TC TM GR-800-1-00211

GR-800-1-00211
thomas yulianto 2024/05/11 10:04:14 JST
Publication No. W561-0102E
02
Torque converter
Transmission
RF80C-76F4
Model RF80M-77J0
page 1 of 67
GR-800-1-00211
Foreword
Foreword
This service manual gives the disassembly and WARNING
reassembly procedures for torque converters and Never touch the body cases during operation
transmissions used in rough terrain cranes. and immediately after operation.
The models covered are listed below. Touching the body can cause burns.
Before starting repair these units, check the model
to
Never get close to rotating parts of the body
code given on the model plate on the unit.
during operation.
Use this manual in conjunction with the relevant parts You can be caught in the rotating parts, resulting
catalog, service manual and other reference materials
in an injury.
and make proper preparations.
Never operate the manual lock device on the tip
of the solenoid valve when the engine is
1. model running.
Applicable crane
When operating the manual lock device
once
The table below shows the relationship between the while the engine is not running, always return it
crane models, the models of torque converters, and to the original state.
transmissions used. If the manual lock device is operated or left in
operation while the engine is running, the
vehicle can start and cause an injury.
Model
Eyes on the
body cases are provided to hang
Crane Torque converter Transmission themselves only. Before lifting, always remove
TR-800XXL-4 the accessories including the pump, propeller
GR-800XL-1 shafts, flexible joints and motors from the main
TR-600XXL-4 unit, otherwise the eyes can be damaged due to
GR-600XL-1 excessive loads, leading to an injury.
RF80C-76F4 RF80M-77J0
GR-700EXL-1
GR-700EX-1
GR-550EX-1
[NOTICE]
There is a case that the appearance and so on
differ from the parts for this crane. Although there is
not so much difference in functions and
disassembly procedures, make sure of the serial
number of this crane and the
part sales unit
described in theparts 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 W561-0102E
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GR-800-1-00211
Foreword
2. Contents 2.4 Control valve assy.....................................27

2.5 Forward-reverse selector valve assy ........27
2.6 Forward-reverse select 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 W561-0102E
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GR-800-1-00211
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 ................................................... 56
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
Torque Converter Circuit ....................... 65
3 W561-0102E
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GR-800-1-00211
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 W561-0102E
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GR-800-1-00211
Structure
1.2 Torque converter external view
5 W561-0102E
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GR-800-1-00211
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 W561-0102E
page 7 of 67
GR-800-1-00211
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 W561-0102E
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GR-800-1-00211
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.Bolt with washer
5.Gasket 23.Washer 41.Shim 59.Flange bolt
6.Gear (N) 24.--- 42.O-ring 60.Flange bolt
7.Snap ring 25.--- 43.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 (output coupling) 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 W561-0102E
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GR-800-1-00211
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 W561-0102E
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GR-800-1-00211
Structure
1.7 Solenoid valve assy
1.Body 2.Gasket 3.Solenoid valve 4.Choke
10 W561-0102E
page 11 of 67
GR-800-1-00211
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 18 13.3 23 17
1.7-4 Choke 7 5.2 10 7.4
Conversion table
Torque, moment
N-cm N-m ft-lbf inch-pound,

kgf-cm kgf-m foot-pound, in-lbf
-2 -1 -3 -3 -2
1 1×10 1.01972×10 1.01972×10 7.37562×10 8.85074×10
2 -1 -1
1×10 1 1.01972×10 1.01972×10 7.37562×10 8.85074
-2 -2 -2 -1
9.80665 9.80665×10 1 1×10 7.23301×10 8.67961×10
2 2
9.80665×10 9.80665 1×10 1 7.23301 8.67961×10
135.58 1.3558 13.83 0.1383 1 12
11.3 0.113 1.1525 0.01153 0.08333 1
11 W561-0102E
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GR-800-1-00211
Structure
2. Transmission
2.1 Transmission sectional view
12 W561-0102E
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GR-800-1-00211
Structure
2.2 Transmission external view
13 W561-0102E
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GR-800-1-00211
Structure
2.3 Transmission assy
14 W561-0102E
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GR-800-1-00211
Structure
15 W561-0102E
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GR-800-1-00211
Structure
16 W561-0102E
page 17 of 67
GR-800-1-00211
Structure
1.Hydraulic clutch assy (F2,R) 49.Spring 98.--- 147.---
2.Hydraulic clutch assy (F3,F1) 50.Spring 99.--- 148.---

3.Control valve assy 51.Shift bar 100.Pressure spring 149.---
4.Transmission housing 52.Shift fork 101.--- 150.---
5.Gasket 53.Spring pin 102.Plug 151 .Snap ring
6.Housing cover 54.Washer 103.--- 152.Choke
7.Gasket 55.Cover 104.Breather 153.Gear (H)
8.Front housing 56.O-ring 105.Coin filter 154.Gear (G)
9.Shaft assy 57.Piston 106.--- 155.Washer
10.--- 58.O-ring 107.Rivet 156.Ball bearing
11.Flange (input coupling) 59.Collar 108.Bracket 157.Washer
12.Output shaft 60.U packing 109.--- 158.Retaining ring

13.Gear (K) 61.Bolt 110.Shroud 159.Roller bearing
14.Gear (U) 62.Washer 111.Joint(elbow) 160.Thrust washer
15.Shaft 63.O-ring 112.O-ring 161.Retaining ring
16.Flange (output coupling) 64.Cover 113.Pressure sensor 162.Ball bearing
17.Sleeve (B) 65.Gasket 114.O-ring 163.Washer
18.Oil seal 66.Speedometer gear 115.O-ring 164.Snap ring
19.Oil seal 67.Ball 116.Gasket 165.Gear (I)
20.O-ring 68.Snap ring 117.Bolt 166.Ballbearing
21.Washer 69.Ball
bearing 118.Bolt 167.Snap ring
22.Bolt 70.Snap ring 119.Bolt 168.Sleeve (A)
23.Parallel pin 71.Speedometer driven gear 120.Bolt 169.Shift fork
24.Gear (W) 72.Speedometer bushing 121.Bolt 170. Shift bar
25.Shaft 73.O-ring 122.Bolt 171. Bolt
26.Speedometer case 74.Hexagon socket set screw 123.Bolt 172. Nut

27.Gasket 75.Oil seal 124.Bolt 173.Wire
28.Cover 76.Strainer assy 125.Flange bolt 174.Adapter
29.Gasket 77.Gasket 126.Flange bolt 175.O-ring
30.Cover 78.Flange 127.Hexagon socket head bolt 176.---
31.Gasket 79.Oil gauge 128.Hexagon socket head bolt 177.Spring
32.Cover 80.Pipe 129.Hexagon socket head bolt 178.Cover
33.Oil seal 81.Plug 130.Hexagon socket head bolt 179.Coller
34.Oil seal 82.O-ring 131.Nut 180.Seal washer
35.Cover (D) 83.Piston 132.Plug 181.Bolt
36.Gasket (D) 84.Pressure spring 133.Plug 182.Spacer
37.Ball bearing 85.Pressure spring 134.Plug 183.Cover
38.Ball bearing 86.Piston 135.Plug 184.O-ring
39.2/4 wheel drive detection 87.pressure spring 136.--- 185.Bolt
switch 88.Valve piston 137.Mark band 186.Ball bearing
40.Seal washer 89.Spring 138.Mark band 187.Bolt
41.Pickup sensor 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.Ballbearing 96.--- 145.---
48.Spacer 97.--- 146.---
17 W561-0102E
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GR-800-1-00211
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 W561-0102E
page 19 of 67
GR-800-1-00211
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 W561-0102E
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GR-800-1-00211
Structure
2.6 Solenoid valve assy (F-R, speed selector)
1.Valve body 6.Gasket (A) 11.Solenoid valve assy 16.Gasket (D)

2.Spool (range selector valve) 7.Cover (B) 12.Clip 17.Coin filter
3.Spool (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 W561-0102E
page 21 of 67
GR-800-1-00211
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
2.3-132 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
Conversion table
Torque, moment
N-cm N-m ft-lbf

inch-pound,
kgf-cm kgf-m foot-pound, in-lbf
-2 -1 -3 -3 -2
1 1×10 1.01972×10 1.01972×10 7.37562×10 8.85074×10
2 -1 -1
1×10 1 1.01972×10 1.01972×10 7.37562×10 8.85074
-2 -2 -2 -1
9.80665 9.80665×10 1 1×10 7.23301×10 8.67961×10
2 2
9.80665×10 9.80665 1×10 1 7.23301 8.67961×10
135.58 1.3558 13.83 0.1383 1 12
11.3 0.113 1.1525 0.01153 0.08333 1
21 W561-0102E
page 22 of 67
GR-800-1-00211
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
Torque converter Fluid coupling

the stator support assy.
2. Usually the driving power from the engine is
transmitted to the impeller wheel, then to the

TP TP
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 has radial vanes, oil flows
(impeller)
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. the turbine blades while
along 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 flow

Rotating
torque, high transmission efficiency can be
achieved.
Pump (impeller) Vortex flow Turbine
IW561-0031J018E
22 W561-0102E
page 23 of 67
GR-800-1-00211
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 W561-0102E
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GR-800-1-00211
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 fluid
as 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
01
0.2 0.4 0.6 0.8 0 .
Speed ratio
IW561-0031J022E
24 W561-0102E
page 25 of 67
GR-800-1-00211
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 W561-0102E
page 26 of 67
GR-800-1-00211
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

st nd rd
Forward 1 (F1), Forward 2 (F2), Forward 3
(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 W561-0102E
page 27 of 67
GR-800-1-00211
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
st
1. This valve controls the forward 1 (F1) clutch,
nd rd
forward 2 (F2) clutch, Forward 3 (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 W561-0102E
page 28 of 67
GR-800-1-00211
Function
4. The pressure oil also flows into the accumulator to 2.6 Forward-reverse select modulation
charge the accumulator built in the transmission.

1. When the gear shift position is in neutral, pressure
rd
5. When the gear shift is at the 3 oil from the charging pump flows through the
position speed,
the solenoid valve is The pressure orifice into the hydraulic valve (F1) (F2)and (F3),
(F3) energized.
oil flows into the valve and and then flows into the solenoid valve (R).
through hydraulic (F3),
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 W561-0102E
page 29 of 67
GR-800-1-00211
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 23 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
F1ONOFFOFFOFFONOFF
F2OFFONOFFOFFONOFF
F3OFFOFFONOFFONOFF
F4ONOFFOFFOFFOFFON
F5OFFONOFFOFFOFFON
F6OFFOFFONOFFOFFON
R1OFFOFFOFFONONOFF
R2OFFOFFOFFONOFFON
N OFF OFF OFF OFF OFF OFF
29 W561-0102E
page 30 of 67
GR-800-1-00211
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 4-wheel drive to 2-wheel
drive. A switch is provided to detect the
2/4-wheel drive position.
30 W561-0102E
page 31 of 67
GR-800-1-00211
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 W561-0102E
page 32 of 67
GR-800-1-00211
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 to the to
leading atmosphere
plates and disks. The shaft supporting the of the clutch.
prevent an erroneous operation
clutches has internal passages for clutch
7. As the clutch drum and clutch piston rotates at
operating oil and lubricating oil.
high speed, the oil remaining between the clutch
2. The disk has a paper type surface for better wear drum and is
piston pressurized by centrifugal
resistance and improved smoothness at the time force and could the clutch and
push piston
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 the to
push piston
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 The
engagement. centrifugal
internal passage to the space between the clutch force steel ball and makes the
moves radially
drum and the clutch piston. the oil in the oil
pinhole open, allowing remaining
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 W561-0102E
page 33 of 67
GR-800-1-00211
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 W561-0102E
page 34 of 67
GR-800-1-00211
Function
2.14 Hydraulic circuit diagram
34 W561-0102E
page 35 of 67
GR-800-1-00211
Troubleshooting
Troubleshooting
1. Power cannot be transmitted.
Fault and cause Measures
Measure the engine speed with the

transmission shifted to neutral and under
Engine Engine does not rotate normally. a stall condition.

within the
the
If the
speed is not
specified limits, adjust or repair
engine.
Insufficient oil Supply oil.
Hydraulic
system
Torquecnvt
Faulty charging pump Repair or replace
Damaged input plate Replace
Mechanical
Broken input plate mounting bolts Replace
parts
Damaged shaft or gear Replace
Damaged piston or spring of inlet relief valve or
main pressure regulating valve

Replace
Hydraulic
Faulty operation of spools in control valve assy
Check and
system replace
(hydraulic valve)
Faulty operation of solenoid valve Repair or replace
Transmi o Mechanical
Damaged
Damaged
seal
shaft
Damaged spline
ring
or gear
Replace
Replace
Repair or replace
Damaged clutch drum Replace
parts
Damaged snap ring for back plate Replace
Damaged clutch drive plates or disks Replace
35 W561-0102E
page 36 of 67
GR-800-1-00211
Troubleshooting
2. Power drops. (Speed cannot increase.)

Measure the engine speed with the

transmission shifted to neutral and
Engine Engine does not rotate normally. under a stall condition.

not within the
the
If the speed is
specified limits, adjust or
repair engine.
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
system Faulty operation of solenoid valve for lock-up Check and replace
Torquecnvt
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
Damaged piston or spring of main pressure

Replace
regulating valve
Damaged piston or spring of inlet relief valve or
main pressure regulating valve

Replace
Hydraulic Faulty operation of spools in control valve assy
Transmi o
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 W561-0102E
page 37 of 67
GR-800-1-00211
Troubleshooting
3. Oil temperature rises abnormally.

Excessive or insufficient oil Adjust oil quantity.

Hydraulic Seized charging pump Check and replace
Torquecnvt
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
Hydraulic
Transmi o
Damaged lubricating oil flow control valve
system Replace
(damaged spring)
Clogged strainer Clean or replace
parts Seized or damaged bearing Replace
4. Unusual noise is heard.
Hydraulic Faulty charging pump Check and replace

system Oil with air mixed in it entered charging pump. Inspect joints and gaskets.
Torquecnvt
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 oil.
(cavitation) Supply
system
Damaged gear or spline Replace
Mechanical
Damaged bearing Replace
Transmi o
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
Shift position not in neutral Set shift position to neutral.
el drive selector
shifted Vehicle not completely stopped Stop vehicle completely.
37 W561-0102E
page 38 of 67
GR-800-1-00211
Troubleshooting
5. There exists drag torque.
Faulty operation of check ball in clutch piston Check and replace

Faulty operation of spool in control valve ass'y
Hydraulic Check and replace
(hydraulic valve)
Transmi o
system
Clogged drain line in solenoid valve or hydraulic Check and replace
valve

parts Damaged clutch return spring Replace
6. Clutches do not properly work.
Damaged clutch seal ring Replace
Hydraulic Faulty operation of check ball in clutch piston Check and replace
Transmi o
system
Clogged hydraulic circuits like modulating valve, Check and clean
hydraulic valve or solenoid valve
Mechanical
Worn-out clutch drive plates and disks Replace
parts
7. Shocks are felt when clutches are changed.
Faulty operation of accumulator piston for speed Check and replace

selector valve
Transmi o Hydraulic
system
Faulty operation of accumulator piston
High/Low selector valve
for
Check and replace
8. Shift between 2-wheel and 4-wheel drives cannot be achieved.
Air cylinder Air leakage due to damaged piston packing Replace packing.
parts
Damaged
Damaged
shifter fork
shifter fork return spring

Replace
Replace
38 W561-0102E
page 39 of 67
GR-800-1-00211
Troubleshooting
9. Shift between High and Low speeds cannot be achieved.
Air cylinder Air leakage due to damaged piston packing Replace packing.
parts
Damaged
Damaged
shifter fork
shifter fork return spring

Replace
Replace
39 W561-0102E
page 40 of 67
GR-800-1-00211
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 W561-0102E
page 41 of 67
GR-800-1-00211
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
bolt unit. Remove O-ring from front cover.

Eye
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,

thrust washer, One-way clutch retainer B, Snap
Gear
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
One-way clutch
Outer race
Inner race Stator

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

bearing
IW561-0081E027
Impeller assy
IW561-0081E025
41 W561-0102E
page 42 of 67
GR-800-1-00211
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
Piston
Disc
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 W561-0102E
page 43 of 67
GR-800-1-00211
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 W561-0102E
page 44 of 67
GR-800-1-00211
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.)
IW561-0081E043
Piston
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
25.Remove snap and out ball plate
ring, pull 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 W561-0102E
page 45 of 67
GR-800-1-00211
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 W561-0102E
page 46 of 67
GR-800-1-00211
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 W561-0102E
page 47 of 67
GR-800-1-00211
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 W561-0102E
page 48 of 67
GR-800-1-00211
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 W561-0102E
page 49 of 67
GR-800-1-00211
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 W561-0102E
page 50 of 67
GR-800-1-00211
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 allhydraulic clutches, the following description on
hydraulic clutch (F3, F1) assy can be applied to
others.
50 W561-0102E
page 51 of 67
GR-800-1-00211
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,
out gear assy and Special

pull using a puller, 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 W561-0102E
page 52 of 67
GR-800-1-00211
Disassembly
2.3 Counter shaft
Do not disassemble gear shrinkage-fitted to shaft.
2.4 Output shaft
52 W561-0102E
page 53 of 67
GR-800-1-00211
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 gaskets with new ones.

parts in clean oil and remove
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 oil flow control valve
lubricating
seals, disks and gaskets. and control valve that are built in the converter
2. oil seals and housing, and apply genuine oil to them before
Replace O-rings, D-shaped rings,
with installing them.
gaskets new ones.
3. bolts to the 4. Tighten bolts to the specified torque. (See

Tighten specified torque. (See
Tightening Torque Table.) Tightening Torque Table.)
4. Wind threads before 5. Wind sealing tape on threads before screwing

sealing tape on screwing
taper pipe threaded parts. Be careful not to allow
taper pipe threaded parts. Be careful not to allow
of to enter any fragments of sealing tape to enter hydraulic

any fragments sealing tape hydraulic
circuits. circuits.
5. threads before threadlockers 6. Degrease threads before applying threadlockers

Degrease applying
to them. Be careful not to allow residual to them. Be careful not to allow residual locking
locking
to enter circuits. compound to enter hydraulic circuits.
compound hydraulic
6. When oil seal, the space 7. When installing an oil seal, pack the space
installing an pack
between with Albania Grease No. 2 No. 3 between lips with Albania Grease No. 2 or No. 3
lips or
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 and
installing O-rings 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 W561-0102E
page 54 of 67
GR-800-1-00211
Oil
Oil [NOTICE]
Check the oil level when the oil temperature is
1. Recommended oil
approx. 50°C(122°F).
[NOTICE] Total oil quantity: approx. 30L (7.93 gal)
Torque converter oil should have the following
properties: 3. Run the for approx. five minutes, and add
engine
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.

6.5L (1.72 gal))
2.2 Oil filling

[NOTICE]
Pour oil while being careful not to allow dusts, water,
etc. to enter.
Either insufficient or excessive oil may cause
troubles.
1. While the engine does not run, remove the oil filler
plug from the torque converter, and pour oil.

(Approx. 25L (6.61 gal))
2. Shift the gear shift lever to 'N' and set the PTO to
-1
'OFF'. With the engine idling (at approx. 670 min ),
gradually add oil.
54 W561-0102E
page 55 of 67
GR-800-1-00211
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] the gear shift lever.
pressures by changing
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, 2
Standard valve kPa {kgf/cm } (psi)
No abnormal vibration, and Item -1 -1
670min 2600min
No oil leakage.
Torque converter 30 {0.3} or more 300-700{3-7}
inlet pressure (4.35) (43.5-101.5)
[NOTICE]
When be to drive the tires Torque converter 20 {0.2} or more 300-500{3-5}
checking conditions, sure
in the 4-wheel drive mode. outlet pressure (2.9) (43.5-72.5)

Clutch pressure 1.9 MPa 2.1 -
2.45 MPa
2. Extend the outrigger jacks and shift the gear shift {19.4} {21.4 25} -
lever to 'N', 'D' and 'R', and change the engine (275.5) (304.5-355.3)
from low to at each shift to Transmission 5-50 80-150
speed high position
lubricating oil {0.05 0.5}
-
{0.8-1.5}
make sure that:
pressure (0.7-7.25) (11.6-21.8)
No unusual noise,
No abnormal vibration, and
No oil leakage.
2. Pressure measurement
1. Run the torque converter to raise the torque

converter oil temperature to approx. 50°C(122°F).
2. Measure the clutch pressure, torque converter
inlet pressure and torque converter outlet

-1
pressure at the idling speed (670 min )andatthe
-1
maximum speed (2600 min ) of the engine.
Keep the gear shift lever at neutral (N). (When
checking the lock-up clutch pressure, keep it at
nd
2 or D.)
3. Read the clutch pressure displayed on the
multi-display device on the crane, and measure
the torque converter inlet pressure and torque

converter outlet pressure by pressure gauges
connected to the torque converter inlet/outlet
pressure check ports (Rc 1/8).
55 W561-0102E
page 56 of 67
GR-800-1-00211
Test
3. Stall test
CAUTION
In the stalled condition, the torque converter

produces the maximum torque. Be extremely
careful not to allow the vehicle to move suddenly.
As the torque converter generates much heat
in the stalled condition, do not stall it more than
30 seconds. And do not perform this test when
the oil temperature is above 90°C(194°F).
[NOTICE]
Be sure to perform this test in the 4-wheel drive
mode.
1. Securely apply the parking brake and foot brake.
2. Set the switches and levers to the following

conditions.
PTO switch: "OFF"

nd "
Gear shift lever: "2
Drive speed select switch: "4-wheel HI"
Service brake: "ON"
3. Fully push the accelerator pedal, and read the
engine speed when it becomes stabilized.
Standard maximum engine speed under stall

-1
condition : approx. 2160 min
56 W561-0102E
page 57 of 67
GR-800-1-00211
Maintenance standards
3. Check all disassembled parts by proper methods
1. Overhaul interval like visual for cracks, flaws, unusual
inspection
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
nd th
Oil seal ring Replace all parts at 2 and 4 overhauls.
Seal ring race surface

Replace parts exceeding its wear limit.
Sintered plate
Stator freewheel
Replace parts exceeding its wear limit.
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 thatnormally 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 W561-0102E
page 58 of 67
GR-800-1-00211
3.1 Torque converter
The numerals in parentheses in the table such as (1.5-43) correspond to the Section No. and Part No. in the
"Structure".
(1mm=0.03937in) (mm)
Standard
Check item Use limit
value
AB
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}
(large)
A
(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)
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)
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 W561-0102E
page 59 of 67
GR-800-1-00211
Oil seal
(mm)
Standard
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)
Standard
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 3.07-3.15 3.30
IW561-0031J117
seal is installed
(D)
ring
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
At the input guide Φ35-
D input (1.4-5) on which seal Inside dia. (C) Φ35.05 Φ35.2
IW561-004203 guide ring slides

side end
of
A: Radial
turbine
thickness Groove width where
shaft Groove width 3.07-3.15 3.30
seal is installed
(D)
B: Axial width ring
C: Inside dia.
D: Groove width
59 W561-0102E
page 60 of 67
GR-800-1-00211
(mm)
Standard
value

Seal ring (1.5-11)
Axial width (B) 2.35-2.4 1.95
At middle Area of stator

of turbine Φ50.2-
support(1.5-9) on Inside dia. Φ50.40
shaft which seal
(C) Φ50.25
ring
slides
Groove width where

seal is installed
(D)
ring
Seal ring (1.5-13)
Teflon ring Axial width (B) 2.30-2.35 1.9
Area of impeller
B At stator
assy(1.4-1) on Φ76-
support Inside dia. (C) Φ76.03 Φ76.2
A which seal ring
slides
Groove width where

seal is installed
(D)
IW561-0031J117
ring
Seal ring (1.6-19)
At end of Axial width 2.85-2.90 2.45
(B)
PTO
Area of cover
C clutch Φ70.2-
(1.5-4) on which Inside dia. (C) Φ70.25 Φ70.4
drive
D seal ring slides
shaft
IW561-004203 Groove width where
seal is installed
(D)
ring
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. Φ50.20-
clutch piston(1.6-4) on Inside dia. Φ50.40
D: Groove width which seal
(C) Φ50.25
drive ring
shaft slides
Groove width where

seal is installed
(D)
ring
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
which seal ring
piston
slides
Groove width where

seal is installed
(D)
ring
60 W561-0102E
page 61 of 67
GR-800-1-00211
3.2 Transmission
The numerals in parentheses in the table such as (2.3-86) correspond to the Section No. and Part No. in the
"Structure".
(1 mm= 0.03937 in) (mm)

Standard
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) --

Converter inlet relief valve
spring (2.3-87)
(small)
Installed length (B) 106 106
Main pressure (2.3-84)
regulator valve
spring (large)
(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

valve spring(2.3-100)
length (B) 97 97
IW561-0031J116
A: Free length (small)
B: Installed 2-wheel/4-wheel
length (2.3-49)
drive selector Force when installed (C) 98N {22.0lbf} 88N {19.8lbf}
C: Spring force
aircylinder Free
when length (A) 113.98 107.58
return spring (large)
installed Installed length (B) 50 50
(2.3-50)
Hydrauric valve(F1),(F2)
and (F3) spool return Installed length (B) 38.4 38.4
spring (2.6-4) Force when installed (C) 57N {12.8lbf} 51N {11.5lbf}
61 W561-0102E
page 62 of 67
GR-800-1-00211
(mm)
Standard
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
(2.3-90) 60N 54N
C accumulator Force when installed (C) {13.5lbf} {12.1lbf}
IW561-0031J116
) spring
A: Free Installed length (B) 73.4 73.4

length (large)
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)
Standard
value
B F1,F2,F3,R clutch
return spring
C
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 W561-0102E
page 63 of 67
GR-800-1-00211
Oil seal
(mm)
Standard
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 W561-0102E
page 64 of 67
GR-800-1-00211
Seal ring
(mm)
Standard
value
Teflon ring Radial thickness 1.6-1.8 1.4
(A)
Seal ring (2.4-22)
B AtR 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
IW561-0031J117
Groove width (D)
seal ring is installed
Radial thickness 2.0-2.2

(A) 1.8
Seal ring (2.4-2)
At Axial width 2.35-2.4
(B) 1.95
middle
C Area of piston(2.4-3)
of F2,R Φ55.20-
on which seal ring Inside dia. Φ55.40
D clutch
(C) Φ55.25
slides
IW561-004203 shaft
Groove width where 2.5-2.6 2.75
Groove width (D)
seal ring is installed
A: Radial
thickness (A) 3.15
Seal ring (2.4-4)
B: Axial width Axial width 2.89-2.94
(B) 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) Φ134.04 Φ134.2
seal ring slides
Groove width where
Groove width 3.025-3.125 3.275
seal ring is installed (D)

(A) 1.4
Seal ring (2.5-23)
At F1 Axial width 2.87-2.92
(B) 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
Seal ring (2.5-2)
At Axial width 2.35-2.4
(B) 1.95
middle Area of piston(2.5-3) Φ55.20-
of F1,F3 on which seal ring Inside dia. (C) Φ55.25 Φ55.40
clutch slides
shaft
Groove width where

(A) 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 3.025-3.125
seal ring is installed (D) 3.275
64 W561-0102E
page 65 of 67
GR-800-1-00211
Torque Converter Circuit
Torque Converter Circuit
347-411-60000 △
1
65 W561-0102E 65
page 66 of 67
GR-800-1-00211
+ΗΔΓ 2ΙΙΛΦΗ .Ρ 6ΛΘΓΗΘ ΦΚΡ 7ΔΝΔΠΔΩ?Ξ -ΔΣΔΘ
2ΨΗΥ?ΗΔ? 6ΗΥΨΛΦΗ ?ΥΡΞΣ

7ΔΓΔΘΡ 5∴ΡθΡΝΞ %ΟΓθ
.ΔΠΗ]ΔΖΔ ΦΚΡΠΗ
6ΞΠΛΓΔ ΝΞ
7ΡΝ∴Ρ -ΔΣΔΘ
7ΗΟ
7ΗΟ ΙΔ[
+Λ?ΩΡΥ∴ ΡΙ ΥΗΨΛ?ΛΡΘ
page 67 of 67

TC TM GR-800-1-00211

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GR-800-1-00211

thomas yulianto 2024/05/11 10:04:14 JST

Publication No. W561-0102E

Please note that, for product Improvement, some

changes may have been incorporated in the machine

2. Contents 2.4 Control valve assy.....................................27

2.6 Forward-reverse select modulation ..........28

Foreword .................................................. 1 2.7 Clutch line pressure diagram ....................29

1. Applicable crane model ............................. 1 positions ..............................................29

2. Contents .................................................... 2 2.10 2-wheel/4-wheel drive selection................30

Structure .................................................. 4 2.13 Hydraulic system.......................................33

1.2 Torque converter external view .................. 5 Troubleshooting .....................................35

1.4 Converter circuit ......................................... 7 2.Power drops. (Speed cannot increase.)..........36

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

2.4 Hydraulic clutch assy (F2,R) .................... 18

2.6 Solenoid valve assy Disassembly............................................40

2.7 Tightening torque table............................. 21 1. Torque converter ..................................... 40

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

2.2 Main pressure regulating valve ................ 26

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

2. Oil changing procedure............................ 54

2.2 Oil filling .................................................... 54

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

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

3. Stall test ................................................... 56

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

2. Replacement interval of important parts .. 57

3. Part replacement standards..................... 57

3.2 Transmission ............................................ 61

Torque Converter Circuit ....................... 65

1.2 Torque converter external view

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

3.Hydraulic clutch assy 9.Name plate 22.Mark band 27.Clip

5.Gear pump assy

1.4 Converter circuit

1.Impeller assy 10.Clutch retainer B 19.Snap ring 28.D-shaped ring

3.Wheel stator 12.Piston 21.Thrust needle bearing 30.Flange bolt

4.Front cover assy 13.Pressure plate 22.Support 31.Plug

6.Input plate 15.Ball bearing 24.O-ring 33.Snap ring

8.One-way clutch 17.Thrust needle bearing 26.O-ring 35.Thrust washer

1.5 Converter transmission

1.6 PTO clutch assy

1.Shaft assy 7.Back plate 13.Snap ring 19.Seal ring

1.7 Solenoid valve assy

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

1.8 Tightening torque table

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