TSM10-001
OKAMURA
TRANSMISSION
SERVICE MANUAL
Y43190A
Y43190Q
Okamura Corporation Dec. 2010
ver.12/2010
.
白紙ページ
ver.12/2010
CONTENTS
1. Technical data
Specifications ．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．． 1-1
Identification ．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．． 1-1
2. Description and operation
Transmission ．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．． 2-1
Transmission power flow ．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．． 2-2
Forward
Reverse
Hydraulic system ．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．． 2-4
3. Disassembly and reassembly
Disassembly of transmission ．．．．．．．．．．．．．．．．．．．．．．．．．．．．． 3-1
Disassembly of clutch pack ．．．．．．．．．．．．．．．．．．．．．．．．．．．．． 3-5
Reassembly of clutch pack ．．．．．．．．．．．．．．．．．．．．．．．．．．．．． 3-6
Clutch pack
Reassembly of transmission ．．．．．．．．．．．．．．．．．．．．．．．．．．．．． 3-9
Special tools ．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．． 3-15
4. Maintenance standards
Maintenance check list ．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．． 4-1
PARTS LIST
Note.
Illustrations and photographs can be different from the actual parts.
The unit of length is mm.
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Technical data 1-1
Technical data
Specification
Torque converter
Torque converter type 3-Element 1-Stage 2-Phase
Converter-out pressure MPa max 0.3
Circular flow ℓ/min 17～21
Input rotation Clockwise viewed from engine
Max input speed rpm 2700
Transmission
Forward 2.178
Gear ratio
Reverse 2.235
Type Wet multiple clutch plates
Main oil pressure MPa 1.0±0.2
Clutch
F oil pressure MPa 1.0±0.2
R oil pressure MPa 1.0±0.2
Control type Power shift
Forward Counterclockwise viewed from output
Output rotation
Reverse Clockwise viewed from output
Transmission ASSY
Mass (Dry) kg 120
Oil type ATF DEXRON Ⅱ
Oil capacity ℓ 8
Max oil temperrature ℃ 120
Others -
Identification
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Description and operation 2-1
Description and Operation
Transmission
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Description and operation 2-2
Transmission power flow
Forward
Torque
converter
OUTPUT
Transmission of power from the turbine
("( )" shows the numbers of gear teeth.)
Turbine → Main shaft → Clutch gear (39) →
Counter gear (38) → Counter shaft → Counter gear (34) →
Output gear (76) → Output shaft
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Description and operation 2-3
Reverse
Torque
converter
OUTPUT
Transmission of power from the turbine
("( )" shows the numbers of gear teeth.)
Turbine → Main shaft → Clutch gear (34) →
Output gear (76) → Output shaft
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Description and operation 2-4
Hydraulic system
The hydraulic system, which is located in the upper section of the transmission case,
comprises a regulator valve, an accumulator valve, an inching valve and a solenoid valve.
When the engine is started, the oil pump will suck up oil from the transmission sump through
the oil screen and supply it to the regulator valve which regulates the pressure to 0.8 to 1.2
MPa. The oil then will go through the accumulator valve and inching valve to the solenoid
valve.
When the solenoid valve opens the circuit, the pressure oil will go through the oil path in the
case and the shaft hole to the clutches and engage the driven plate with the clutch plate.
The clutch hydraulic pressure is increased gradually by the accumulator valve to provide
smoother clutch engagemnt.
During inching operation, the inching valve keeps the driving clutch slip or release.
The circulation oil for the torque converter will be restricted by the orifice of the regulator
valve before entering the torque converter.
The oil discharged from the torque converter will be directed into the transmission
lubrication circuit through the oil cooler and be used to cool and lubricate the transmission
components.
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Disassembly and reassembly 3-1
Disassembly of the Transmission
1 Remove the drain plug ① and drain oil in
the transmission.
Remove the T/C Assy ②.
2
1
2 Remove the coupling ③.
3 Remove the solenoid valve ④ and the
inching valve ⑤. Remove the gasket.
4 Remove the accumlator ⑥ and the
regulator ⑦.
7
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Disassembly and reassembly 3-2
1 Remove the suction strainer ① and the
gasket.
2 Remove the level gauge ② and the
breather ③.
2
3
3 Unscrew the bolts fixing the torque
converter case ④ and the transmission 4
case ⑤.
Hang the converter case to a hoist to
separate it from the transmission case.
Remove the gasket.
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Disassembly and reassembly 3-3
1 After remove the bearing ①, remove the
counter gear ②, the spacer ③ and the 1
output gear ④.
2
4 3
2 Remove the clutch pack ASSY ⑤.
3 Remove the counter shaft ASSY ⑥.
6
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Disassembly and reassembly 3-4
1 Remove the oil pump case ASSY with the
stator shaft ①.
2 Remove the gear cover ② and the magnet
③.
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Disassembly and reassembly 3-5
Disassembly of clutch pack
Refer to the following page.
1 Remove seal rings, and using a puller,
remove the bearing and the clutch gear.
2 Remove the snap ring and plates.
3 Using a special tool, compress the clutch
spring, and remove the snap ring.
Special tool SST1
4 Remove the clutch piston.
Remove piston rings from the clutch piston
and the shaft.
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Disassembly and reassembly 3-6
Resassembly of clutch pack
Refer to the following page.
1 Install the piston ring ① to the clutch
piston ②.
Install the piston ring ③ to the shaft, and
install the clutch piston with the piston
ring. 1
2
3
2 To install the snap ring, compress the
clutch spring with a special tool.
Special tool SST1
3 Install clutch plates, driven plates, the
camber plate, the pressure plate and the
snap ring ④.
Using a special tool, press the clutch gear
with the bearing and the snap ring ⑤, and
install the spacer ⑥.
7
Be careful not to damage teeth of the
clutch plate.
6
Using a special tool, press the bearing ⑦.
5
Special tool SST2
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Disassembly and reassembly 3-7
1 Apply air to the clutch piston through oil
hole to make sure that the piston moves
freely.
FORWARD
REVERSE
FORWARD
REVERSE
2 Install seal rings.
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Disassembly and reassembly 3-8
Clutch pack
Installing plate
1) Make sure that the combination and
number of plates are correct.
Number of plates
Clutch plate 5
Driven plate 5
2) Install the camber plate by setting its
inside face against the driven plate.
Clutch plate
Pressure plate
Driven plate
Camber plate
Piston
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Disassembly and reassembly 3-9
Reassembly of transmission
1 Apply ThreeBond No.1102 to theouter side
of the oil seal ①, and using a spesial tool,
install the oil seal. And install the O-ring ②
to the oil pump case ③. 1
Be caseful not to damage a lip of the oil
seal.
Sealant ThreeBond No.1102 3
Special tool SST3
2
2 Install the oil pump drive gear ④ and the
oil pump driven gear ⑤ to the oil pump
case.
4
3 Install the stator shaft ⑥ and the gasket
⑦ to the oil pump case with the oil pump
gear and the oil pump driven gear.
Be careful that the oil pump drive gear and
the oil pump driven gear don't come off.
7
4 Install the oil pump ASSY with the stator
shaft and the gasket ⑧ to the T/C case,
and tighten the bolts ⑨.
Tightening Torque 18.6 to 24.5 Nm
9
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Disassembly and reassembly 3-10
1 Install the gear cover ① and the magnet
②.
2 Apply ThreeBond No.1102 to theouter side
of the oil seal ③, and using a spesial tool, 4
install the oil seal to the T/M case ④
Be caseful not to damage a lip of the oil
seal.
Sealant ThreeBond No.1102 3
Special tool SST3
3 Install the counter shaft Assy ⑤.
5
38T
4 Install the clutch pack Assy ⑥.
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Disassembly and reassembly 3-11
1 Install the output gear Assy ①, the spacer
34T 4
②, the counter gear ③ and the bearing ④.
3
1 2
2 Install the gasket. Hang the converter case
⑤ to a hoist, and lower the case onto the
converter case by aligning the input shaft 5
with the transmission.
Tightening Torque 47.0 to 55.9 Nm
3 Install the breather ⑦ and the level gauge
⑧.
8
7
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Disassembly and reassembly 3-12
1 After applying LOCTITE No.572 to both
sides of the gasket, install the suction
strainer ①.
Sealant LOCTITE No.572
Tightening Torque 18.6 to 24.5 Nm
2 Install the accumulator ②.
Tightening Torque 107.8 to127.4 Nm
3 Install the regulator ③.
Tightening Torque 49.0 to 58.6 Nm
4 Install the gasket and inching valve ④.
Tightening Torque 18.6 to 24.5 Nm
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Disassembly and reassembly 3-13
1 Install the solenoid valve ①.
1
Tightening Torque 4.9 to 7.8 Nm
2 Install the drain plug ②.
2
3 Install the seal ring ④ to the T/C ASSY
③.
4
4 Fix two eyebolts (SST4) ⑤ on the T/C
ASSY ③, and install the T/C ASSY. 5
Special tool SST4
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Disassembly and reassembly 3-14
1 Install the flexible plate ①.
Be careful to the direction. 1
Tightening Torque 18.6 to 24.5 Nm
After installing, check that the height of
between the flexible plate and the T/C
case is about 11mm.
2 Install the coupling ②.
3 Reassembly is over.
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Disassembly and reassembly 3-15
Special tools
SST1 Piston tool
SST2 Installer
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Disassembly and reassembly 3-16
SST3 Installer
SST4 Eyebolt
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Maintenance standards 4-1
Maintenance standards
Maintenance check List
A = Standard B = Repair or service limit
Unit：mm
Transmission
Items A B
Fluctuation of the flexible plate - 0.5
Outside diameter of pilot boss end 15 14.95
Outside diameter of the pump boss (sliding surface with the oil seal) 60 59.9
Clutch pack
Items A B
Clearance between width of the seal ring and that of groove - 0.3
Clearance between width of the piston seal ring (inside) and that of groove - 0.3
Clearance between width of the piston seal ring (outside) and that of groove - 0.3
Side clearance of the piston ring - 0.3
Thickness of the mating plate 1.6 1.4
Thickness of the friction plate 2.6 2.4
Free length of the return spring 45 42.8
Regulator valve
Items A B
Outside diameter of the regulator spool (main pressure) 12 11.92
Free length of the spring (main pressure) 95 90
Inside diameter of the valve body (sliding surface with the regulator spool) 12 12.07
Accumulator valve
Items A B
Outside diameter of the accumulator piston 32 31.92
Inside diameter of the valve body (sliding surface with the accumulator piston) 32 32.07
Free length of spring (at the accumulator piston) (outside) 100.5 90.5
Free length of spring (at the accumulator piston) (inside) 95 85
Inching valve
Items A B
Outside diameter of the inching spool 22 21.92
Inside diameter of the valve body (sliding surface with the inching spool) 22 22.07
Free length of spring (at the inching spool) 64 58
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Maintenance standards 4-2
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OKAMURA
TRANSMISSION
PARTS LIST
Y43190A SERIAL NO.0001～
Y43190Q SERIAL NO.0001～
Okamura Corporation Dec. 2010
ver.12/2010
.
ver.12/2010
ＣＯＮＴＥＮＴＳ
ＧＲＯＵＰ ＮＯ． ＧＲＯＵＰ ＮＡＭＥ ＰＡＧＥ
01-01-01 TRANSMISSION (PART-1) ･･････････････････････････････････････････････････････････ 2
01-01-02 TRANSMISSION (PART-2) ･･････････････････････････････････････････････････････････ 4
01-01-03 TRANSMISSION (PART-3) ･･････････････････････････････････････････････････････････ 6
01-01-04 TRANSMISSION (PART-4) ･･････････････････････････････････････････････････････････ 8
01-01-05 TRANSMISSION (PART-5) ･･････････････････････････････････････････････････････････ 10
01-02 INCHING VALVE ･･････････････････････････････････････････････････････････ 12
02-01 OVERHAUL KIT ･･････････････････････････････････････････････････････････ 14
Note.
Parts that there is * sign in the part number column are not supplied as a repair parts.
Parts and Part NO. is subject to change without notice.
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01-01-01 TRANSMISSION(PART-1)
-2-
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01-01-01 TRANSMISSION(PART-1)
-3-
Ｑ MODEL & APPLICABLE SERIAL NO.
REF. PART NO. PART NAME & DESCRIPTION Ｔ Y43190A Y43190Q
-NO. Ｙ
@FROM- @FROM-
-@UPTO -@UPTO
1 C12414 BOLT 8
2 C99514 WASHER,SPRING 8
3 441442A PLATE,FLEXIBLE 1
4 470005B T/C ASSY 1
5 R61800 RING,SEAL 1
6 R63030 OIL SEAL 1
7 430442A CASE,OILPUMP ASSY 1
7 01 * CASE,OILPUMP NOT SHOWN 1
7 02 * DRIVE GEAR ASSY NOT SHOWN 1
7 03 * DRIVEN GEAR,OILPUMP NOT SHOWN 1
8 R62545A O RING 1
9 431735C SHAFT,STATOR 1
10 432519A GASKET 1
11 C54425 PIN 2
12 C93814 PLUG 1
13 C94614 WASHER,SEAL 1
14 440419A T/C CASE ASSY 1
14 01 * CASE,T/C 1
14 02 K60912 PLUG 1
14 03 C94618 WASHER,SEAL 1
14 04 C93818 PLUG 1
14 05 * PLUG NOT SHOWN 1
14 06 * BALL,STEEL NOT SHOWN 4
15 C99514 WASHER,SPRING 7
16 C12435 BOLT 3
16 C12445 BOLT 4
17 C12410 BOLT 2
18 C99514 WASHER,SPRING 2
19 K62028B COVER 1
20 R63114 GAUGE,LEVEL 1
21 R60325 BREATHER 1
22 591306C SPOOL,REGULATOR 1
23 491427A SPRING,REGULATOR 1
24 C94624 WASHER,SEAL 1
25 C93824 PLUG 1
26 564501B GASKET 1
27 564102B SUCTION STRAINER 1
28 C99514 WASHER,SPRING 4
29 C12416 BOLT 4
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01-01-02 TRANSMISSION(PART-2)
-4-
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01-01-02 TRANSMISSION(PART-2)
-5-
Ｑ MODEL & APPLICABLE SERIAL NO.
REF. PART NO. PART NAME & DESCRIPTION Ｔ Y43190A Y43190Q
-NO. Ｙ
@FROM- @FROM-
-@UPTO -@UPTO
1 C99514 WASHER,SPRING 3
2 C12416 BOLT 3
3 487017B COVER,GEAR A 1
4 C76012 BEARING,BALL 1
5 484778A GEAR,OUTPUT Z=76 1
6 C76212 BEARING,BALL 1
7 R62824 MAGNET 2
8 487018A COVER,GEAR B 1
9 C99514 WASHER,SPRING 2
10 C12416 BOLT 2
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01-01-03 TRANSMISSION(PART-3)
-6-
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01-01-03 TRANSMISSION(PART-3)
-7-
Ｑ MODEL & APPLICABLE SERIAL NO.
REF. PART NO. PART NAME & DESCRIPTION Ｔ Y43190A Y43190Q
-NO. Ｙ
@FROM- @FROM-
-@UPTO -@UPTO
1 C09030 RING,SEAL 4
2 C76306 BEARING,BALL 2
3 R63115 SPACER 2
4 C95262 RING,SNAP 2
5 C75206 BEARING,BALL 2
6 484154A GEAR,CLUTCH Z=34 1
7 480252B CLUTCH ASSY 1
8 484155A GEAR,CLUTCH Z=39 1
9 C76307 BEARING,BALL 2
10 484527A GEAR,COUNTER Z=34 1
11 R63116 SPACER 2
12 482227A SHAFT,COUNTER 1
13 484528A GEAR,COUNTER Z=38 1
14 480162A T/M CASE ASSY 1
14 01 K69527 ORIFICE 1
14 02 K60912 PLUG 2
14 03 * CASE,T/M 1
14 04 K69518 ORIFICE 1
14 05 * BALL,STEEL NOT SHOWN 7
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01-01-04 TRANSMISSION(PART-4)
-8-
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01-01-04 TRANSMISSION(PART-4)
-9-
Ｑ MODEL & APPLICABLE SERIAL NO.
REF. PART NO. PART NAME & DESCRIPTION Ｔ Y43190A Y43190Q
-NO. Ｙ
@FROM- @FROM-
-@UPTO -@UPTO
1 C12455 BOLT 8
2 C99514 WASHER,SPRING 8
3 590276A INCHING VALVE ASSY 1
4 592215B GASKET 1
5 C29245 HEXAGON SOCKET BOLT 4
6 490306A SOLENOID VALVE ASSY 1
7 R63125 CAP,OIL INLET 1
8 488430B GASKET 1
9 C54425 PIN 2
10 K60304 PLATE,EYE 2
11 C99515 WASHER,SPRING 18
12 C15530 BOLT L=30 11
C15535 BOLT L=35 2
C15565 BOLT L=65 5
13 * PLATE,NAME 1
14 * RIVET 2
15 493607A SPRING,ACC INNER 1
16 493606A SPRING,ACC OUTER 1
17 593508C PISTON,ACC 1
18 C94633 WASHER,SEAL 1
19 C93833 PLUG 1
20 R63122 SEAL,OIL 1
21 487538A COUPLING 1
22 N60088 PLUG 1
23 C94616 WASHER,SEAL 1
24 C93816 PLUG 1
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01-01-05 TRANSMISSION(PART-5)
-10-
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01-01-05 TRANSMISSION(PART-5)
-11-
Ｑ MODEL & APPLICABLE SERIAL NO.
REF. PART NO. PART NAME & DESCRIPTION Ｔ Y43190A Y43190Q
-NO. Ｙ
@FROM- @FROM-
-@UPTO -@UPTO
1 480252B CLUTCH ASSY 1
2 * RING,SNAP 2
3 * PLATE,PRESSURE 2
4 483019A PLATE,CLUTCH 10
5 483116A PLATE,DRIVEN 10
6 483117A PLATE,CAMBER 2
7 * RING,SNAP 2
8 * RETAINER,SPRING 2
9 * SPRING,RETURN 2
10 * PISTON,CLUTCH 2
11 * RING,PISTON 2
12 * RING,PISTON 2
13 480396A MAIN SHAFT & DRUM ASSY 1
13 01 * PLUG 2
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01-02 INCHING VALVE
-12-
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01-02 INCHING VALVE
-13-
Ｑ MODEL & APPLICABLE SERIAL NO.
REF. PART NO. PART NAME & DESCRIPTION Ｔ Y43190A Y43190Q
-NO. Ｙ
@FROM- @FROM-
-@UPTO -@UPTO
1 590276A INCHING VALVE ASSY 1
2 C93824 PLUG 1
3 C94624 WASHER,SEAL 1
4 590622B INCHING SPOOL ASSY 1
5 592715A SPRING,RETURN 1
6 592031A VALVE BODY,INCHING 1
7 594145A RETAINER,SPRING 1
8 R62552 SEAL,OIL 1
9 C93818 PLUG 1
10 C94618 WASHER,SEAL 1
11 594147A SPRING 1
12 R62423 FILTER,COIN 1
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02-01 OVERHAUL KIT
-14-
Ｑ
REF. PART NO. PART NAME & DESCRIPTION Ｔ PARTS INDEX
-NO. Ｙ
GRP NO. REF NO.
1 T60930 OVERHAUL KIT 1
1 01 R61800 RING,SEAL 1 01-01-01 5
1 02 R63030 SEAL,OIL 1 01-01-01 6
1 03 432519A GASKET 1 01-01-01 10
1 04 R62545A O-RING 1 01-01-01 8
1 05 564501B GASKET 1 01-01-01 26
1 06 564102B STRAINER,SUCTION 1 01-01-01 27
1 07 C09030 RING,SEAL 4 01-01-03 1
1 08 592215B GASKET 1 01-01-04 3
1 09 488430B GASKET 1 01-01-04 8
1 10 R63122 SEAL,OIL 1 01-01-04 20
1 11 R62423 FILTER,COIN 1 01-02 12
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