TCM E835 E840 L26 Wheel Loader Drive Unit Shop Manual - PDF DOWNLOAD

No．MU−64125AE

●丁ひ㊥

SHOPMANUAL ●

●

DRLV．E UNIT APPLICABLEMODEL： WHEELLOADER

●

E835●E840●L26

TOYOUM臥NKICO，LJD

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●

●

CONTENTS l

1．1TORQUECONVERTER DISASSEMBLY

l

1．DISASSEMBLY 1 2

Removlnganddisassemblingparkingbrake

つ−

︶

l

︶

RemovlngCharglngPumP

︵ ︵

（SPlit−tyPehousing） 5

（3）Removinganddisassemblingparkingbrake （One−Piecetypehousing） ︶ ︶ 4 7 ︵‖6

′b

∠U

5

5

RemovlngPumPdrivegear

0ノ ︵

●

つ▲

︶

Disassemblingconverterwheels（E840・L26）

0

︶

Removingconverterwheels（E840・L26）

7

︶

Removinganddisassemblingconverterwheels（E835）

7

︶

RemovlngtOrqueCOnVerterPrOPer

︵

RemovlngSafetyvalve

︵ ︵ ︵ ︶ ︶

RemovlngCOntrOIvalve

︶ ︶

Removlngdistributorcapandpiplng

1 2 4

1

5 ︵

1

︵

︵ ︵

︶

3

︶ 1 2 つJ 4 5 ︵ ︵ ︵ ︵

3 3 つJ

︶ ︵

3 4

Reassemblingandreinstallingconverterwheels（E835）

つ▲ 2 2 つJ 4 0ノ l

︶

Reinstallingconverterwheels（E840・L26）

つJ

︶

Reassemblingconverterwheels（E840・L26）

0

︶

Reinstallingsafetyvalve Reinstallingpumpdrivegear

2 3

2．1TORQUECONVERTERREASSEMBLY

2

2．REASSEMBLY

Qノ Qノ

（2）Disassemblingvalve（lowersection）

2

︵

（1）Disassemblingvalve（uppersection）

00

3

︶

つん

1．4 CONTROLVALNEDISASSEMBLY

7

l

︶

Disassemblinglst／2ndspeedclutchshaft

5

︵

Disassembling3rd／4thspeedclutchshaft

5

︵

Disassemblingforward／reverseclutchshaft

21 1 2 2 つ▲

1

︵

1．3 CLUTCHSHAFTDISASSEMBLY

●

3

3

●

0ノ

︶

RemovlngClutchshafts RemovlngOutPutShaft Removlngbackgear

l 7 l7 l7l 00

︵

l．2 TRANSMISSlON DISASSEMBLY

4

5 7

4

0ノ

︵

つJ

ヽ■−′

0 5 0 5 1 5

（l）Reassemblingvalve（lowersection）

4

︵

ヽ■■′

つ一

2．3 CONTROLVALNEREASSEMBLX

4

＼l■′

1

︵

Reassemblingforward／reverseclutchshaft Reassembling3rd／4thspeedclutchshaft Reassemblinglst／2ndspeedclutchshaft

5

2．2 CLUTCHSHAFTREASSEMBLX

（2）Reassemblingvalve（uppersection） 5

3

︶

3

︶ ︶

Reinstallingoutputshaft

5

2．4 TRANSM［SS10N REASSEMBLY

Reinstallingclutchshafts Reinstallingdistributorcapandpiplng

5

︶

′0

︶

5

︶

Reinstallingbackgear

︶ l つ︼ 5 ′0

00

4

′D

つJ

Reinstallingtorqueconverter

︵ ︵

14 1

︵

（One−Piecetypehousing）

0

︵

′b

7

ReinstallingcontroIvalve Reassemblingandreinstallingparkingbrake

︵ ︵

∠U

0ノ

／h︶

0

7 7

3．3 PARKINGBRAKETROUBLESHOOTING

qノ

3．2 TRANSMISSIONTROUBLESHOOTING

2

3．TROUBLESHOOTINGGULDE 3．1TORQUECONVERTERTROUBLESHOOTING

′0

（9）Reinstallingchargingpump

U

（SPlittypehousing）

U

︵

（8）Reassemblingandreinstallingparkingbrake

2

4．STANDARDVALUESFORMAINTENANCE 5．MAJORBOLJTORQUECHART

1．DISASSEMBLY

Note：Whendisassemblingthedriveunit，itisgoodpracticetouseaworkbench，hoistandhanger

（M16，MlO）toensuresafe，eaSySerVicing．

亡彗∃unitweight：E835，512kg（11301bs）；E840，532kg（11701bs）；L26，537kg（11801bs） Note：Thedisassemblyandreassemblyofthedriveunitareexplaineduslngthesketchesofthemodel

L26・Rememberthattheactualappearanceofyourdriveunitmaybesomewhatdifferentthano artisticsketch．

1．1TORQUECONVERTERDISASSEMBLY

（1）Removingchargingpump

●

①Installthehanger（M16）intothetappedholein thetopofthedriveunitatitstransmissioncase side andlift the drive unit with a hoist． Removethedrainpluganddraintheoilfrom thedriveunit． 、

▲

▲

■

Oillevel：20e（5．3U．S．gal）for E835・E840

●

25e（6．6U．S．gal）forL26 Afterthat，Slowlyputthedriveunitonthework bench．

② Removethesuctiontubeandchargingpump． IfthecharglngPumPmOuntlngSeatistoohard toloosen，taPltWithasofthammer・

Note：ThecharglngPumPVariesin shapewith differentloadermodels．

③ Removethepumpsleevefrominsidethe COnVerterhouslng．

● Fig．3 −1−

④ Removethestrainerandl−0，一−ringfromthe transmission case．Ifthe straineris hard to remove，rakeitoutbyitsinnerdiameteruslnga SCreWdriver．

⑤ Removethefrontflange．

（2）Removinganddisassemblingparkingbrake （splittypehousing）

Note：IfthepIStOnhouslnglSSeParatedfromthe brakehouslng，reftrtothesketchontheright．

①RemovetheplugaFthecenterofthecap． Release thebrakeby tighteningthebrake releasebolt．

Fig．7

ー2−

② Beforedisassemblingtheparkingbrake，matCh marktheoutsideofthebrakehouslng．

③ Removethe4socketbolts．Removethecap andpistonhouslngaSOneunit．Donotloosen the2hex．boltsyet．

④ Removethe2socketbolts．Removethebrake

houslngWithascrewdriveroraprylngtOOl・ Remove the2

●

0

−rings from the brake

houslng．

● ⑤Rem。Vetheendplate，，plates。nd6disks．

● ⑥ Removethesnapringfromtheshaft．Remove thediskhub．

● 3

⑦ Removethebrakereleaseboltatthecenterof thecapofthebrakesubassemblyremoved・

⑧ Loosenthe2capfittingboltsalternatelylittle bylittle，andremoveboth・

Separatethecapfromthehouslng・

▲usecautionwhenlooseningthec？ntting bolts，becausemultiplestrongsprlngS are incorporated．Loosenthe2boltscarefu11y

untilyoucometofbelnospringfbrce．

⑨ Detachthecapandremovethe18springs（1）． Removethepiston（2）fromthepistonhousing （3）．

Removethe‖0‖−ringfromthepIStOnhouslng・

⑲ Remove the2一一D

−rings from the outer

diameterofthepIStOn．

Fig．15

−4−

（3）Removinganddisassemblingparkingbrake （one・piecetypehousing） Note：Inthistypeofhouslng，thepIStOnhouslngand

thebrakehouslng aremadeintoonepleCe． Seethesketchontheright．

① Removethe2hex．boltssecuringthecap，and theparkingbrakereleasebolt．

●

② Loosenthe4socketboltsinturnslittlebylittle andremovethem．

▲Astheboltsareloosened：thecapwi11 rise．Usecautionwhenloosenlngthesocket bolts，becausemultiplestrongsprlngS are incorporated．Loosentheboltscarefu11y

untilyoucometofbelnospringfbrce．

③ Detachthecapandremovethe18springs．

●

Fig．19 5

④ Removethepistonfromthebrakehousing． Remove the2 D −rings from the outer diameterOfthepIStOn．

⑤ Removethebrakehousing．Ifitishardto remove，uSeaSCreWdriveroraprylngtOOl．

Remove the2 0 −rings from the brake houslng．

⑥ Removetheendplate，7platesand6disks．

⑦ Removethesnapringfromtheclutchshaft． Removethediskhub．

Fig．23

−6−

（4）Removingtorqueconverterproper ① Lifttheconverterhousingalittleandhold． Removethe26boltssecurlngtheconverterto

thetransmission． Note：17boltsfromthe converter side and9from thetransmissionside．

② using4pullerbolts，1if［theconverterfromthe transmissionalittle．

●

● （5）Removing and disassembling converter Wheels

（E835）

① Removethe8boltssecuringtheinputplateand removetheplate．

② Removethe24boltssecuringthefrontcover． Using2pullerbolts，remOVethefrontcover．

●

Fig．27 7

③ Removethesnapringfromtheturbinewheel．

PinchtherivetheadswithtwopalrSOfpliers andremovetheturbinewheel．

④ Removethesnapring．Removethestator wheel．

G）Removetheco11arfromtheshaft．

⑥ Removethe3boltssecuringtheoilbaffle，from theoutputsideofthetorqueconverter・

Fig．31

−8−

⑦ pullouttheimpellerwheel，tOgetherwiththe Oilbameandimpellergear． Iftheimpelleris hardtoremove，attaCh a

hangertoitandliftitwithahoist．

⑧ Removethesnapringfromoutsidetheimpeller Wheelhub．Removethegearandoilbaffle． Removethesnaprlngfrominsidetheimpeller

●

Wheelhub，andremovethebearlng．

● ⑨ usingascrewdriver，remOVetheoilsealfrom theoilbaffle．

● ⑲ Removethe7boltssecuringthestatorsupport， fromtheoutputsideofthetorqueconverter．

Fig．35 −9一

⑪ Removeboththestatorsupportandtheturbine Shaft，taPPlngtheturbine shaftwithasoft hamer．

⑫ Removethesealringfromtheturbineshaft． Removethesnaprlngandtakeoutthebearlng．

⑬ Removethesealringfromthestatorsupport．

（6）Removingconverterwheels （E840・L2 ）

① Removethe3boltssecuringthesealcarrier（Oil baffle），fromtherearside．

Fig．3，

ー10−

② Removethe7boltssecuringtheguidecarrier

●

（statorsupport）．

③ Attachahangertotheinputguideandliftthe COnVerterSubassemblywithahoist，tOSeParate itfromthehouslnglittlebylittle．

●

亡彗ヨConvertersubassembly： 55kg（1201bs）

● ④Rem。Vethet。rbinesha銃whichremainsinthe houslng，alongwiththebearlng．Removethe

SnaPrlngfromthehouslng．

⑤ Removethesealringfromtheturbineshaft． Removethesnaprlnganddrawoutthebearlng．

●

Fig．43

ー11−

（7）Disassemblingconverterwheels （E840・L2 ）

① Removethe12boltssecuringtheinputplate．

② Removethespacerandinputplate．

③（E840）Removethe6boltssecuringtheinput guide．Removetheinputguide．

（L26）Using2pullerbolts，remOVetheinput

guide．

Fig．47

ー12−

④ Turntheconvertersubassemblyupsidedown． Removethe20bolts securingtheimpeller wheel．

⑤ Turntheconvertersubassemblyupsidedown agaln．Using2pullerbolts，remOVethecover

wheel． Remove the turbine wheelfrominside the COVerWheel．

⑥ Removethe 0‖−ringffomtheimpellerwheel．

⑦ Removethesnapringfromthestatorwheel llub．

⑧ pushintheendoftheguidecarrier（StatOr SuPPOrt）with apress toremovethe guide Carrler．

Removethesealringfromtheguidecarrier．

Fig．51

−13−

⑨ Removethestatorwheelandspacer．

⑲ Removethesocketboltssecuringtheimpeller hub，impellerwheel，andpumpdrivesleeve．

Thenumberofbolts： 60nE840 120nL26

⑪ Turntheconvertersubassemblyupsidedown． Pressthebearlnglnitsshouldertoremovethe impe11erhubwithbearlng．

⑫ separatetheimpellerhubfromthepumpdrive sleeve．

Removethe 0 一−ringfromthepump drive sleeve．

Fig．55

−14−

⑬ Removethebearingfromtheimpellerhubwith

●

apreSS・

⑭ Removethesnapringfromthepumpdrive gear．Removethe gearand sealcarrier（Oil ba董判e）．

●

⑮ usingascrewdriver，remOVetheoilsealfrom thesealcarrier．

（8）Removingpumpdrivegear

① Removethepumpdrivegearfittingboltand removethegear，bearlng，andbearlngSuPPOrt as one unlt．

●

Fig．59

−15−

② Removethesnapringfrominsidethegear removed．Remove thebearing andbearing SuPPOrtaSOneunit．

③ Removethebearingsupportfromthebearing． ④ usingthesameprocedure，remOVetheother pump drive gear.

（9）Removingsafbtyvalve

① Loosenthesafetyvalveplug．

② Removetheplug，SPring，andplunger． Note：TheplungermountlngSeatis stronglyntted intothecase．Donotremoveitaslongasit isnormal．

Fig． 3

−16−

1．2 TRANSM［SS］ON DLSASSEMBLY （1）RemovingcontroIvalve

① Attachahanger（MlO）tothevalve（upper SeCtion）andliftitwithahoisttemporarily． 亡≡≡コUppervalve：16kg（351bs）

② Removethellboltssecuringthevalve（upper SeCtion）．Remove thevalve（upper section） tapplngltWithasofthammer． Note：Recordthepositionofthe■shortbolt・

③ usingthesamemanner，remOVethevalve （lowersection）．Thenumberofboltsis3．

●

亡至∃Lowervalve＝26kg（571bs）

● （2）Removingdistributorcapandpiping ① Removetheboxnutssecuringthepipebetween thelst／2ndspeedcapandthe3rd／4thspeed CaP．Removetheplpe．

② using the same procedure，remOVe the remainlngPIPeS．

（∋ Loosentherotationsensorlocknutandremove thesensor，turnlngltWithaspanner．

Fig． 7 −17−

④ Remove the 3 bolts securing the forward／reversedistributorcap．Removethe distributorcap・Removethe21

0一

−ringsfrom

thematlngSurfaces．

⑤ usingthesameprocedure，remOVethelsu2nd SPeedand3rd／4thspeeddistributorcaps and ■■0■ −rings．

（3）Removingclutchshafts

① putthetransmissioncaseupright．Removethe SnaPrlngfromtheouterdiameterofeachofthe rearbearingsonthe3clutchshafts．Remove

the3sealringsfromeachofthe3shafts．

② putthetransmissioncasewithitsopening upward・Using apuller，remOVethebearlng

fromtheidlershaft．

③ Removethesnapring．Removetheidlergear 丘omthesha銃．

Fig．71

ー18−

④ Attachahangertotheforward／reverseshaft andremoveitfromthecasewithahoist． 【≡三≡コClutchshaft＝35kg（771bs）

⑤ Removethelsu2ndspeedshaft，idlershaft，and 3rd／4thspeedshaftinthatorder．

●

E5clutchshaft：42kg（931bs）

⑥ usingapuller，remOVethebearingfromthe idlershaft・Removethesnaprlnganddrawout thegear．

● （4）Removingoutputshaft

① Loosenthe3boltssecuringthecompanion flangeattherearSideofthecase．

●

Fig．75

−19−

② Removetheplate，‖0‖−ring，andcompanion nange．

③ Removethe4boltssecuringthebearingcap． RemovethebearlngCaP・ RemovetheoilsealfromthebearlngCaP・

④ Removethespacerandbearinginnerracefrom theshaft．

⑤ Turnthecaseupsidedown．Loosenthe4bolts SeCuring thebearingcap andremovethe

bearlngCaP． RemovetheoilsealfromthebearlngCaP・

Fig．79

−20−

⑥ Removethesnapringfromthegrooveinthe CaSeattheouterdiameterofthefrontbearlng．

⑦ putaspacerofanappropriatelengthbetween theoutputgearandthecase・（Thispreventsthe

gearfrommovlngWhentheshaftistappedin thenextstep．）

●

（む Drivethe shaftfromrearsidewithasoft hammertoremoveittowardthefrontside．

⑨ Afterremovingtheshaft，20utPutgearSand

bearlnglnnerraCeremaininthecase・Remove them．

●

Fig．83 一21一

⑲ Removethesnapringfromthegrooveinthe CaSeattheouterdiameteroftherollerbearlng．

⑪ presstheouterraceoftherollerbearingwitha JlgtOremOVeitfromthecase．

⑫ Removethebearingandsnapringfromthe OutPutShaft．

⑬ Removethe3boltssecuringtheoilbaffle，from therearsideofthecase．

⑭ Removetheoilbafflefrominsidethecase．

Fig．＄7

−22−

（5）Removingbackgear

●

①Removethesnaprin拍OmthebackgeN・

②Insertapullerstudintothetappedhole（MlO） inthebackgearshaftandremovetheshaft．Use Cautionnottolosethelockball．

●

● ③Rem。Vetheba。kgear．

④ Removethespacerfrominsidethecase．

●

Fig．91 ー23−

⑤ Removethe2bearingsandsnapringfrom insidethebackgear．

Fig．92

●

●

● ー24−

1．3 CLUTCHSHAFTDISASSEMBLY （1）Disassembling払rward／reverseclutchshaft

① puttheshaftuprightwiththeforwardclutch PaCk（SPlinedshaftside）upward，andsecureit・

② Removethesnapringfromthegrooveinthe Sha氏．

③ usingachisel，mOVethegearoutwardalittle SOthatthepullerlsclawcatchesthegear・

④ usingapu11er，remOVethehubgear．

⑤ usingajig，remOVethebearingfrominsidethe hubgear．

Fig．少 −25−

⑥ usingascrewdriver，remOVethesnapringfrom thegrooveintheclutchdrum．

▲Returnspringsareinstalledbetweenthe Clutchplates．Payattentiontotheendplate

Whichmightpopout．

⑦ Removetheendplate，disks，returnSpringsand Platesinthatorder．

⑧ usingapuller，remOVethebearingfromthe sha氏．

⑨ Turntheclutchshaftupsidedown．Feedair throughtheforwardclutchoilpressureholeto downthepIStOnandremovethepistonfromthe Clutchdrum．

Fig．100 −26−

⑲ Removethesealring（Outer）fromthepiston． ⑪ Removethepistonsealring（inner）fromthe Clutchshaft．

⑫ Turntheclutchshaftupsidedownsothatthe reverseclutchpackispolntedupward．Holdthe Shaftsecurely．

⑬ Removethesnapringfromtheshaft．Usinga Puller，remOVe the bearing．Remove the

remainlngSnaPrlng．

⑭ Disassemble theclutchshaftinthe same mannerasforthefbrwardclutchpack．

（2）Disassembling3rd／4thspeedclutch

① puttheclutchshaftwiththegear−fittedside POlntedupwardandsecureit．

② Removethesnapringfromtheshaft．Usinga Puller，remOVe the bearing．Remove the remainlngSnaPrlng．

③ Removethesnapringfromtheshaft．Remove thegear．

Fig．104

−27一

④ usingapuller，remOVethehubgear． ⑤ Removethebearingh・Ominsidethehubgear．

⑥ Holddowntheendplatewithapressto COmPreSSthereturnSPrlngS．Removethesnap rlngfromthegrooveintheclutchdrum．

▲ThereturnspringsarepOWerfu1・Make SuretO uSeaPreSS tO holddown the end

plate．

⑦ Loosenthepressanddisassemblethereverse Clutchpackinthe samemanneras forthe fbrwardclutchpack．

⑧ Disassemblethe4thspeedclutchpackinthe SamemanneraSforthereverseclutchpack．

Fig．107 （3）Disassemblinglst／2ndspeedclutchshaft Forthedisassemblyprocedure，reftrto

（2）Disassembling3rd／4thspeedclutchshaft．‖

● −28−

1．4 CONTROLVALVEDLSASSEMBLY （1）Disassemblingvalve（uppersection）

① Removethe6boltssecuringthe6−boltcover． Remove the cover．If the coveris hard to remove，taPltWithasofthammer・

Ausecau？onwhen ．

COVer．Loosentheboltsinturnslittle by littleuntilyoucometofbelnosprlngn）rCe．

Rememberthatthecentra12boltsarelonger thantheothers．

② Removetherod（l），innerspring（2），Outer SPring（3）andcenterspring（4）andloadpiston （5）fromtheouterspoolbore・Removetheflow SenSingspool（6）andspring（7）fromthecenter SPOOlbore．Removetheplug（8）andregulator Spring（9）・

③ Removethe7boltssecuringthecoveratthe OPPOSiteside・Removethecover・Ifthecover ishardtoremove，taPltWithasofthammer・

▲usecau？onwhen ．

COVer．Loosentheboltsinturnslittle by littleuntilyoucometofbelnospringfbrce．

④ Removetherod（1），innerspring（2），Outer SPring（3），CenterSPring（4）andloadpiston（5）

fromtheouterspoolbore． Removethespring（6），innerspring（11）（L26 0nly），andmodulationspool（7）fromthecenter SPOOlbore．Removetheregulatorspool（8）and

●

Piston（10）fromtheremainingspoolbore・

Fig．111 −29−

（2）Disassemblingvalve（lowersection）

① Removethemanualspoollockplateandlock boltfromtheuppersurfaceofthevalve．Draw

Outthespool．

O Remove the 5 socket bolts securing the SOlenoidvalveadapters．Removetheadapters ffomthevalvebody，tOgetherwiththesolenoid Valves・Iftheadaptersarehardtoremove，taP themwithasofthammer．

③ Removethe4solenoidvalveswithaspecial SPanner・

Note：Specialspannersize

Widthacrossflat：34mm（1．34in） Thickness：

3mm（0．12in）

④ Remove the8bolts securingthe cover． Remove the cover．If the coveris hard to remove，taPltWithasof［hammer．

Fig．115

ー30−

⑤RemovetheF／Rselectspool（1），adapter（2） andspring（3）fromthespoolbore．Remove

thespooIA（4）andselectspring（5）fromthe

CenterSPOOlbore・RemovethespooIB（6）and Selectspring（5）fromtheremainingspoolbore．

⑥ There8throttleplugs‥4intheadapterand40n thevalvebody surfacewhichmateswiththe

uppervalvebody・Theycanberemoveduslng

●

aplugwrench． Note：Thethrottleplugsareselectnt．Ifmorethan

2throttle plugs are to be removed，Put matchmarks to ensure correct reinstallation． Incorrectly installed throttle plugs might

CauSePOOrPerformanceoftheloader．

Fig．117

●

●

ー31−

2．REASSEMBLY

■Caution＄tObetakenwhenreassembling ・CleanallthedisassembledpartsincleanlngSOIvent，thendrywithcompressedair・Inparticular，remOVe

LOCTITEandgasketsthoroughlyfromthematlngSurfacesofthecaseandothers・ ・Makesurethecleanedpartsarefreefromdirtorforelgnmatter・Handlethemcarefu11ysoasnotto CauSedent，SCOreOrSCratChes． ・Checkthedisassembledpartsforwearordamage，rePlaclngWithnewonesifdefective・Referto‖4・ STANDARDVALUESFORMAINTENANCE．‖

・Replaceallthesealswithnewones・

2．1TORQUECONVERTERREASSEMBLY （1）Reinstallingsa鎚tyvalve

①Inserttheplungerandspringintothesafety Valvefittinghole．

② Attachanew‖Ol一−ringtotheplugandscrew PluglntOthecase．

Fig．11，

● −32−

（2）Reinstal1ingpumpdrivegear

●

①Fitthebearingsupponintothebearing・

② Fitthebearing（withbearingsupport）intothe gear・

●

● ③Attachthesn。Pringt。SeC。，ethebearing．

● ④Inserttheassembledgearintothesupporthole inthehouslng．

Gear fitting position （whenlookingfrompumpfittingside）

E835

●

E840 L26

Left⑧

Right④

79T

75T

67T

60T

Fig．123

ー33−

⑤ ApplyLOCTITE＃2620nthethreadedareaof eachoftheboltsandsecurethegearbearlng

SuPPOrtWiththebolts． ぢ：：：：コ4・7kg−m（34糾bs）

⑥ usingthesameprocedure，installtheother PumPdrivegear．

（3）Reassemblingconverterwheel （E840・L2 ）

① Applygreaseonthelipsofoilsealfortheseal Carrier（Oilbaffle）．ApplyLOCTITE＃2620n the outer diameter ofthe oilseal．Fit the oil

Sealintotothesealcarrier． Note：Theoilsealshouldbeinstalledwiththemain lip（SPringside）pointedupward．

② Applygreaseonthe 0‖−ringandinstal1iton theouterdiameterofthesealcarrier．

③Installthesealcarrierontothepumpdrive Sleeve． Note：Usecautionnottoallowtheoilseallipturn up・

Fig．127 −34−

①Installthepumpdrivegearontothepumpdrive

●

Sleeveandsecurewiththesnaprlng．

⑤ Applyconverteroilonthesealring，andinstall itontheguidecarrier（StatOrSuPPOrt）．Install

thepumpdrivesleeveontheguidecarrier．

●

●

⑥ Applygreaseonan一一Orl−ring，andinstallitin thegrooveinthepumpdrivesleeve．Putthe

impellerwheelonthepumpdrivesleeve．

⑦ Fitthebearingintotheimpellerhubwiththe ba11groovepolntedtowardoutputside．

Fig．131 −35−

⑧Installtheimpellerhubontotheguidecarrier andpressitdownuntilithitsthebearlng・

Note：Pay attentiontotheboltholepositionand bearing ball groove when installing the

impellerhub．（Seethesketchontheright・）

⑨ press theimpe11er hub to eliminate the clearance．Secureitwithsocketbolts．

Thenumberofbolts： 60nE840 12 on L26 ぢ＝：：：コ 5・2−5・9kg−m（38−43糾bs）

⑲Installthespacerontheguidecarrier．

Fig．135

−36−

⑪ usingapress，installthestatorwheel（With hub）ontotheguidecarrieralongthekeyway．

⑫Installakeyontheguidecarrierandsecurethe StatOrWheelwiththesnaprlng・

⑬ Fitthebearingontotheturbineshaftwith SeCureWithsnaprlngSatbothends． Applyconverteroilonasealrlngandinstallit．

⑭ puttheturbineshaf［upright．Installtheguide Carrierontotheturbineshaft． Applygreaseonan‖0

r−ringandinstallitonto

theimpellerwheel．

Fig．139 −37−

⑮ Makesuretheturbinewheelisfittedwiththe bearing． Installtheturbinewheelontotheturbineshaft， alignlngtheinnersplines．

⑯ putthecoverwheelandturntheassembly upsidedownandtighten20bolts． （芯＝コ E840：2．1−2．3kg−m（15−17ft−1bs） L26：4−4．5kg−m（29−33氏−1bs）

⑰ Applygreaseonan‖Ol一−ringandinstalliton theinputguide． Installtheinputguideonthecoverwheel． （E8400nly）Tighten6fittingboltstosecurethe

lnPutguide．

ぢ＝コ4．3−4．8kg−m（31−35虹1bs）

⑬（E840）Installtheinputplateandspaceronthe COVerWheelandsecurethemwith12bolts．

（妄＝コ 4．3−4．8kg−m（31−35糾bs）

Fig．143

−38−

（L26）Installtheinputplateandspaceronthe lnPutguideandsecurethemtothecoverwheel

with12bolts．

ぢ＝＝コ 5．5−6．2kg−m（40−45乱−1bs）

（4）Reinstal1ingconverterwheel （E840・L2 ）

① Fitthesnapringintotheturbineshaftfitting

●

holeintheconverterhouslng．

② Removetheturbineshaftfromtheassembled COnVerterWheel． Installthe turbine shaft onto the converter

houslnguntilthebearlnghitsthesnaprlng．

③ Applygreaseontheouterdiameteroftheseal Carrierinthe areawhichcomesincontactwith

the一 0‖−ring（theareaindicatedbythearrowin thesketchontheright）．

（む Lif［theconverterwheelwithahoistandscrew inastud［MlO，1＝200mm（8in）］intothebolt holeinthesealcarrier．

Fig．147

−39−

⑤ Aligningtheholesintheguidecarrierwiththe holesinthehousing（usingthestudasaguide），

lowertheconverterwheellittlebylittle．

⑥ Aftermakingsurethepumpdrivegearengages PrOPerly，fittheguidecarrierintothesocket

and splgOtJOintofthehousingwithasoft hammer．

⑦ Turntheconverterhousingupsidedown，and tightenthe7guidecarrierfittingbolts．

ぢ：：：：コ10．3kg−m（74．5糾bs）

⑧ Removethestud（usedasaguide）andtighten the3sealcarrierfittingbolts． ぢ：：：：：：コ 5．6kg−m（4‖Hbs）

Fig．151

−40−

（5）Reassembling and reinstalling converter Wheel（E835）

① Applyconverteroilonasealringandinsta11it Onthestatorsupport．

②Installthestatorsupportintothesocketand SPlgOtJOintoftheconverterhouslng．Secure tightenlng7bolts丘■OmrearSide．

●

（忘＝コ10．3kg−m（74．5鋸bs）

● ③ Fitthebearingontotherearendoftheturbine ShaftandsecurewithsnaprlngSatbothsides・ Applyconverteroilonasealringandinstallit onthetutbineshaft．

● ④ Fittheturbineshaftintotheconverterhousing fromoutputsideuntilthesnaprlnggrOOVein

thehouslngCOmeSintoview． Afterfitting，1nSta11thesnaprlng・

Fig．155 −41−

⑤ Fittheballbearinginsidetheimpellerwheel hubandsecurewiththesnaprlng．

⑥ Applygreaseonthelipsoftheoilbaffleoil Sealand LOCTITE＃2620n the outer diameter Ofthe oilseal．Installthe oilsealinto the oil bame．

Note：Theoilsealshouldbeinsta11edwithitsmain lip（SPringside）pointedtowardtheconvexof theoilbattle．

⑦ Applygreaseonanl−0‖−ringandinstalliton theouterdiameteroftheoilbafne．

⑧Installtheoilbaffleontotheimpellerwheel hubwiththeboltsholespolntedupward・ Installtheimpellerhubgearwithitsspotfaced

Surfaceupward・Secureitwiththesnaprlng・

Fig．15，

ー42−

⑨Installalongstudintothescrewholeintheoil baffle，tOaligntheoilbafflenttingscrewholes・ Screwsize：MlOxl．25

⑲Installtheimpellerwheelassemblyontothe StatOrSuPPOrt．Make suretheoilbafflehole alignmentstudisalignedwiththeholeinthe

COnVerterhouslng． FitthebearlngOntOthestatorsupportuntilthe

bearlng．S Shouldercomesincontactwiththe StePPedareaofthestatorsupport．

⑪ Removethestudfromrear．Tightenthe30il bafflefittingbolts．

ぢ＝コ 5・6kg−m（4‖Hbs）

⑫Installthecollarandstatorwheelontothe StatOrSuPPOrt・Securewiththesnaprlng．

●

Fig．1 3

⑬Installthesnapring，turbinewheelandsnap rlngOntOtheturbineshaftinthatorder．

⑭Installthefrontcoverassembly（Withneedle bearingattachedatitscenter）ontotheimpe11er Wheel，andsecurewith24bolts． ぢ＝コ 2kg−m（14ft−1bs）

⑮Installtheinputplateontothefrontcover． Install the washer onto the front cover with its Chamferedsurfacepolntedtowardtheinput Plate．ApplyLOCTITE＃2620nthethreaded

areaofeachof8bolts andsecuretheinput Platewiththebolts． ぢ＝＝コ 6・2kg−m（45糾bs）

Fig．1

● ー44−

2．2 CLUTCHSHAFTREASSEMBLY （1）Reassemblingforward／reverseclutchshaft

①Installagreasedoutersealringontheclutch plStOn・

Note：As showninthe sketchontheright，make

Surethesealring−slippolntedupward．

（む Puttheclutchshaftonaworkbenchwiththe

fbrwardclutchdrumPOlntedupward・

● ③Installagreasedinnersealringontotheclutch shaft．

④Inserttheclutchpistonintothedrum．

⑤Installthenecessarynumberofplates，return SPrlngS，anddisksintothedruminthatorder． FinallylnStalltheendplatewiththe sprlng

s

COnVeXPOlntlngOutWard．

⑥ Holddowntheendplatewithapress，tO COmPreSSthereturnSprlngSinside．Installthe SnaPrlnginthegrooveinsidethe．clutchdrum．

● Fig．170 ー45一

⑦ Fitthehubgearballbearing（inner）ontothe Clutchshaft．

Note：Rememberthattheinnerbearlngdoesnot haveashield．

⑧ Makesurethat2snapringsarefittedinsidethe hubgear． ⑨Installthehubgearinsidetheclutchdrum， turnlngthehubgeartotherightandleftby

handtoengagethehubgearteethwiththedisk SPlines． Fitthehubgearontotheshaftbytapplnglt untilthegearcomesincontactwiththebearlng Ontheshaftwithasofthammer．

⑲ Fittheshieldbearingintothehubgearwiththe Shieldpolntedoutward． Putthesnaprlnglnthegrooveintheshaf［to SeCurethebear1ng．

⑪ usingthesameprocedure，reaSSemblethe reverseclutchpack．（Refertosteps①−⑲．） ⑫Installthesnapringontotheclutchshaftandnt thebearingontotheshaftwithits snaprlng grooveattheouterdiameterupward．

Instal1thesnaprlngOntOtheshaft．

Fig．174

ー46−

（2）Reassembling3rd／4thspeedclutch

●

① usingthesameprocedurefortheforward Clutchpack，reaSSemblethe3rdspeedclutch PaCktilltheclutchpiston．［Referto（1）①−

④．】

②Installthenecessarynumberofplates，return SPrlngSanddisksinthedruminthatorder．

Itisadvisabletouserodjigs④foraligningthe Platesplines．

③ Finallyputtheendplateandpressitto COmPreSSthereturnsprlnguntilthesnaprlng

grooveinsidethedrumCOmeSintoview．

④ Removealltherodjigsandattachthesnapring intothegrooveinthedrum．

Fig．17＄

−47一

⑤ Fitthehubgearballbearing（inner）ontothe Clutchshaft．

Note：Rememberthattheinnerbearlngdoesnot haveashield．

⑥ Makesurethesnapringisnttedinsidethehub gear・

⑦Installthehubgearinsidetheclutchdrum， turmngthegeartotherightandleftbyhandto

alignthegearteethwiththedisksplines．

Fitthe hub gear onto the shaft with a soft hammer untilit comesin contact with the

bear1ngOntheshaft．

⑧Instal1theshieldbearingintothehubgearwith theshieldpointedoutside．

⑨Installthegearontotheshaftwithitsboss downward．

Securethegearwiththesnaprlng．

Fig．182

−48−

⑲Installthesnapringontotheclutchshaft． InstallthebearlngOntOtheshaftwithitssnap

ringgrooveonitsouterdiameterpointing upward． Instal1thesnaprlngOntOtheshaft．

⑪ Turntheclutchshaftupsidedown．Reassemble the4thspeedclutchpack，uSingthe same PrOCedurefortheforwardclutchpack．

Fig．1＄3

（3）Reassemblinglstr2ndspeedclutchshaft Forthereassemblyofthelst／3rdspeedclutchshaft，referto［（2）Reassembling3rd／4thspeedclutch Shaf叶

● −49−

2．3 CONTROLVALVEREASSEMBLY

■cautionstobetakenwhenreassembling ・CleanallthedisassembledpartsincleanlngSOIventanddrywithcompressedair・Donotuseashoprag OrPaPerforcleanlngPurPOSeS；Otherwisedirtorlintmightenterthehydrauliccircuit，thusCauSlngthe

malfunctionofthesystem．

・Checktheoilpassageandorinceofeachspoolforclogglng・Ifanyspoolisfoundtobecloggedinits Oilpassageororifice，remOVetheclogandcleanthespool． ●Whenreinstallingplugswithout‖0‖−ring，aPPlyLOCTITE＃5720ntheirthreadedarea．

●Donotusesealingtapebecauseitmightcauseclogglng． （l）Reassemblingvalve（lowersection）

① ApplyLOCTITE＃5720nthethreadedareaof each ofthe8throttleplugs：40nthe side Surfaceand40nthetopsurface．Installthe throttleplugsintothevalvebody．Usecaution

nottohavethewrongpositions．

②Instal1thespring（3），adapter（2）andF／Rselect SPOOl（1）intothe8−boltholeside． Installtheselectspring（5）andspooIA（4）into

thecentralspoolbore． Instal1theselectspring（5）andspooIB（6）into

theremainlngSPOOlbore．

③ Bondagaskettothecoverandinsta11thecover tothevalvebodyuslng8bolts．Tightenthe8 boltsinturnslittlebylittle，tOCOmPreSSthe SPrlngSinsidethecoverproperly．

6：＝コ 4．2kg−m（30銃」bs）

Fig．1＄ −50−

④usingthesamespannerwhichwasusedduring disassembly，installthe4solenoidvalvesonto

theadapter．

⑤Bondgaskettotheadapter．Installtheadapter tothevalvebodywith5socketbolts．

芯＝コ4．2kg−m（30糾bs）

●

⑥Insertthemanualspoolintotheadapterand SeCureitwiththelockplateandlockbolt．

（2）Reassemb）ingvalve（upperseetion）

①Installtheloadpiston（5），CenterSPring（4）， innerspring（2），OuterSPring（3）androd（1） intothe7−boltholeside． Installthespring（6），innerspring（11）（L26

0nly）andmodulatespool（7）intothecentral SPOOlbore・Installtheregulatorspool（8）and Piston（10）intotheremainingspoolbore．

●

Fig．1，0

−51−

② Bondagaskettothecoverandinstallthecover tothevalvebodywith7bolts．Tightenthe7 boltsinturnslittlebylittle，tOCOmPreSSthe SPrlngSinsidethecoverproperly・ （芯＝コ 4・2kg−m（30氏」bs）

③Installtheloadpiston（5），CenterSPring（4）， innerspring（2），OuterSPring（3）androd（1） intothe6−boltholeside．

Installtheflowsensingspool（6）andspring（7） intothecentralspoolbore・Installtheregulator

SPring（9）intotheplugholeandtightenthe plug（8）・

④ Bondagaskettothecoverandinstallthecover tothevalvebodywith6bolts． Tightenthe6boltsinturnslittlebylittle，tO COmPreSSthesprlngSinsidethecoverproperly・

Notethatthetwocenterboltsarelongerthan theothers．

（忘＝コ4．2kg−m（30糾bs） Fig．1，3

● ー52−

2．4 TRANSMISS］ON REASSEMBLY （1）Reinstallingoutputshaft

① puttheoilbaffleinsidethetransmissioncase． Secureitwith3boltsandsealwashersfromthe rearsideofthecase．

②Installthesnapringontotheoutputshaft．

●

Turnthe shaftupsidedown andfittheball

bearlng．

●▲

③ Fittherollerbearingouterraceontotherear sideofthecase．

④Installthesnapringintothegrooveofthecase attheouterdiameteroftheouterrace．

● Fig．1，7 ー53−

⑤Installtherollerbearinginnerracefrominside ofthecase．

⑥ putthe20utPutgearSintheoilbafflewiththeir bossedsurfacesmatlngtOeaChother． Installtheoutputshaftintothecasefrom丘■Ont Sidethroughthe2gears．

⑦ Taptheoutputshaf［withasofthammerfrom theffontsidethroughthebearlng．

⑧ Attachthesnapringintothegrooveofthecase attheouterdiameteroftheballbearing，tO

SeCuretheoutputshaft．

Fig．201

●

⑨ ApplyLOCTITE＃2620ntheouterdiameterof theoilsealandfititintothefrontbearlngCaP， Withtheoilsealmainlip（springside）pointed towardtheinsideofthecase． Applygreaseontheoilseallips．

⑲ withanewgasket，installthebearingcaptothe frontsideofthetransmissioncasewith4bolts．

●

6：＝＝：：：コ1．9kg−m（14糾bs）

⑪Installtherollerbearinginnerraceontotherear Sideoftheoutputshaft．

⑫ putthespacerontheinnerraceandfititwitha hammer untilit comesin contact with the bearlng■sshoulder．

●

Fig．205

−55−

⑬ usingthesameprocedureforthefrontside， installanoilsealintherear−Sidebearlng．

Withanewgasket，1nStallthebearlngCaPOntO thetransmissioncaseandsecurewith4bolts． 1芯＝コ1・9kg−m（14ft−1bs）

⑭ Applygreaseonthechamferedareaandsliding Surfaceonthecompanionflange・Insta11the COmPanionflangeontotherearsideofthe OutPutShaft．Slidetheflangebackandfortha ftwtimestoensuresnug丘toftheseallip．

⑮Installthe‖0 −ringbetweentheshaftand nange．

⑯ puttheplateandapplyLOCTITE＃2620nthe threadedareaofeachofthe3bolts．Securethe Platewiththebolts．

ぢ：：：：コ 9．3kg−m（67ft−1bs）

（2）Reinstal1ingbackgear

①Installsnapringsintothebackgear．Fitball bearlngSfrombothsides．

Fig．209

ー56−

② setagreasedlockballintotheholeinthe larger−diameterendofthebackgearshaft．Use

Cautionnottodroptheball．

③ Attachthespacerinthetransmissioncaseinthe

areaonwhichthebackgear shaftfrontend rests．

④ putbackgearinpositioninthecase．Fitthe ShaftalignlngWiththelockballposition．

● ⑤ Afterinstallingtheshaft，attaChthesnapringin thegrooveinthecasetosecuretheshaft．

●

Fig．213

ー57−

（3）Reinstallingclutchshaft

① Liftthe3rd／4thspeedshaftwithahoist．Install the rearbearinglntO the holeinthe case， engaglngWiththeoutputgear．

②Installthesnapring，Smallergear（43T），and SnaPrlngOntOtheidlershaftinthatorder．Fit thebearlngOntOtheendoftheshaft． Installthe snaprlngOntOtheoppositeendof theshaft．

③ Engagetheidlershaftwiththehubgearonthe 3rd／4thspeedshaftandthebackgear．Fitthe

rearbearlnglntOtheholeinthecase．

④ Engagethelst／2ndspeedshaftwiththeidler gearandoutputgear．FittherearbearlnglntO theholeinthecase．

Fig．217

ー58−

⑤ Engagetheforward／reverseshaftwiththeback

gear・FittherearbearlnglntOtheholeinthe CaSe．

⑥ Attachthe55Tgearontotheidlershaft． Engagethatgearwiththehubgearoneachof

theclutchshaftsandsecurewiththesnaprlng・

● ⑦Fitthebe。血g。nt。theend。ftheidlersha氏．

⑧ putthetransmissioncaseupright．Installthe SnaPrlnglntOthegrooveattheouterdiameter

Oftherearbearingoneachofthe3clutch Sha氏s．

●

Fig．221 ー59−

⑨Instal13sealringsontheendofeachofthe3 Clutchshafts，andapplyconverteroil．

（4）Reinstallingdistributorcapandpiping

① put21−Ol一−ringsandagasketoneachofthe3 Clutch shaftsin the distributor cap fitting Surface．Putthedistributorcapandsecurewith 3bolts．

ぢ＝＝コ1．9kg−m（14氏−1bs）

② ApplyLOCTITE＃5720nthethreadedareaof therotationsensor． Screw the rotation sensorinto the case untilit

COmeSincontactwiththeoutputgear．Then backitoff1．5turns andsecurethe sensorwith thelocknut．

③Installapipebetweenthe3rd／4thspeedcapand lst／2ndspeedcap．

Installother2pipes．

Fig．225

ー60−

（5）Reinstallingtorqueconverter

① ApplyLOCTITEFMD−1270nthetransmission CaSeinitstorqueconvertermountlngSurface withoutabreak．Avoidtheboltholes．

② Liftthetorqueconverterwithahoistandmount itonthetransmissioncasealignlngthebearlng holesineachoftheshafts．

●

Alignthepositionsofthe2knockpinsandfit

theconveyerhouslngtOthetransmissioncase bytapplngWithasofthammer，untilthereisno

gapbetweenboth．

③ Tightenthe26bolts． Note：17boltsfrom the converter side and9from thetransmissionside． （忘：＝コ1・9kg−m（14糾bs）

● （6）ReinstallingcontroIvalve

① withanewgasket，installthevalve（lower SeCtion）ontothetransmissioncasewith3bolts．

ぢ＝コ 5・1kg−mn（37糾bs）

●

Fig．22，

−61−

② withanewgasket，installthevalve（upper SeCtion）ontothevalve（lowersection）withll bolts．

6：：：：コ 5．1kg−m（37銃−1bs）

（7）Reassemblingparkingbrakeandreinstalling it（One・Piecehousing）

①Installthediskhubontotheffont−Sidesplines Ofthelst／2ndspeedshaftandsecurewiththe SnaPrlng・

②Instal17platesand6disksontothediskhub alternately，and丘nallyattachtheendplate．

③ Applygreaseinthe‖0 −ringgroovesinthe brakehouslng andinstal12 0‖−rlngSinthe grOOVeS・

Fig．233 −62−

④Installthebrakehousingontotheconverter houslng，turn1ngthebrakehouslngtOtheright andlef［toengagewiththeplateteeth．

⑤ Apply2D−rings（1argeandsmall）andinstall intothegrooves attheouterdiameterofthe plStOn・

●

⑥ Applyagenerousamountofgreaseonthe brakehousinglnthepIStOn Sealcontacting

Surface．InstallthepIStOninto thebrake

houslng．

⑦ put18springsintotheholesinthepiston．

●

Fig．237

−63−

⑧ putthecapsoastoproperlyhousethesprings andknockpins．Installittothebrakehouslng With4socketbolts，tightenlngtheboltsinturns tocompressthesprlngSprOPerly・

（芯＝コ 5・1kg−m（37糾bs）

⑨Installtheremaining2hex．boltsandbrake releasebolt．

ぢ＝＝コ Hex．bolt（2）：5・1kg−m（37ft−1bs） ApplyLOCTITE＃5720nthethreadedareaof theplugandinstalltheplugtothecenterofthe Cap・

（8）Reassemblingbrakehousingandreinstalling it（splittypehousing）

① Applygreaseonthebrakepistonsliding surface． Applygreaseon2D−rings（1argeandsmall），

andinstallthemintothegroovesattheouter

diameterOfthebrakepIStOn．

②Installagreased‖0■，−ringintothe‖0 −ring grooveinthepistonhouslng・

③Instal1thebrakepistonintothepistonhousing．

Fig．241

ー64−

④ put18springsintotheholesinthepiston．

●

⑤ putthecapsoastoproperlyhousethesprings and knock plnS．Tighten2hex・bolts

alternatelytoproperlycompressthesprlngS

●

inside． （忘＝コ 5・1kg−m（37ft−1bs）

⑥Installthediskhubontothefront−Sidesplines Ofthelst／2ndspeedshaftandsecurewiththe SnaPrlng・

● ⑦In岳tal12greased‖0 −ringsintothe‖0‖−ring

groovesinthebrakehouslng・

⑧Installthebrakehousingtotheconverter houslngWith2socketbolts・ 6：：：：：コ 5・1kg−m（37ft−1bs）

●

Fig．245

−65−

⑨Instal17platesand6disksalternatelyontothe diskhub，andnnallyinstalltheendplate．

⑲Installtheparkingbrakesubassemblyontothe brakehouslngWith4socketbolts．

6：：：：：コ 5．1kg−m（37銃」bs）

⑪Installtheparkingbrakereleaseboltatthe POSitionshowninthesketchontheright．

ApplyLOCTITE＃5720nthethreadedareaof theplugandinstalltheplugtothecenterofthe Cap・

（9）Reinstallingchargingpump ①Instal1theflange（Withplug）ontothefrontside Oftheoutputshaft．

Fig．24，

−66−

（むInsertthesuctionstrainerintothetransmission CaSeandinstallthe‖0一

−ringbetweenthecase

andstrainer．

③ withanewgasket，installthesuctiontubeto thetransmissioncase．Tighten4bolts．

●

④Insertthepumpsleeveintothepumpdrive gear・

● ⑤ ApplyLOCTITEFMD−1270nthecharging fittingsurface．

Fig．253

ー67−

⑥Installthechargingpumpontotheconverter houslngandsecureitwith2bolts． ぢ＝＝コ 5・1kg−m（37ft−1bs）

⑦Installthe■一0一一−ringtotheflangesurfaceofthe SuCtiontube．Installtheflangetothecharglng pump・

Tighten4bolts．

Fig．255

● ー68−

3．TROUBLESHOOTINGGUIDE 3．1TORQUECONVERTERTROUBLESHOOTING Problem

Checkingmethod

Probablecause Low oil level

Checkoillevelwithoilsightgaugei

Remedy Addoiltospecined 1evel．

Useofimproperqualityof

ChangetospeciBedtype

oil

ofoil．

Defective cooler line

Checkcoolingwaterforcontamination． Checktorqueconverterinletoilpressure・

Clean．

Disassembleandreplace

thepart． Oilsealringdefective

Safety valve defective

Checkforoilblowlngfrombreather． Checktorqueconverterinletoilpressure・

Overheatingorlow

Disassembleandreplace thepart． Disassembleandreplace thepart・

Output

Checkforforelgnmatterindrainfrom transmlSSlOn．

Brokenbeanng Checkin−1inefilterandoil．

Disassembleandreplace thepart．

Checktransmissionstrainerforclogglng．

Clean．

Checktorqueconverterinletoilpressure・

Replacepump・

Checktransmissionclutchoilpressure．

Replacepump・

Abuse of loader

ChecktheoperatlngCOnditionand procedure

Use the loader in a PrOPermanner

Defectivetransmission

Reftrto‖3．2TRANSMISSIONTROUBLESHOOTING．

Insumcientdischargefrom CharglngpumP

Oilbaffleoilsealdefective Checkforleaksatflywheelside． Oilleaks（from flywheel）

Disassembleandreplace thepart．

Oilbaffle‖0‖−rlng defective

一

Replacethepart．

Checkわrleaksatflywheelside．

Replacethepart．

Checkforfbrelgnmatterindrainfrom transmlSS10n．

Disassembleandreplace thepart．

Checkthein−1inenlterandoil．

Disassembleandreplace

Bearingbroken

thepart・

Brokengearorimproper

Checkwithnoisedetector．

Disassembleandreplace 也epa丘

backlash Noise

Brokenpumporpumpdrive Checkwithnoisedetector．

Disassembleandreplace thepa丘

Airmixedinoil

Drainasmallamountofoilandcheckfor RetightenplPlngOr airbubbles．

replacethepart・

Useofimproperqualityof

Changetospecifiedtype

oil

ofoil．

−69−

3．2 TRANSM［SS10NTROUBLESHOOT［NG Problem

Checkingmethod

Probablecause

Remedy

Overheatedtorqueconverter Referto 3．1TORQUECONVERTERTROUBLESHOOTING． Low oil level

Checkoi11evelwithoilsightgauge．

Addoiltospecified 1evel．

Useofimproperqualityof

Changetospecifiedtype

oil．

Ofoil．

Checktransmissionclutchoilpressure．

OverheatlngOrlow Output

Lowclutchlube．oil

Checktorqueconverteroutletoilpressure．

Disassembleandreplace thepart． Cleanoilcooler．

preSSure・

Brokenbearlng

Checkforforelgnmatterindrainfrorn transmlSSlOn．

Disassembleandreplace thepan．

Checkin−1inefilterandoil．

LowenglneOutPutand Speed

CheckenglneStallspeed．

Adjustenglne．

Brokenbearingorimproper assemblyofbearing． Checkforforelgnmatterindrainfrom

Disassembleandreplace

transmlSSlOn．

thepart・

Checkin−1inefilterandoil． Noise

Brokengearortoomuch backlash．

Checkwithnoisedetector．

Checkfor董brelgnmatterindrainftom

Disassembleandreplace

transmlSSlOn．

血epa几

Checkin−1inenlterandoil． Seizedclutch

Checktransmissionclutchoilpressure．

Disassembleandreplace thepart．

Low oil level

Checkoillevelwithoilsightgauge．

Addoiltospecihedoil 1evel．

Defectivechargingpump． Checktransmissionclutchoilpressure（low Theloaderwon．t moveforwardor backward．

ineachspeedraヮge）・

Regulatorvalvestuckopen．

Checktransmissionclutchoilpressure（low Disassembleandreplace ineachspeedrange）． thepart．

Torqu？COnVerterlnputPlate mounting bolts broken Parkingbrakewonltbe

Referto

3．3PARKINGBRAKETROUBLESHOOTING．一一

released（stuckordragging）．

● ー70−

Problem

Checkingmethod

Probablecause

Manualspool（emergency Checkthepositionofmanualspoolin

travelspool）keptpushed controIvalve．

1ntOreVerSePOSitlOn

Remedy Pulloutspooltonormal posidon．

Loaderwon−tmove

forward（CanmOVe inreverse）．

Forwafdclutchslipping（F Checkforwardclutchoilpressure． solenoidvalveisnot

Disassemble and replace thepart．

Operating．） Reverse clutch seized

Checkwhetherloadermovesbackwardwith Disassembleandreplace Shiftleverinneutral． thepart．

Manualspool（emergency Checkthepositionofmanualspoolin travelspool）keptpulledout toforwardposition． Loaderwon

Disassemble and replace

tmove

backward（can

moveinforward）．

Pushinspooltonormal POSition．

solenoidvalveisnot

thepa丘

OPerating．） Forward clutch seized

Checkwhetherloadermovesforwardwith Di＄aSSembleandreplace shiftleverinneutral． thepart．

Loaderwon tmove 2ndspeedclutchslipping（A Check2ndspeedclutchoilpressure．

Disassemble and replace

Withshiftleverin

thepart・

Loaderwonltmove 1stspeedclutchslipping（A Checklstspeedclutchoilpressure．

Disassemble and replace thepart．

2ndspeedposition withshiftleverin

1stspeedposition．

Loaderwon．tmove 4thspeedclutchslipping（B Check4thspeedclutchoilpressure． Withshiftlevr ．

●

● −71−

Disassemble and replace thepart．

3．3 PARKING BRAKETROUBLESHOOT［NG Problem

Parking brake

Oilleaksfromparking brakepiston（Dring defective）

Remedy

Checkingmethod

Probablecause

Checkbrakeoilpressure（Checkforoil 1eaks）．

Disassembleandreplace thepart．

Disassembleandcheck．

Washandreplacethe

won−tbereleased （StuCkordragging）

Diskbrakedefective

（foreignmattercaughtin

Part・

plStOn，StuCkpiston，Or

brakedisksseized） Diskbrake−sbrakespnng

Replacethepart・

deteriorated or broken

Parking brake WOn．tbeapplied・

Disassembleandcheck．

Replacethepart．

（foreignmattercaughtin plStOn，StuCkpiston，Or

brakediskworn）

●

● −72−

4．STANDARDVALUES FOR MAINTENANCE （1）Tbrqueconverter（E835） Unit：mm（in）

Standardvalue

Item

Usefu11imit

0．13−0．23 （0．0051−0．0091）

Pump drive gear backlash

1．7

Width（axial）

1．95−2．05 （0．0768−0．0807）

（0．067）

Thickness（radial）

1．95−2．05 （0．0768−0．0807）

（0．075）

Widthofsealringgrooveinturbineshaft

2．1−2．2 （0．083−0．087）

（0．091）

I．D．ofstatorsupportinturbineshaftsealring

60．33−60．35 （2．375−2．376）

（2．378）

Width（a不ial）

1．95−2．05 （0．0768−0．0807）

（0．067）

Thickness（radial）

1．95−2．05 （0．0768−0．0807）

（0．075）

Widthofsealringgrooveinstatorsupport

2．1−2．2 （0．083−0．087）

（0．091）

I．D．ofimplellerwheelhubinstatorsupportsealring

79．38−79．40 （3．125−3．126）

（3．129）

Turbineshaftsealring

Slidingarea Statorsupportsealrlng

Slidingarea

1．9 2．3 60．41 1．7 1．9 2．3 79．48

（2）Tbrqueconverter（E840・L26）

Unit：mm（in） Standardvalue

Item

Pump drive gear backlash

Usefu11imit

2．0（0．079）

1．7（0．067）

Thickness（radial）

2．4（0．094）

2．2（0．087）

Widthofsealringgrooveinturbineshaft

2．1（0．083）

2．3（0．091）

I．D．ofturbineshaftinsealringslidingarea

52（2．05）

52．2（2．055）

2．38（0．0937）

2．1（0．083）

3．2（0．126）

3．0（0．118）

Widthofsealring亭rOOVeinguidecarrier

2．5（0．098）

2．7（0．106）

Ⅰ．D．ofguidecarrierinsealringslidingarea （I．D．ofpumpdrivesleeve）

92（3．62）

92．2（3．63）

（Ⅰ．D．ofguidecarrier）

Guidecarriersealring

Width（axial） Thickness（radial）

（3）ControIvalve（E835・E840・L26）

Unit：mm（in） Standardvalue

Item

Regulatorsprlng

Modulationsprlng

Remarks

0．13−0．23 （0．0051−0．0091） Width（axial）

Turbineshaftsealrlng

Remarks

Usefu11imit

Freeheight

97．9（3．85）

94．0（3．70）

Settingload kg（1bs）

31．62（69．71）

28．5（62．83）

Settingheight Freeheight

82．4（3．24） 53．1（2．09）

51．0（2．01）

Settingload kg（1bs）

7．27（16．0）

6．5（14．3）

Settingheight

34．5（1．36）

ー73−

Remarks

L26：Outer

Unit：mm（in） Item

Modulation spring （L260nly）

FlowsenslngSprlng

Standardvalue

Usefu11imit

Freeheight

53．1（2．09）

50．1（1．97）

Settingloadkg（1bs）

3．61（7．96）

3．3（7．28）

Settingheight Freeheight

34．5（1．36） 65．4（2．57）

Settingload kg（1bs）

0・90（2・0）

LoadpistonLspnng

116（4．57）

111．4（4．386）

Settingload kg（1bs）

10．58（23．32）

9．5（20．9）

SpooIAspnng SpooIBspnng

Throttlediameter

Inner

90（3．54）

Settingload kg（1bs）

116（4．57）

111．4（4．39）

27．38（60．36）

24．6（54．2）

Center

90（3．54）

Settingload kg（1bs）

F／RselectspooIspnng

0．8（1．8）

57．5（2．26）

Settingheight Freeheight

LoadpistonHsprlng

L26：Inner

62．8（2．47）

Settingheight Freeheight Settingheight Freeheight

Remarks

91（3．58）

87．4（3．44）

32．76（72．22）

29．5（65．0）

Settingheight Freeheight

109．9（4．327）

105．5（4．154）

Settingload kg（1bs）

15．69（34．59）

14．1（31．1）

Outer

65（2．56）

Settingheight Freeheight

109．9（4．327）

105．5（4．154）

Settingload kg（1bs）

23．23（51．21）

20．9（46．1）

Inner

85（3．35）

Settingheight Freeheight

84．9（3．34）

81．5（3．21）

Settingload kg（1bs）

28．16（62．08）

25．3（55．8）

Center

85（3．35）

Settingheight Free height

60（2．36） 39（1．54）

37．4（1．47）

Settingload kg（1bs）

8．47（18．7）

7．6（16．8）

Settingheight Freeheight

26．5（1．04） 43（1．69）

41．3（1．63）

Settingload kg（1bs）

6．84（15．1）

6．2（13．7）

Settingheight

32．5（1．28）

main（W）

6．0（0．236）

1st／2ndspeed（X）

0．9（0．035）

2ndspeed（Y）

0．9（0．035）

3rd／4thspeed（Z）

1．5（0．059）

solenoidvalve

0．8（0．031）

Outer

● −74−

（4）Transmission（E835・E840・L26） Unit：mm（in）

Item

Standardvalue

Ⅰ・D・OfdistributorcaplnClutchshaftsealringslidingarea

50．000−50．030 （1．9685−1．9697）

（fwd／rev，1st／2nd，3rd／4th）

Usefu11imit 50．08 （1．972）

1．7

1．95−2．05 （0．076・8−0．0807）

（0．067）

1．95−2．05 （0．0768−0．0807）

（0．075）

Widthofsealringgrooveinclutchshaft

2．10−2．15 （0．0827−0．0846）

（0．091）

Clutchplatethickness

1．65−1．75 （0．0650−0．0689）

（0．059）

Clutchdiskthickness

2，12−2．28 （0．0835−0．0898）

（0．075）

4．105−4．355 （0．1616−0．1715）

（0．155）

Width（axial）

Clutchshaftsealring Thickness（radial）

Freeheight Returnsprlng

Compressionloadwhen heightis2．20mm

92．2−112．8 （203．3−248．7）

（0．0866in）kg（1bs）

●

−75−

1．9 2．3 1．5 1．9 3．94

83．0 （183）

Remarks

5．MAJORBOLJTORQUECHART （l）Tbrqueconverter（E835） Tighteningtorquekg−m（ft−1bs）

Remarks

Pumpdrivegearfittingbolt

4．7（34）

ApplyLOCTITE＃262

Statorsupportfittingbolt

10．3（74．5）

Item

Oilbafflefittingbolt

5．6（41）

Frontcoverfittingbolt

2．0（14）

Inputplatenttingbolt

6．2（45）

Chargingpumpnttingbolt

5．1（37）

ApplyLOCTITE＃262

（2）Tbrqueconverter（E840・L26） Tighteningtorquekg−m（ft−1bs）

Remarks

Pumpdrivegearfittingbolt

4．7（34）

ApplyLOCTITE＃262

Guidecarrier（statorsupport）fittingbolt

10．3（74．5）

Sealcamier（Oilbafne）httingbolt

5．6（41）

Item

BoltsecurlnglmPellerwheel

E840

2．ト2．3（15−17）

tocoverwheel

L26

4．0−4．5（29−33）

Impeller hub fitting bolt

5．2−5．9（38−43）

Inputguidefittingbolt（E8400nly）

4．3−4．8（31−35）

Inputplatenttingbolt

E840

4．3−4．8（3l−35）

L26

5．5−6，2（40−45）

Charging pump fitting bolt

5．1（37）

（3）Transmission（E835・E840・L26） Item

Tighteningtorquekg−m（ft−1bs）

Distributorcapfittingbolt

1．9（14）

Outputshaftbearingcapnttingbolt

1．9（14）

Outputcompanionflangeretainerplate fittingbolt

9．3（67）

Parkingbrakenttingbolt

5．1（37）

Converterhousingnttingbolt

1．9（14）

ControIvalvefittingbolt

5．1（37）

−7（卜

Remarks

ApplyLOCTITE＃262

●

●

●

No．MU−64125AE lSSUED：Dec．，1997

TOYOUMFnNKICQ，LJD． 15−5，1−Chome，Nishi−Shimbashi，Minato−ku，lbkyo，105Japan FAX：Japan3・35918152 TELEX：）−23991TCMTOK

TRADINGOFF［CE：

●

AILrightsreserved

OT−0912040（F−085）PrintedinJapan

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● M TOYOUM臥NKICQLJD