and replace.
                                  (hydraulic valve)
Transmission




                                  Faulty operation of solenoid valve                  Repair or replace.
                                  Damaged seal ring                                   Replace.
                                  Damaged shaft or gear                               Replace.
                                  Damaged spline                                      Repair or replace.
                   Mechanical
                                  Damaged clutch drum                                 Replace.
                   parts
                                  Damaged snap ring for back plate                    Replace.
                                  Damaged clutch drive plates or disks                Replace.




                                                                       35      W561-0101E
                                                          Troubleshooting


2. Power drops. (Speed cannot increase.)
                                       Fault area and cause                                           Correction
                                                                                      Measure the engine speed with the
                                                                                      transmission shifted to neutral and
Engine




                   Engine does not rotate normally.                                   under a stall condition. If the speed is
                                                                                      not within the specified limits, adjust or
                                                                                      repair the engine.
                                  Insufficient oil                                    Supply oil.
                                  Oil with air mixed in it entered charging pump.     Inspect joints and gaskets.
                                  Clogged line filter                                 Clean or replace.
                   Hydraulic      Decreased charging pump delivery rate               Check and replace.
Torque converter




                   system         Faulty operation of solenoid valve for lock-up
                                                                                      Check and replace.
                                  clutch
                                  Damaged seal ring or O-ring                         Replace.
                                  Use of wrong (unspecified) oil                      Use specified oil.
                                  Vane wheels are damaged or interfering with
                                                                                      Check and replace.
                                  each other.
                   Machanical
                                  One-way clutch is faulty.                           Replace
                   parts
                                  Lock-up clutch disc is worn or damage.              Replace
                                  Bearing is binding or damaged.                      Replace
                                  Insufficient oil                                    Supply oil.
                                  Damaged piston or spring of main pressure
                                                                                      Replace.
                                  regulating valve
                                  Damaged piston or spring of inlet relief valve or
                                                                                      Replace.
                                  main pressure regulating valve
Transmission




                   Hydraulic      Faulty operation of spools in control valve assy
                   system                                                             Check and replace.
                                  (hydraulic valve)
                                  Damaged seal ring                                   Replace.
                                  Clogged strainer                                    Clean or replace.
                                  Use of wrong (unspecified) oil                      Use specified oil.
                                  Oil with air mixed in it entered charging pump.     Inspect joints and gaskets.
                   Mechanical     Seized clutch                                       Replace.
                   parts          Seized or damaged bearing                           Replace.




                                                                     36        W561-0101E
                                                                   Troubleshooting


3. Oil temperature rises abnormally.
                                            Fault area and cause                                           Correction
                                       Excessive or insufficient oil                      Adjust oil quantity.
Torque converter




                   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                                  Replace.
                   parts
                                       Seized or damaged bearing                          Replace.
                                       Excessive or insufficient oil                      Adjust oil quantity.
                                       Clogged hydraulic line                             Check and replace.
Transmission




                   Hydraulic
                   system              Damaged lubricating oil flow control valve
                                                                                          Replace.
                                       (damaged spring)
                                       Clogged strainer                                   Clean or replace.
                   Mechanical          Seized clutch                                      Replace.
                   parts               Seized or damaged bearing                          Replace.


4. Unusual noise is heard.

                                            Fault area and cause                                           Correction
                   Hydraulic            Faulty charging pump                              Check and replace.
Torque converter




                   system               Oil with air mixed in it entered charging pump.   Inspect joints and gaskets.
                                        Damaged input plate                               Replace.
                                        Damaged gear or spline                            Replace.
                   Mechanical
                                        Damaged bearing                                   Replace.
                   parts
                                        Vane wheels touch each other.                     Check and replace.
                                        Damaged damper spring in turbine wheel            Replace.
                   Hydraulic
                                        Insufficient oil (cavitation)                     Supply oil.
                   system
                                        Damaged gear or spline                            Replace.
Transmission




                   Mechanical
                                        Damaged bearing                                   Replace.
                   parts
                                        Seized clutch                                     Replace.
                   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 selector    Shift position not in neutral                     Set shift position to neutral.
                   shifted              Vehicle not completely stopped                    Stop vehicle completely.




                                                                           37       W561-0101E
                                                         Troubleshooting


5. There exists drag torque.

                                    Fault area and cause                                          Correction
                                Faulty operation of check ball in clutch piston     Check and replace.
                                Faulty operation of spool in control valve ass'y
 Transmission




                 Hydraulic                                                          Check and replace.
                                (hydraulic valve)
                 system
                                Clogged drain line in solenoid valve or hydraulic
                                                                                    Check and replace.
                                valve
                 Mechanical     Seized clutch                                       Replace.
                 parts          Damaged clutch return spring                        Replace.


6. Clutches do not properly work.

                                    Fault area and cause                                          Correction
                                Damaged clutch seal ring                            Replace.
  Transmission




                 Hydraulic      Faulty operation of check ball in clutch piston     Check and replace.
                 system
                                Clogged hydraulic circuits like modulating valve,
                                                                                    Check and clean.
                                hydraulic valve or solenoid valve
                 Mechanical
                                Worn clutch drive plates and disks                  Replace.
                 parts


7. Shocks are felt when clutches are changed.

                                    Fault area and cause                                          Correction

                                Faulty operation of accumulator piston for speed
Transmission




                                                                                 Check and replace.
                                selector valve
                 Hydraulic
                 system
                                Faulty operation of accumulator piston for
                                                                                    Check and replace.
                                High/Low selector valve



8. Shift between 2-wheel and 4-wheel drives cannot be achieved.
                                    Fault area and cause                                          Correction

                 Air cylinder   Air leakage due to damaged piston packing           Replace packing.
 Transmission




                                Damaged shifter fork                                Replace.
                 Mechanical
                 parts
                                Damaged shifter fork return spring                  Replace.




                                                                     38       W561-0101E
                                                      Troubleshooting


9. Shift between High and Low speeds cannot be achieved.
                                  Fault area and cause                                       Correction

               Air cylinder   Air leakage due to damaged piston packing        Replace packing.
Transmission




                              Damaged shifter fork                             Replace.
               Mechanical
               parts
                              Damaged shifter fork return spring               Replace.




                                                                   39     W561-0101E
                                                 Disassembly


Disassembly                                                     3. Remove input guide and O-ring.
1. Torque converter                                               Input guide                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 plates.                                                                  O-ring



                                                                                                          IW561-0081E020



                                                                4. Remove seal ring from the end of turbine shaft,
                                                                  and remove snap ring fixing turbine shaft assy
                                                                  and remove washers and shim.

                                                                                 Washer
                                                                 Snap ring




                                                                Seal ring          Shim
                                                                             Turbine shaft
                                                                                                           IW561-0081E021



                                                                5. 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.




                                                           40       W561-0101E
                                                Disassembly


6. Using a sling and eye bolts, pull out converter              9. Using tapped extractor holes and a sling and eye
   circuit and cover as a unit from housing.                       bolts, remove front cover and turbine assy as a
       Eye bolt                                                    unit. Remove O-ring from front cover.
                                      Converter circuit
                                                                     Eye bolt




                                                                                                                O-ring
                                        Cover




                                          IW561-0081E023



7. Remove snap ring fixing PTO drive gear, and
  remove gears and cover. Remove O-ring from                                                         IW561-0081E026

  cover.

                                    Snap ring                   10.Remove thrust washer, thrust needle bearing,
                                                Gear              thrust washer, One-way clutch retainer•B, Snap
                                                                  ring, Outer race, One-way clutch, Inner race,
    O-ring                                    Cover               Stator, One-way clutch retainer•A, thrust washer,
                                                                  thrust needle bearing from impeller assy.
       Oil seal
                                                                 Thrust needle                    Thrust washer
                                                                 bearing
                                                                                                  Thrust washer
                                                                  One-way
                                                                  clutch                            Snap ring
                                                                  retainer・B
                                        IW561-0081E024
                                                                      Outer race                One-way clutch

                                                                    Inner race                              Stator
8. Remove flange bolts (M8, 24 pcs.) fixing front
                                                                One-way
   cover to impeller assy.                                      clutch                                      Thrust
                                                                retainer・A                                  washer
    Bolt
                  Front cover



                                                                                                          Thrust
                                                                  Impeller assy                           needle
                                                                                                          bearing
                                                                                                        IW561-0081E027




 Impeller assy

                                         IW561-0081E025




                                                           41       W561-0101E
                                                    Disassembly


                                                                  14.Remove flange bolts (M10, 2pcs.), and remove
11.Remove snap ring from the end of turbine hub,
                                                                    charging pump and gasket.
  and pull turbine assy out of front cover assy.
   (If difficult to remove, carefully tap the end of
  turbine hub with a plastic hammer.)

                 Turbine assy




           Snap ring             Ball bearing




                                                                  15.Remove bolts (M10, 2 pcs.), and remove solenoid
           Snap ring            Front cover assy                    valve assy and gasket.
                                            IW561-0081E028




12.Remove snap ring, and remove pressure plate,
  disc, piston and D-shaped rings from front cover.

        Snap ring

        Pressure plate


        Disc                       Piston
                                                                  16.Remove bolts (M10, 10 pcs.), and remove cover
                                                                    and gasket.


                                     D-shaped
                                     ring


 Front cover                                IW561-0081E029




13.Remove bolt (M16), washer and O-ring, and pull
  out flange.

                                  Flange

                                  O-ring         Bolt




                                       Washer

                                            IW561-0081E030




                                                             42       W561-0101E
                                                  Disassembly


17.Remove PTO clutfh. (If difficult to remove,                     20.Remove O-ring in the steering pump mounting
  carefully tap the shaft end from inside housing.)                  portion.

                        Housing
                                     PTO clutch




                                          IW561-0081E034




18.Pull out output shaft with bearings, spacer and
                                                                   21.Remove snap rings retaining PTO gears, and
  gear. (If difficult to remove, carefully tap the shaft
                                                                     remove washer and gear.
  end from inside housing.)




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




                                             IW561-0081E036




                                                              43       W561-0101E
                                                     Disassembly


 23.Pull out shaft with bearings. (If difficult to                     26.Remove snap ring holding back plate and piston.
   remove, carefully tap the shaft end from inside
                                                                       Snap ring            Back plate
   housing.)




                                                                                                 Piston             IW561-0081E043




                                                                       27.Remove snap ring holding return spring with a
                                                                         special tool.
 24.Remove flange bolts (M10, 6 pcs.), and pull out
    stator support.                                                                 Snap ring
                     Bolt
                                                                                                          Special tool




                                                                                                           IW561-0081E044




          Stator support                                               28.Pull out back plate, discs, drive plates, washer,
                                                                         return spring, piston and seal ring.

                                                                                                                Back plate
                                              IW561-0081E041
                                                                            Drive                                   Disc
                                                                            plate
 25.Remove snap ring, and pull out ball bearing,
    thrust washer, and PTO driven gear from PTO
                                                                                                                Washer
    clutch.
                                                                                                                Return
Snap ring
                                                                                                                spring
       Thrust washer
                            PTO driven gear                                                                     Piston

                                                                                                                Seal ring




Ball                                                                                                        IW561-0081E045

bearing
                                                 IW561-0081E042




                                                                  44       W561-0101E
                                                    Disassembly


29.Remove flange bolts (M8, 4 pcs.) from lock-up
  accumulator valve, and remove cover and gasket.

Bolt         Cover
                 Gasket




                                         IW561-0081E046




30.Take out springs, stopper and piston.

Piston                 Spring




         Stopper
                                         IW561-0081E047




31.Remove solenoid from solenoid valve.

                        Solenoid




                                   IW561-0081E048




                                                          45   W561-0101E
                                              Disassembly


2. Transmission                                               4. Remove bolts (M10, 8pcs.), and remove
                                                                 2-wheel/4-wheel drive selector cover with shaft
[NOTICE]                                                         using tapped extractor holes from housing, and
 Thoroughly clean the outside before starting                    remove gasket and springs(2pcs).
 disassembly. Disassemble the transmission on a
 clear surface.
 Note the installation positions of disassembled parts
 by putting tags on them for later reassembly.

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 (fromt) with O-ring, and remove spacer.




                                                              6. Remove bolt (M8) and washer inside air cylinder,
                                                                and remove piston.
                                                                                     Bolt
 3. Unbend washer. Remove bolt (M16) and washer,
                                                                                     Washer
   and remove output flange(rear) with O-ring.
                                                                                     Piston




                                                                                                    IW561-0081E054




                                                         46       W561-0101E
                                                 Disassembly


7. Pull out shift fork, sleeve, and needle bearing, and        10. Remove bolts (M10, 23pcs.) and hexagon socket
   remove O-ring.                                                head bolts (M8, 13pcs.), and remove front
                                                                 housing and gasket from housing cover.




8. Remove snap ring retaining bearing, and pull out
  shaft.


                                                               11.Remove bolts (M10, 6pcs.), and remove cover
                           Snap ring                             and gasket from housing cover.


                           Shaft




                                       IW561-0081E056




9. Remove hexagon socket head bolts (M8, 8pcs.),
  and remove solenoid valve assy (F-R, speed
  selector) and gasket from housing.




                                                          47       W561-0101E
                                               Disassembly


                                                             15.Using tapped extractor holes and a sling and eye
12.Remove snap rings that position shaft end
                                                               bolts, remove housing cover and gasket from
  bearings to housing cover. (If difficult to remove,
                                                               housing.
  carefully tap shaft ends from behind housing.)




                                                             16. At emergency steering pump mounting portion,
                                                               remove flange bolts(M8, 3pcs.), remove shroud
                                                               from housing cover.




13. Remove hexagon socket head bolt(M10, 4pcs.)
  and bolt(M10, 4pcs.), remove ball bearing, spacer
  and cover, remove o-rings.




                                                             17. Remove snap ring retaining gear, and remove
                                                               gear.

14.Remove bolts (M10, 21pcs.) fixing housing cover.




                                                        48       W561-0101E
                                           Disassembly


18. Remove bolts(M10, 5pcs.), and remove                 21. Remove snap ring, and pull out shaft from
  speedometer with shaft assy from housing cover,          speedometer.
  and remove gasket.




                                                         22.Pull out valve pistons, springs and stoppers from
                                                           housing.


19.Remove screw (M8), and pull out speedometer
  driven gear.




20.Remove snap ring, and take out drive gear and
  steel ball.
                                                         23. Remove plug with O-ring from front housing, and
                                                           remove pressure spring and piston.




                                                    49       W561-0101E
                                              Disassembly


24.Remove flange bolts (M8, 3pcs.), and remove
                                                              26.Using a sling and a special tool, pull out hydraulic
  plate from shroud.
                                                                clutch (F2, R) assy and hydraulic clutch (R3, F1)
                                                                assy.




25.Using a sling and eye bolt, pull out counter shaft
  and output shaft.

                                                             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.




                                                        50        W561-0101E
                                              Disassembly


1. Remove seal rings (3 pcs.) from the shaft end,           4. Using minus driver, remove snap ring holding
  and remove snap ring and washer.                            back plate, and remove conical plate, back
                                                              plate,discs and drive plates.




2. Using a puller, pull out ball bearing, and remove
   washer.




                                                            5. Remove snap ring holding return spring with a
                                                              special tool.

                                                                                        Snap ring
3. In addition, remove snap ring and thrust washer,
                                                                                           Special
  pull out gear assy using a puller, and remove
                                                                                           tool
  thrust washer and snap ring.




                                                                                          IW561-0081E079




                                                            6.Take out thrust washer, return spring, thrust
                                                               washers, piston and seal ring.




                                                            7.Disassemble the clutch on the other side in the
                                                              same manner.



                                                       51       W561-0101E
                                              Disassembly

2.3 Counter shaft




 Do not disassemble gear shrinkage-fitted to shaft.

2.4 Output shaft




                                                      52   W561-0101E
                                                  Reassembly


Reassembly                                                    2. Transmission
[NOTICE]                                                       1. Wash disassembled parts in clean oil and remove
 Perform reassembly operations in the reverse order              foreign material from them. Especially carefully
 of disassembly while paying attention to the                    clean oil grooves and oil passages. But it is not
 following notes.
                                                                 necessary to wash O-rings, D-shaped rings, oil
                                                                 seals, disks and gaskets.
1. Torque converter
                                                               2. Replace O-rings, D-shaped rings, oil seals and
 1. Wash disassembled parts in clean oil and remove              gaskets with new ones.
   foreign material from them. Especially carefully
                                                               3. Wash parts (spools and pistons) of the main
   clean oil grooves and oil passages. But it is not
                                                                  pressure regulating valve, torque converter inlet
   necessary to wash O-rings, D-shaped rings, oil
                                                                  relief valve, the lubricating oil flow control valve
   seals, disks and gaskets.
                                                                  and control valve that are built in the converter
 2. Replace O-rings, D-shaped rings, oil seals and                housing, and apply genuine oil to them before
    gaskets with new ones.                                        installing them.

 3. Tighten bolts to the specified torque. (See                4. Tighten bolts to the specified torque. (See
   Tightening Torque Table.)                                     Tightening Torque Table.)

 4. Wind sealing tape on threads before screwing               5. Wind sealing tape on threads before screwing
   taper pipe threaded parts. Be careful not to allow            taper pipe threaded parts. Be careful not to allow
   any fragments of sealing tape to enter hydraulic              any fragments of sealing tape to enter hydraulic
   circuits.                                                     circuits.

 5. Degrease threads before applying threadlockers             6. Degrease threads before applying threadlockers
    to them. Be careful not to allow residual locking             to them. Be careful not to allow residual locking
    compound to enter hydraulic circuits.                         compound to enter hydraulic circuits.

 6. When installing an oil seal, pack the space                7. When installing an oil seal, pack the space
   between lips with Albania Grease No. 2 or No. 3               between lips with Albania Grease No. 2 or No. 3
   to approx. one-third to a half of the space volume.           to approx. one-third to a half of the space volume.
                                                                 Pack the space between oil seals in tandem at the
 7. Adjust shim thickness at the turbine shaft end to            output flange with the grease to approx. one-third
   keep a clearance of 0 - 0.2 mm(0-0.008 in).                   of the volume.
 8. At the end of reassembly operation, make sure              8. Before installing O-rings and U-shaped gaskets,
    that all sliding parts can move smoothly.                    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.




                                                         53        W561-0101E
                                                           Oil


Oil                                                             [NOTICE]
1. Recommended oil                                               Check the oil level when the oil temperature is
                                                                 approx. 50°C(122°F).
[NOTICE]
                                                                 Total oil quantity: approx. 30lit.(1830.6in3)
  Torque converter oil should have the following
  properties:                                                    3. Run the engine for approx. five minutes, and add
  • Proper viscosity at high temperature                           oil until the oil level stabilizes at the height
  • Good fluidity at low temperature                               between the center of the oil level gauge and 'H'.
  • 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.
Recommended oils
      Manufacturer                Brand name
 Mobil                      Mobil ATF220
 Esso                       Esso ATF


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.
  6.5lit.(396.6in3))

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. 25lit.(1525.5in3))

 2. Shift the gear shift lever to 'N' and set the PTO to
    'OFF'. With the engine idling (at approx. 670 rpm),
    gradually add oil.


                                                           54        W561-0101E
                                                          Test


Test                                                            [NOTICE]
                                                                  When measuring the pressure, be sure to drive the
[NOTICE]                                                          tires in the 4-wheel drive mode.
 When driving the tires for measurement and
 adjustment purposes with them lifted off the ground             4. When measuring the individual clutch pressures,
 by extending outrigger jacks, make sure that the                  PTO clutch pressure and lubricating oil pressure,
 4-wheel drive mode is selected.
                                                                   connect pressure gauges to the respective
1. Operational check                                               pressure check ports, extend the outrigger jacks
                                                                   to lift the tires off the ground and measure the
[NOTISE]
                                                                   pressures by changing the gear shift lever.
 Set the transmission clutch to 'N' for a no load
 condition.                                                     Standard pressure table

 1. Drive the torque converter at various speeds from            • Oil temperature for measurement: 70 to 80°C
    low to high, and make sure that:                                (158 to 176°F)
    • No unusual noise,                                                                   Standard valve MPa {psi}
                                                                        Item
    • No abnormal vibration, and                                                           670rpm         2600rpm
    • No oil leakage.                                           Torque converter       0.03 or more       0.3 - 0.7
                                                                inlet pressure             {4.35}        {43.5-101.5}
[NOTICE]
                                                                Torque converter       0.02 or more       0.15-0.39
 When checking conditions, be sure to drive the tires           outlet pressure             {2.9}         {21.8-56.6}
 in the 4-wheel drive mode.
                                                                Clutch pressure              1.9         2.1 - 2.45
                                                                                            {275.5}     {304.5-355.3}
 2. Extend the outrigger jacks and shift the gear shift
                                                                Transmission
   lever to 'N', 'D' and 'R', and change the engine                                       0.005-0.05      0.08-0.15
                                                                lubricating oil
   speed from low to high at each shift position to                                          {0.7-7}      {11.6-21.8}
                                                                pressure
   make sure that:
   • No unusual noise,                                          3. Stall test
   • No abnormal vibration, and                                                         CAUTION
   • No oil leakage.                                                 In the stalled condition, the torque converter
2. Pressure measurement                                            produces the maximum torque. Be extremely
                                                                   careful not to allow the vehicle to move suddenly.
 1. Run the torque converter to raise the torque                     As the torque converter generates much heat
    converter oil temperature to approx. 50°C(122°F).              in the stalled condition, do not stall it more than
                                                                   30 seconds. And do not perform this test when
 2. Measure the clutch pressure, torque converter                  the oil temperature is above 90°C(194°F).
   inlet pressure and torque converter outlet
   pressure at the idling speed (670 rpm) and at the            [NOTICE]
   maximum speed (2600 rpm) of the engine. Keep                   Be sure to perform this test in the 4-wheel drive
   the gear shift lever at neutral (N). (When                     mode.
   checking the lock-up clutch pressure, keep it at
                                                                 1. Securely apply the parking brake and foot brake.
   2nd or D.)
                                                                 2. Set the switches and levers to the following
 3. Read the clutch pressure displayed on the
                                                                   conditions.
   multi-display device on the crane, and measure
                                                                   • PTO switch: "OFF"
   the torque converter inlet pressure and torque
                                                                   • Gear shift lever: "2nd"
   converter outlet pressure by pressure gauges
                                                                   • Drive speed select switch: "4-wheel HI"
   connected to the torque converter inlet/outlet
                                                                   • Service brake: "ON"
   pressure check ports (Rc 1/4).


                                                           55        W561-0101E
                                                     Test


 3. Fully push the accelerator pedal, and read the
    engine speed when it becomes stabilized.

Standard maximum engine speed under stall
condition : approx. 2160 min-1




                                                      56    W561-0101E
                                          Maintenance standards


Maintenance standards
                                                                   3. Check all disassembled parts by proper methods
1. Overhaul interval                                                 like visual inspection for cracks, flaws, unusual
                                                                     wear, corrosion, etc. If these defects are evident,
 1. It is recommended that an overhaul should be
                                                                     replace or repair them.
     given every two years or 4,000 hours of operation,
     whichever comes first.                                        4. If a part is worn over the 'part replacement
                                                                     standards' below, only itself or its pair or the entire
 2. Replace rubber parts such as oil seals and
                                                                     set should be replaced.
     O-rings, gaskets and copper gaskets.

2. Replacement interval of important parts
                            Time
                                          At first overhaul                    At second overhaul and later
Parts
 Oil seal
 O-ring
                                         Replace all parts.          Replace all parts at overhaul.
 Gasket
 Copper gasket
 Oil seal ring                                                       Replace all parts at 2nd and 4th overhauls.
 Seal ring race surface
                                                                     Replace parts exceeding its wear limit.
 Sintered plate
                                                                      Replace parts exceeding its wear limit.
 Stator freewheel
                                                                      Replace flat springs if defective.
                                       Inspect the condition.
 Oil seal sliding surface
 Clutch piston sliding surface
 Bushing bore                                                        Replace parts exceeding its wear limit.
 Bearing
 Spring


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                   Oil seal ring, snap ring, fiber plate, steel
 B
        frequent replacement at               Clutch plates                plate
        overhauls
        Parts that do not need to be          Bearings
        replaced at every overhaul, but                                    Bearing, bushing, parts for freewheel set,
 C                                            Race surface of seal
        should be replaced if found                                        seal race
        defective.                            rings
        Parts that normally do not need to Gears
                                                                           Various gears, clutch shaft, turbine shaft,
 D      be replaced, but should be
                                           Shafts                          flange
        replaced only if found defective.




                                                              57       W561-0101E
                                            Maintenance standards

3.1 Torque converter
                                                                                    (1mm=0.03937in)                  (mm)

                                      Check item                                           Standard
                                                                                                            Use limit
                                                                                             value


         A                B
                              Clearance between lock-up accumulator piston
                                                                                          0.020-0.065         0.085
           IW561-0031J115     (1.5-43)and housing bore (A - B)
 A: Housing bore ID
 B: Piston OD
                                                             Free length (A)                 71.51            67.27
                              PTO clutch return
                                                             Installed length (B)             29.1            29.1
                              spring(1.6-9)
                                                             Force when installed (C)   321N {72.1lbf}    289N {64.9lbf}

                                                             Free length (A)                 84.16            82.87
                                                  (large)
          A                                                  Installed length (B)             70.4            70.4
                                                  (1.5-46)
               B                                             Force when installed (C)    113N {25.4lbf}   102N {22.9lbf}
           C
                                                           Free length (A)                  120.05           117.89
         IW561-0031J116
                              Accumulator         (middle)
                                                           Installed length (B)               98.4            98.4
                              spring              (1.5-45)
 A: Free length                                            Force when installed (C)      253N {56.9lbf}   228N {51.2lbf}
 B: Installed length
                                                             Free length (A)                 111.25          109.97
 C: Spring force                                  (small)
      when installed                                         Installed length (B)             98.4            98.4
                                                  (1.5-44)
                                                             Force when installed (C)    75N {16.8lbf}    67N {15.1lbf}


                                                  Disc(1.6-6) thickness                    2.5-2.65            2.2


               A                                  Drive plate(1.6-5) thickness             1.53-1.67           1.4
                              PTO clutch
        IW561-0031J119

 A: Clearance for
                                                  Clearance for disenagement (A)            1.5-2.3            3.5
     clutch
     disengagement
 Lock-up clutch disc(1.4-32) thickness                                                     4.95-5.25           4.5




                                                             58        W561-0101E
                                     Maintenance standards


Oil seal
                                                                                                         (mm)

                                 Check item                                        Standard
                                                                                                Use limit
                                                                                     value
 Impeller assy

                           Peripheral surface of impeller assy(1.4-1) that         φ119.913
                                                                                                φ119.78
                           contacts oil seal(1.5-3)                                 -φ120


 Output coupling

                           Peripheral surface of output coupling (1.5-32)          φ54.926
                                                                                                φ54.81
                           that contacts oil seal(1.5-36),(1.5-37)                  -φ55




Seal ring
                                                                                                         (mm)

                                  Check item                                        Standard
                                                                                                Use limit
                                                                                      value
 Teflon ring
                                                            Radial thickness (A)     1.4-1.6       1.2
                      At the      Seal ring (1.5-12)
              B                                             Axial width (B)          2.95-3.0      2.55
                      cover
                      side end    Area of cover (1.5-4)
      A                                                                               φ35-
                      of          on which seal ring        Inside dia. (C)          φ35.05       φ35.2
                      turbine     slides
                      shaft       Groove width where
                                                            Groove width (D)        3.07-3.15      3.30
     IW561-0031J117
                                  seal ring is installed
                                                            Radial thickness (A)     1.4-1.6       1.2
                                  Seal ring (1.5-12)
                                                            Axial width (B)          2.95-3.0      2.55
                  C               Area of input guide
                      At the                                                          φ35-
                      input       (1.4-5) on which seal     Inside dia. (C)          φ35.05       φ35.2
          D
                      guide       ring slides
      IW561-004203
                      side end
                      of
 A: Radial            turbine
      thickness       shaft       Groove width where                                3.07-3.15
                                                            Groove width (D)                       3.30
 B: Axial width                   seal ring is installed
 C: Inside dia.
 D: Groove width




                                                       59      W561-0101E
                                     Maintenance standards



                                  Check item                                        Standard
                                                                                                Use limit
                                                                                      value
                                                             Radial thickness (A)    2.0-2.2      1.8
                                   Seal ring (1.5-11)
                                                             Axial width (B)        2.35-2.4      1.95
                     At middle     Area of stator
                     of turbine    support(1.5-9) on                                 φ50.2-
                     shaft                                   Inside dia. (C)         φ50.25     φ50.40
                                   which seal ring
                                   slides
                                   Groove width where                                2.5-2.6
                                                             Groove width (D)                     2.75
                                   seal ring is installed
                                                             Radial thickness (A)    3.1-3.3      2.9
                                   Seal ring (1.5-13)
Teflon ring                                                  Axial width (B)        2.30-2.35     1.9

                     At stator     Area of impeller
             B
                     support       assy(1.4-1) on                                     φ76-
                                                             Inside dia. (C)         φ76.03      φ76.2
     A                             which seal ring
                                   slides
                                   Groove width where                               2.44-2.49
                                                             Groove width (D)                     2.64
                                   seal ring is installed
    IW561-0031J117

                                                             Radial thickness (A)    1.6-1.8      1.4
                                   Seal ring (1.6-19)
                     At end of                               Axial width (B)        2.85-2.90     2.45
                     PTO
                                   Area of cover                                     φ70.2-
                 C   clutch
                                   (1.5-4) on which          Inside dia. (C)         φ70.25      φ70.4
                     drive
         D                         seal ring slides
                     shaft
     IW561-004203                  Groove width where                                3.0-3.1
                                                             Groove width (D)                     3.25
                                   seal ring is installed
A: Radial                                                    Radial thickness (A)    2.0-2.2      1.8
     thickness                     Seal ring (1.6-3)
                                                             Axial width (B)        2.35-2.40     1.95
B: Axial width       At middle
                     of PTO        Area of PTO clutch
C: Inside dia.                     piston(1.6-4) on                                 φ50.20-
                     clutch                                  Inside dia. (C)                    φ50.40
D: Groove width                    which seal ring                                  φ50.25
                     drive
                     shaft         slides
                                   Groove width where                                2.5-2.6
                                                             Groove width (D)                     2.75
                                   seal ring is installed
                                                             Radial thickness (A)    3.5-3.7      3.3
                                   Seal ring (1.6-2)
                                                             Axial width (B)        2.40-2.45     2.00
                     At PTO        Area of shaft
                     clutch        assy(1.6-1) on                                   φ122.00-
                                                             Inside dia. (C)        φ122.15     φ122.2
                     piston        which seal ring
                                   slides
                                   Groove width where                               2.51-2.62
                                                             Groove width (D)                     2.77
                                   seal ring is installed




                                                        60      W561-0101E
                                            Maintenance standards

3.2 Transmission                                                                    (1 mm= 0.03937 in)
                                                                                                                   (mm)

                                     Check item                                         Standard
                                                                                                         Use limit
                                                                                          value
                          Clearance between converter inlet relief valve
                                                                                       0.020-0.071          0.09
                 A        piston(2.3-86) and housing bore (A – B)
                          Clearance between main pressure regulator valve
                                                                                       0.015-0.049          0.07
                          piston(2.3-83-a) and housing bore (A – B)
                 B        Clearance between lubricating oil flow control valve
                                                                                       0.015-0.049          0.07
                          piston(2.3-83-b) and valve body bore (A – B)
                          Clearance between hydrauric valve(F1),(F2)
                 C                                                                     0.020-0.061         0.080
                          spool(2.6-3) and valve body bore (A – C)
                          Clearance between hydrauric valve(F3) spool(2.6-2)
     IW561-0031J120                                                                    0.020-0.061         0.080
                          and valve body bore (A – C)
 A: Housing bore ID
 B: Piston OD             Clearance between F1,F2,F3,R accumulator
                                                                                       0.020-0.065         0.085
 C: Spool OD              piston(2.3-88) and housing bore (A – B)
                                                         Free length (A)                   64.5            63.67
                          Converter inlet relief valve
                                                         Installed length (B)              56.2             56.2
                          spring (2.3-87)
                                                         Force when installed (C)     98N {22.0lbf}    88N {19.8lbf}
                                                         Free length (A)                  112.3            111.7
                                             (small)
                                                         Installed length (B)              106              106
                          Main pressure      (2.3-84)
                                                         Force when installed (C)     141N {31.7lbf}   127N {28.6lbf}
                          regulator valve
                          spring                         Free length (A)                   97.1            95.79
                                             (large)
                                                         Installed length (B)               84               84
                                             (2.3-85)
          A                                              Force when installed (C)     174N {39.1lbf}   157N {35.3lbf}
               B                                         Free length (A)                  118.2            116.1
           C              Lubricating oil flow control
                                                         Installed length (B)               97               97
         IW561-0031J116
                          valve spring(2.3-100)
                                                         Force when installed (C)      42N {9.4lbf}     37N {8.3lbf}
                                                         Free length (A)                  62.18            60.96
 A: Free length                               (small)
                          2-wheel/4-whe                  Installed length (B)               50               50
 B: Installed length      el drive           (2.3-49)
                                                         Force when installed (C)     98N {22.0lbf}    88N {19.8lbf}
 C: Spring force          selector air
      when                cylinder return                Free length (A)                 113.98           107.58
                                             (large)
      installed           spring                         Installed length (B)               50               50
                                             (2.3-50)
                                                         Force when installed (C)     49N {11.0lbf}     44N {9.9lbf}

                          Hydrauric valve(F1),(F2)       Free length (A)                  43.13            42.66
                          and (F3) spool return          Installed length (B)              38.4             38.4
                          spring
                                                         Force when installed (C)     57N {12.8lbf}    51N {11.5lbf}




                                                         61        W561-0101E
                                            Maintenance standards


                                                                                                            (mm)

                                       Check item                                     Standard
                                                                                                   Use limit
                                                                                        value
                                                           Free length (A)              105.84       105.4
                                            (small)
                                                           Installed length (B)          101.4       101.4
                                            (2.3-89)                                      25N         23N
                                                           Force when installed (C)     {5.6lbf}    {5.2lbf}
                                                          Free length (A)               106.51       106.0
           A                                (middle)
                   B          F1,F2,F3,R                   Installed length (B)         101.4        101.4
                                            (2.3-90)                                     60N          54N
           C                  accumulator                  Force when installed (C)    {13.5lbf}    {12.1lbf}
         IW561-0031J116   )   spring
                                                           Free length (A)               78.06       77.59

 A: Free length                             (large)        Installed length (B)          73.4         73.4
 B: Installed length                        (2.3-91)
                                                                                          38N         34N
 C: Spring force                                           Force when installed (C)     {8.5lbf}    {7.6lbf}
      when installed
                                            Disc(2.4-6),(2.5-6) thickness               2.8-3.0       2.2

                                            Drive plate(2.4-5),(2.5-5)thickness       1.95-2.05       1.80
                   A          F1,F2,F3,R
      IW561-0031J121          clutch
 A: Clearance for                           Clearance for disenagement (A)              2.8-3.2       4.5
   clutch
   disengagement




Clutch return spring
                                                                                                            (mm)

                                       Check item                                     Standard
                                                                                                   Use limit
                                                                                        value
                                                         Free length (A)                73.51        69.46

                                                         Installed length (B)            33           33



            A
                   B           F1,F2,F3,R clutch
               C               return spring
           IW561-0031J116
                               (2.4-11),(2.5-11)                                        640N         576N
                                                         Force when installed (C)     {143.9lbf}   {129.5lbf}

 A: Free length
 B: Installed length
 C: Spring force
      when installed




                                                           62        W561-0101E
                               Maintenance standards



Oil seal
                                                                                             (mm)

                           Check item                                      Standard
                                                                                      Use limit
                                                                             value
 Input coupling

                      Peripheral surface of input coupling (2.3-11) that   Φ54.926-
                                                                             Ф55       Ф54.81
                      contacts oil seal(2.3-18), (2.3-19)



 Output coupling
                      Peripheral surface of output coupling (2.3-16)       Φ79.926-
                      that contacts oil seal(2.3-33), (2.3-34) (front        Φ80       Φ79.81
                      wheel side, rear wheel side)




 Speedometer driven   Peripheral surface of speedometer driven gear        Φ9.964-
                                                                            Φ10        Φ9.90
 gear                 (2.3-71) that contacts oil seal(2.3-75)




                                                63        W561-0101E
                                      Maintenance standards


Seal ring
                                                                                                                (mm)

                                 Check item                                          Standard
                                                                                                      Use limit
                                                                                       value
 Teflon ring                                                  Radial thickness (A)    1.6-1.8             1.4
                                Seal ring (2.4-22)
            B        At R                                        Axial width (B)     2.87-2.92           2.47
                     side end   Area of front
    A                of F2,R                                                          Φ45.20-
                                housing(2.3-8) on             Inside dia. (C)         Φ45.25            Φ45.35
                     clutch     which seal ring slides
                     shaft
                                Groove width where                                    3.0-3.15           3.30
                                                              Groove width (D)
    IW561-0031J117              seal ring is installed
                                                              Radial thickness (A)     2.0-2.2            1.8
                                Seal ring (2.4-2)
                     At                                       Axial width (B)         2.35-2.4           1.95
                C
                     middle     Area of piston(2.4-3)
                     of F2,R                                                          Φ55.20-
                                on which seal ring            Inside dia. (C)         Φ55.25            Φ55.40
        D            clutch     slides
     IW561-004203    shaft
                                Groove width where                                     2.5-2.6           2.75
                                                              Groove width (D)
                                seal ring is installed
 A: Radial
                                                              Radial thickness (A)    3.35-3.65          3.15
    thickness
                                Seal ring (2.4-4)
 B: Axial width                                               Axial width (B)         2.89-2.94          2.49
 C: Inside dia.      At F2,R    Area of shaft
                                                                                      Φ134.00-
 D: Groove width     piston     assy(2.4-1) on which          Inside dia. (C)                           Φ134.2
                                                                                      Φ134.04
                                seal ring slides
                                Groove width where
                                                              Groove width (D)       3.025-3.125         3.275
                                seal ring is installed
                                                              Radial thickness (A)     1.6-1.8            1.4
                                Seal ring (2.5-23)
                     At F1                                    Axial width (B)         2.87-2.92          2.47
                     side end   Area of front
                     of F1,F3                                                         Φ45.20-
                                housing(2.3-8) on             Inside dia. (C)         Φ45.25            Φ45.35
                     clutch     which seal ring slides
                     shaft      Groove width where
                                                              Groove width (D)        3.0-3.15           3.30
                                seal ring is installed
                                                              Radial thickness (A)     2.0-2.2            1.8
                                Seal ring (2.5-2)
                     At                                       Axial width (B)         2.35-2.4           1.95
                     middle     Area of piston(2.5-3)
                     of F1,F3                                                         Φ55.20-
                                on which seal ring            Inside dia. (C)         Φ55.25            Φ55.40
                     clutch     slides
                     shaft      Groove width where
                                                              Groove width (D)         2.5-2.6           2.75
                                seal ring is installed
                                                              Radial thickness (A)    3.35-3.65          3.15
                                Seal ring (2.5-4)
                                                              Axial width (B)         2.89-2.94          2.49
                     At F1,F3   Area of shaft
                                                                                      Φ134.00-
                     piston     assy(2.5-1) on which          Inside dia. (C)         Φ134.04           Φ134.2
                                seal ring slides
                                Groove width where
                                                              Groove width (D)       3.025-3.125         3.275
                                seal ring is installed

                                                                                                   363-705-50000   △
                                                                                                                   0

                                                                                                   363-505-90000   △
                                                                                                                   1




                                                         64         W561-0101E
Head Office     Ko-34,Sinden-cho, Takamatsu, Japan


Overseas Service Group
                Tadano Ryogoku Bldg.
                4-12, Kamezawa 2-chome,
                Sumida-ku,
                Tokyo, Japan
                Tel.    81 (3) 3621-7765
                Tel fax 81 (3) 3621-7785




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DOCUMENT INFO
Description: sevice manaul tadano GR700E