TORQFLOW TRANSMISSION No.1 No.2 No.3 No.4 Nos il 7 8/9 fio jn ye fis] ia) as [ts Wome” 8 is 20 at ae 23 4 017502 F DIS5A-2 50901 and up Detail P 10-10017802 1 2. 3, 4, 5. 6 2. 8. a 10. "1 12, 13, 14. 16. 16. 7. 18 19, 20. 21 22. 23. 24, 28. 26. 27. 28, 29, 30, 31. 32, 33, 34, 36, 36. 37, 38, 39, 40. 41 42, 43, 44, 45, 46, Input coupling Front cover Input shaft (with gear No. 8) No. 1 sun gear (33 teeth) Pinion shaft 3. No. 1 planet gear (24 teeth) /. No. 1 ring gear (81 teeth) No. 2 sun gear (21 teeth) No. 2 ring gear (81 teeth) No. 2 planet gear (24 teeth) No. 3 ring gear (81 teeth) No. 3 planet gear (24 teeth) No. 4 ring gear (81 teeth) No. 4 planet gear (19 teeth) Pinion shaft No. 3, 4 sun gear (33 teeth, 42 teeth} ‘Transmission case No. 5 gear No. § clutch piston No. § clutch spring Output shaft ‘Transfer drive gear (29 teeth) Transfer case Bearing cage Bevel pinion (21 teeth) Cover Bearing cage Transfer driven gear (24 teeth) No. § piston housing No. § clutch housing Rear housing No. 4 carrier No. 4 plate No. 3, 4 piston housing No. 1, 2, 3 carrier No. 2 piston housing No. 2 planet gear (23 teeth) Pinion shaft No. 1, 2 plate Clutch spring Clutch plate Clutch dise Clutch piston Tie bolt Front housing Bearing cage ‘Speeds and operating clutches ‘Speed Operating clutch Neutral No clutch Firstspeed | No.1 and No.S clutches Forward | Second speed | No.1 and Nod clutches Third speed | No.1 and No clutches Neutral No.5 clutch reverse | Fifstspeed | No.2 andNoS clutches *S° | Second speed | No.2 and No.4 clutches Third speed | No.2 andNo clutches Number of dises and plates on each clutch Clutch No. | Number of dises] Number of plates No.t clutch 4 3 No.2 clutch 4 3 No.3 cluteh 3 2 No.é clutch 2 1 No clutch 5 4 10-11FUNCTION OF PISTON To lock ring gear (7), the discs (42) and plates (41) are brought into close contact. The clutch consists of a clutch piston (43), cluthe plates (41), clutch dises (42), pins (50) and piston return springs (40). ‘The disc's internal teeth engage with the ring gear’s external teeth, The plates, whose notch on the outside diameter engage with pins (50) on housing (45), are locked against the rotating direction. Piston (43) also is locked against the rotating direction, * Clutch engaged (oil pressure is acting) Oil from the control valve flows under pres- sure through the port in housing (45) to the piston (43). The piston presses clutch plates (41) and clutch discs (42) together, and the frictional force developed stops clutch discs (42) revolution, thus ring gear (7) meshing with the diso’s internal teeth is locked. + Cluteh disengaged {oil pressure is not acting) When the supply of pressure oil from the control valve is shut off, piston (43) returns to the initial position by the force of piston return spring (40), thus relieving the frictional force between plates (41) and discs (42), making the ring gear (7) free. 10-12 F15A01010 4 oe 017802 F15A01011 F15A01012Cc FUNCTION OF NO.5 CLUTCH When the gear shift lever is put “1st speed”, oil hole in the housings and output shaft (21), and then enters chamber A of piston housing (29). The oil entering chamber A pushes ball check valve (52) and closes passage a, and pushes piston (19) to the left, and then lock disc (42) and plate (41) with No. § gear (18). In other words, the motive force from No. 4 carrier (32) passes through No. 5 gear (18), clutch housing (30) and piston housing (29), and transmitted to output shaft (21). From the control valve 2. Clutch disengaged When the gear shift lever is put into 2nd or 3rd speed, the oil entering chamber A returns to the control valve, and the hydraulic force | pushing piston (19) is lost. ‘When this happens, piston (19) is returned to | the right by the tension of spring (20), and the force pushing disc (42) and plate (41) together is lost, so the transmission of motive force from No. 4 carrier (32) to output shaft (21) is lost During this action, if the return of oil from chamber A to the control valve is not carried 3 out quickly, No. 5 clutch will slip, and this will cause premature wear of the disc and plate. To prevent this, ball check valve (52) is in- stalled to drain the oil from chamber A to the transmission case to carry out disengage- ment of the clutch quickly. If the oil entering chamber A returns to the control valve, the force pushing ball check valve (52) on to seat (51) is lost. Ball check valve (52) then move to the outside under the centrifugal force caused by the rotation. Tae ee + To the As a result, the oil entering chamber A jeontrol vale! passes through the passage a and drains to the transmission case. F15A01013— | 017502 FIBSAOIONS 10-13 |POWER TRAIN OF TRANSMISSION FIRST FORWARD SPEED No.1 No.2 No.2 No.8 Nos, clutch Clutch elutch clutch lute 3 1 Fe cae ga) “2nd tat” \ a fom No. 1 clutch and No. 5 clutches engaged and No. 1 ring gear fixed, No. 5 gear and output shaft are engaged. With No. 1 and No. 5 clutches engaged, No. 1 ring gear (7) is fixed and No. 5 gear (18) and output shaft (21) are engaged. When No, 1 ring gear (7) is fixed, the rotation of the engine is transmitted to No. 1, 2, 3 carrier (35) with reduced turning speed through input shaft (3) and No. 1 sun gear (4). No. 1, 2, 3 carrier (35), then, rotates in the same direction as input shaft (3). 10-14 wo 8 a b F17502006 Since No. § gear (18) and output shaft (21) are engaged, No. 3, 4 sun gear (16), No. 3 ring gear (11), No. 4 carrier (32), No. 5 gear (18), No. 5 clutch housing (30) and No. § piston housing (29) are all engaged as a unit. The rotation of No. 1, 2, 3 cartier (35) is then transmitted to output shaft (21) in the same direction and at the same speed. The rotation of output shaft (21) is transmitted to bevel pinion (25) with reduced turning speed through transfer drive gear (22) and transfer driven gear (28) Bevel pinion (25) then rotates in the opposite direction to output shaft (21) 017502 (G 017802 FIRST REVERSE SPEED No.1 No.2 No.3 No.4 clutch clutch clutch clutch 4 1 ieee Sed oe 3 6 No, 2 clutch and No. 5 clutches engaged and No. 2 ring gear fixed, No. § gear and output shaft are engaged, With No. 2 and No. 5 clutches engaged, No. 2 ring gear (9) is fixed and No. 5 gear (18) and output shaft (21) are engaged When No. 2 ring gear (9) is fixed, the rotation of the engine is transmitted to No. 1, 2, 3 carrier (35) with reduced turning speed through input shaft (31, No. 2 sun gear (8) and 2 sets planetary gears. No. 1, 2, 3 carrier (35), then, rotates in the opposite direction as input shaft (3) 28d TLE Y, No. § cluich Ist 3 18 4 2 30 a a au F17502007 Since No. 5 gear (18) and output shaft (21) are engaged. The rotation of No. 1, 2, 3 carrier (35) is transmitted to output shaft (21) in the same Way as in first forward speed. The rotation of output shaft (21) is transmitted to bevel pinion (25) with reduced turning speed through transfer drive gear (22) and transfer driven gear (28) Bevel pinion (25) then rotates in the opposite direction to output shaft (21) 10-15TRANSMISSION CONTROL c 017602 178F02017 1. Gear shift lever 2. Lock lever 3. Transmission control valve @ 10-16017502 TORQFLOW HYDRAULIC PIPING Oil cooler 2. Torque converter 3. Torque converter regulator valve 4. Transmission pump (FALO45) 5. Transmission lubricating valve 6. Transmission control valve Detail Y 178F02018 7. Brake lubricating valve 8 Oil strainer 9. Steering main relief valve 10. Torque converter relief valve 11, Torque converter scavenging pump 12. Transmission oil filter 10-17TORQFLOW HYDRAULIC SYSTEM ( F17502008 10-18017802 TORQFLOW HYDRAULIC CIRCUIT DIAGRAM %£1. Applicable Serial No. $0901 and up. [_ |Set pressure: 20 kg/em* “1 GE1. 22 kg/em?) [Tbe Set pressure: 12.6 kg/em? {tet 2nd and XK AL TR c (no. otutch (150 So . LIF Wo. 4 clutch ned a \—{F-Wo.3etuch (ara Ur) Cracking = oI T pressure: SELETRT=——3, setpressure | |g 12kg/em ALT WL aS kfm | bt 4 > Ce ° a Lf no,2 ttch or FALOaS : | [Set pressure a} LTE ito. eaten 7 Kaien Discharge ee savmin [a Satpesre Engine at AF] > ete kalomt—t 2,000 spn) a “4 } | : M i (« 2 -—— wh 8 tal ; PO tae, sda T Set pressure’ 1 Le : by ut ieee 17502609 1, Steering case 2.Oil strainer 3. Transmission pump. (FALO45) Oil filter Modulating valve . Quick return valve Reducing valve Speed valve F-R valve Torque converter relief valve Seanann 11. Torque converter 12. Torque converter regulator valve 13. Oil cooler 14.P.1.0. lubrication 15. Transmission lubrica~ tion relief valve 16. Transmission lubrication 17. Torque converter case 18. Scavenging pump 19. Brake lubrication relief valve 20. Brake lubrication A. Plug for transmission clutch pressure 8. Plug for relief pressure C. Plug for regulater pressure ©. To steering pump E, From steering main relief valve 10-19TRANSMISSION CONTROL VALVE D155A-2 50001 — 50900 tt a | Cc eee 017502 KS 175F02016 10-20017602 1. Cover 2. Modulating valve spring 3, Modulating sleeve spring 4.Spring seat 5. Modulating valve spring 6. Valve body 7. Modulating valve spool 8. Modulating vaive sleeve 9.Piston 10. Piston spring 11 Piston 12. Stopper 13. Cover 14. Quick return valve sleeve 1. Quick return valve 16. Piston 17.Spring 18. Piston 19. Reducing valve 20. Reducing valve spring 21. Stopper 22. Stopper 23.F-R valve 24. Valve body 25. Spacer 26. Cover 27. Speed valve spool To torque converter circuit From transmission pump To speed valve H To speed valve K To forward clutch port (No. 1) To reverse clutch port (No. 2) To 1st speed clutch port (No. 5) From reducing valve C To 2nd speed clutch port (No. 4) From reducing vaive D To 3rd speed clutch port (No. 3) ce RAGrOmmMoOD> MODULATING VALVE OUTLINE + The modulating valve consists of a modulat- ing relief vaive and @ quick return valve, and acts to modulates the pressure. + When the gear shift lever is operated to shift gear, the clutch is pushed into close contact by the piston. However, if high pressure is suddenly applied, the piston will suddenly engage the clutch. This will make the ma- chine suddenly start, and it will receive an ex- cessive shock To prevent this, the modulating valve is in- stalled. When the gear shift lever is operated to shift gear, the pressure on the piston grad- ually rises to the set pressure and the clutch is engaged smoothly. This allows the ma- chine to start without any shock, thereby improving the durability of the power train ‘and at the same time providing a comfortable ride for the operator. The figure shows the relationship between the time and the increase in the hydraulic pressure of the modulating valve. For example, when the gear is shifted from F1 to F2, the oil from the pump passes throug the speed valve spool, flows to the second clutch and fills the circuit up to the clutch piston port. The time taken for the circuit to be filled up to the clutch piston port is called the “filling ime”, and the oil pressure during this time is O kg/em*. When the circuit up to the clutch piston port is filed with oil, the oil pressure starts to rise. The time taken for the pressure to rise to the set pressure is called the “build-up time”. The filling time and build-up time together are called the “modulating time”. Modulating graph Modulating tine a erie a. een 20) | Dy 3 i © 10 = = a) Time F15a01022 10-21D155A-2 50901 and up \\AA EEL ZA, 017802 b 17503001 10-21-1c i 017502 1. Cover 2, Modutating valve spring 3. Modulating sleeve spring 4 Spring seat 5. Modulating valve spring 6. Valve body 7, Modulating valve spool 8. Modulating valve sleeve 9. Piston 10. Piston spring 11. Piston 12. Stopper 13. Cover 14. Quick return valve sleeve 15. Quick return valve 16.Piston 17. Spring 18.Piston 19. Reducing valve 20. Reducing valve spring 21. Stopper 22. Stopper 23.F-R valve 24, Valve body 25. Speed valve spool To torque converter circuit From transmission pump. To speed valve H To speed valve K To forward clutch port (No. 1) To reverse clutch port (No. 2) To 1st speed clutch port (No. 5) From reducing valve C To 2nd speed clutch port (No. 4) From reducing valve D To 3rd speed clutch port (No. 3) rACZO™MoORD MODULATING VALVE OUTLINE + The modulating vaive consists of a modulat- ing relief valve and a quick return valve, and acts to modulates the pressure. + When the gear shift lever is operated to shift gear, the clutch is pushed into close contact by the piston. However, if high pressure is suddenly applied, the piston will suddenly engage the clutch. This will make the ma- chine suddenly start, and it will receive an ex- cessive shock. To prevent this, the modulating valve is in- stalled. When the gear shift lever is operated to shift gear, the pressure on the piston grad- vally rises to the set pressure and the clutch is engaged smoothly. This allows the ma- chine to start without any shock, thereby improving the durability of the power train and at the same time providing a comfortable tide for the operator. + The figure shows the relationship between the time and the increase in the hydraulic pressure of the modulating valve. For.example, when the gear is shifted from FI to F2, the oil from the pump passes throug the speed valve spool, flows to the second clutch and fills the circuit up to the clutch piston port. The time taken for the circuit to be filled up to the clutch piston port is called the “filling time", and the oil pressure during this time is, Okg/om?. When the circuit up to the clutch piston port is filled with oi, the oil pressure starts to rise. The time taken for the pressure to rise to the set pressure is called the “build-up time”. The filling time and build-up time together are called the “modulating time”. + Modulating graph Modulating time (kg/em [8 fng C= buon A - D nt ji ? to} 33-7, {Seo Time F15A01022A, 10-21-2OPERATION 1. While traveling (Range A and D in Fig. F15A01022) The oil from the transmission pump en- ters port A, chamber B and chamber E. The oil passes through orifice b and goes from chamber F through the reducing valve, speed valve and F-R valve to fill the two sets of clutch piston ports. The pressure in this circuit is always set by the action of modulating valve to 20 kg/cm? (31. 22 kg/cm?).When the press- ure inside the circuit becomes higher, the modulating valve (7) and sleeve (8) moves to the left. It opens the passage between chamber B and port D, so the oil from the pump is relieved to port D. If the pressure inside the circuit drops be- cause of leakage of oil from the clutch piston or valve, the modulating valve (7) and sleeve (8) moves to the right. This closes the passage between chamber B and port D, so the oil from the pump all flows from port A into the circuit to the clutch piston port. 2. Immediately after shifting gear shift lever (Range B in Fig. F15A01022) When the gear shift lever is moved, the cirouit from the transmission pump to the piston port of the clutch after gear shift- ing is opened and oil flows to the clutch piston port. When this happens, a difference in press- ure is generated between chamber E and chamber F because the oil is restricted by orifice b. Because of the pressure at chamber E, quick return valve (15) moves to the left. This connects chamber G and drain port H and relieves the back press- ure on sleeve (8) When this happens, modulating valve (7) and sleeve (8) are moved to the right by the tension of springs (2), (3) and (5). %#1. Applicable Serial No. 50901 and up 10-22 fotorque From {Lg cower pom A 8 et oi oe (ex € 4 -f 4 2 b- : 7 a ‘To reducing valve 8 Fisazio18 {1 a Smete pump Ae f ee ry 45 roretucing vate 18 riseator9 Towwaue Fon gg 8. TD converter : pump > ie MW tet a ae ‘ cI X 2 by : ECP dk 2 ‘To reducing valve % F15¢21020 017502@ 017502 3. While clutch pressure is rising (Range C in Fig. F15A01022) When the oil sent under pressure from the pump fills the circuit from port A to the clutch piston port, the oil pressure starts to rise, When this happens, the difference in pres- sure on both sides of orifice .b is removed. Quick return valve (15) moves to the right and the passage between chamber G and drain port H is closed. The oil flows through orifice a to chamber C and pushes piston (11). The reaction to this makes modulating valve (7) compress springs (2) and (5) and move to the left. This opens the passage from chamber B to port D. At the same time, the oil passing from orifice ¢ through the chamber in the cener of quick return valve (15) then passes through orifice d and enters chamber G. The oil becomes the back pressure of sleeve (8), compresses spring (3) and move the sleeve (8) to the left to the passage between close chamber B and port D. This operation is repeated continously to in- crease the load on springs (21, (3) and (6). In this way, the hydraulic pressure inside the cir cuit gradually rises and finally sleeve (8) comes into’ contact with the cover and cannot move any further. When this happens, modulating valve (7) stops in a position where the passage be- tween chamber B and port D is open, and the rise in pressure is completed. The hydraulic pressure at this point is 20 kg/om?. The oil relieved from chamber B to port D flows from port D into the torque con- verter circuit. Totorqe From 81 ©. converter pump faa Toroducing valve 1 9 Tetorque From converter pump A tet i] 2 » 35% oresucing vane do Soi pomp tht ACW 1 eee F oe 3 § © Toredueing valve pos u s e a 4 15 15421021 aoe n 1. £ a 4 15 F18421022 arc vil ie . 4 ie 15 £18421023 10-23