POWERSHIFT TRANSMISSION

Description ................................................................................................ 5 – 1
Hydraulic Circuit ......................................................................................... 5 – 2 Control ....................................................................................................... 5 – 3

Removal and Installation ....................................................................... 5 – 3 Disassembly and Reassembly ............................................................. 5 – 4
Transmission Assembly .............................................................................. 5 – 4 Disassembly ............................................................................................. 5 – 4 Reassembly.............................................................................................. 5 – 10 Pump Assembly ..................................................................................... 5 – 10 Transmission Assembly .......................................................................... 5 – 14 Control Valve .............................................................................................. 5 – 17 Disassembly ............................................................................................ 5 – 17 Reassembly.............................................................................................. 5 – 18

5

Inspection and Adjustment ................................................................... 5 – 19
Testing Hydraulic Pressure......................................................................... 5 – 19 Adjusting Inching Pedal .............................................................................. 5 – 21 Testing Clutch Valve ................................................................................... 5 – 23 Testing Stall Speed..................................................................................... 5 – 23 10-m (33-ft) Start Acceleration Test ............................................................ 5 – 24

Troubleshooting ........................................................................................ 5 – 25 Service Data .............................................................................................. 5 – 29

POWERSHIFT TRANSMISSION

Description

a (36)

b (31)

d (31)

c (35)

e (70)

Figures shown in ( ) indicate the number of gear teeth.

207116

The transmission, integrally coupled to the torque converter, provides a choice of one forward ratio and one reverse ratio. It has built-in multi-disc clutches, which are hydraulically actuated to control the flow of drive from the converter. The control lever — shift lever — is for operating a hydraulic control valve. Thus this transmission is of a “powershift” type. The transmission housing and the torque converter housing can be separated from each other. The pump, turbine and stator can be removed as one assembled unit from the starter shaft and from the input shaft. The torque converter is of one-piece construction fabricated by welding and is meant to be replaced as one assembled unit. The transmission parts, except for torque converter, clutch valve, the output flange and universal joints, are common to all models. 5-1

1.0 to 1.8 ton classes Model Type Range F (Forward) R (Reverse) 66H7

2 to 3.5 ton classes 66H8

Three-element, single-stage, two-phase Powerflow a ⎯→ cde b ⎯⎯→ e

Transmission reduction ratio F (Forward) R (Reverse) 35 70 36 × 31 = 2.195 70 31 = 2.258

in.)/2400 rpm (Gasoline models) 33 liters (2014 cu.Torque converter inlet pressure e Oil cooler c Accumulator valve Lube oil Hydraulic Circuit POWERSHIFT TRANSMISSION F R Main regulator valve Clutch valve F ←⎯→ R Selector valve d b b a F Torque converter outlet pressure 5-2 a c e Unit: kPa (kgf/cm2) [psi] Main pressure b Clutch pressure Torque converter inlet pressure d Torque converter outlet pressure Lube oil pressure Engine speed: 1500 ± 100 rpm 204869 Filter (100 mesh) with magnet Oil pump Actual capacity : 36 liters (2197 cu.5 to 3) [21 to 43] 98 to 147 (1 to 1.5) [14 to 21] . in.)/2200 rpm (Diesel models) 883 to 1079 (9 to 11) [128 to 156] 883 to 1079 (9 to 11) [128 to 156] 196 to 490 (2 to 5) [28 to 71] 147 to 294 (1.

it is an indication that the torque converter is improperly coupled to the engine. To do this.97 to 2.20 in. (2) Tighten the bolts securing the flexible plate to the flywheel through the access hole in the converter housing.) when the torque converter is coupled to the engine. (2) Unscrew the bolts securing the flexible plate through the access hole in the torque converter housing.04 to 0. The clearance between the flywheel and flexible plate should be 1 to 5 mm (0. 5-3 . place the torque converter in the transmission housing so that the distance between the end face of the housing and the mating face of flexible plate is 50 to 52 mm (1. refer to “GROUP 4 POWER TRAIN”.POWERSHIFT TRANSMISSION Control R F N 1 3 4 2 6 5 207136 1 2 3 4 Transmission shift lever Clutch (inching) pedal Bracket (inching) Control valve assembly 5 6 Clutch valve plunger Solenoid valve assembly (for forward-reverse) Removal and Installation Removal (1) Remove the engine and transmission as an assembly from the truck.). If this clearance is zero. Installation (1) Couple the torque converter and transmission to the engine. recouple the converter to the engine properly. (3) Separate the torque converter and transmission from the engine.05 in. NOTE For the removal and installation of the engine and transmission. NOTE Tighten the bolts in a criss-cross pattern.

Mating plates. Drain plug. Thrust washer Snap ring. Magnet strainer Control valve Stator shaft. Clutch spring Snap ring. Washer. Thrust washer Seal ring. Idler gear Input shaft assembly (consisting of 14 thru 20) 14 15 16 17 18 19 20 21 22 23 24 Seal ring. O-ring. Internal gear. Flexible plate Sender unit. Snap ring. Ball bearing. Snap ring Output gear. Friction plates. O-ring Transmission housing. Gasket. Ball bearing Baffle plate Torque converter housing. Seal ring. Thrust washer REVERSE gear. Gasket Output flange Filter case. Drive gear. Belleville spring Clutch piston. Needle roller bearing. Pressure plate. Gasket Oil level gauge. Steel ball. Pipe Air breather Oil pipe. Spring retainer. Spring. Ball bearing. Ball bearing. Thrust washer FORWARD gear. O-ring. Steel ball Pump body. Relief valve. Plug Ball bearing. Eye joint.POWERSHIFT TRANSMISSION Disassembly and Reassembly Transmission Assembly Disassembly 20 17 16 19 10 18 15 14 21 12 5 3 9 1 Bracket (inching) 2 8 4 5 23 24 2 11 6 22 Mount bracket 11 7 207119 Sequence 1 2 3 4 5 6 7 8 9 10 11 12 13 Torque converter assembly. O-ring. Oil seal. Input shaft Idler shaft. Needle roller bearing. Steel ball 5-4 .

2) Remove the input shaft as an assembly including 14 thru 20.POWERSHIFT TRANSMISSION NOTE 1) Remove the pump as an assembly including 9 and 10. Remove two mount brackets from the transmission housing. Start by: 1. and disassemble it in the order shown. Remove the brackets (inching) and springs. 204829 5-5 . 2. Prepare a container to catch the oil that flows out of the converter. Removing torque converter assembly Remove the torque converter assembly complete with the flexible plate. Suggestions for Disassembly 1.

Removing input shaft ball bearing Using a special tool.2 in. remove the ball bearing from the input shaft. 1 2 3 4 Tool name Puller Plate Bolt Gear puller T-24 (BANZAI make) Part No. 4. tap the transmission and clutch housing flanges near the dowel pins with a plastic hammer to separate the transmission housing from the torque converter housing.25 holes in the pump body to remove the pump assembly.05100 ❋ 209911 3.10020 – Q’ty 4 2 3 207120 2 1 2 1 5-6 . Unscrew the transmission housing bolts.13820 F1035 . or the threads will suffer damage. Be sure to tighten the bolts equally. Removing transmission housing Lay the transmission and torque converter assembly with transmission housing down. 1 Special tools needed Ref.13810 91268 . Removing transmission housing bolts After removing the pump assembly. Use M8 × 1. No.) Special tools needed Bolt 91268 .10025) from the torque converter housing side.POWERSHIFT TRANSMISSION 2. 91268 .25 bolts having an effective thread length of 55 mm (2. Removing pump assembly Lifting bolt holes (at locations marked ❋) ❋ Unscrew the pump mounting bolts and screw two bolts (special tool) into the M8 × 1. 204830 5. unscrew two transmission housing bolts (F1805 . Hang the transmission housing to a hoist.

(2) Check the width of each seal ring groove for wear. Disassembling input shaft Using a special tool or an arbor press. compress the clutch spring. also check the groove for damage. 207160 Inspection after disassembly 1. and remove the snap ring. free from sign of clogging. 2) Do not remove oil seals from the pump body and transmission housing unless they are defective. 5-7 .POWERSHIFT TRANSMISSION 6. Special tools needed Piston tool 91268 . Clutch drums (1) Check the sliding surfaces of mating and friction plates for wear or damage. 3. Oil passages 207121 Seal ring grooves 2.07100 NOTE 1) Do not remove steel balls and sealing caps from the transmission housing and torque converter housing. (3) Check to be sure that oil grooves and passages are open and clean. Gears Check the gears and splines for wear or defects. Input shaft (1) Check the splines for wear or damage.

9. Magnet strainer Check for clogging or breakage. Output flange Check the splines for wear or damage.POWERSHIFT TRANSMISSION 4. 7.6 ± 0. Seal ring Plug NOTE Do not disassemble the piston unless it is defective. Also. Friction plates and mating plates (1) Check for sign of seizure. (2) Check the splines for wear or damage. screw the plug until its head gets into piston end face.063 ± 0. and caulk the plug. Idler shaft Check the splines for wear or damage.6 ± 0. (2) Check the seal rings and their grooves for wear or damage.3 (0. 8. Seal ring 207123 6.2 (0. Clutch pistons (1) Shake each piston.087) Mating plate Friction plate Thickness of mating plate A B A B 207122 Thickness of friction plate 5.0039) 1.051) 2.004) 2. A: Standard value B: Repair or service limit Unit: mm (in.1 (0. check the oil seal contact surface for defects. Transmission housing Check the seal ring contact surfaces for wear or damage. warpage or excessive wear. uneven contact. 5-8 .10 (0.) 1. make sure that the balls move freely in it.1023 ± 0. When piston is overhauled and cleaned.

A: Standard value No.30 (0.0118) Drive gear A C B 204831 A Gear backlash B 5-9 .33 (0.083 (0.016) 0. Oil pump (1) Check top clearance A between the drive gear and pump body with feeler gauges.1 to 0. and check clearance C between the gear and pump boss. (4) Put the drive gear on the torque converter pump impeller.00591) 0.040 to 0. (3) Check the backlash between the drive gear and internal gear with feeler gauges.0118 to 0.4 (0.0039 to 0.10 to 0.00327) 0.0130) 0.004 to 0.0071) 0.POWERSHIFT TRANSMISSION 10.) Dimension 0. (2) Check side clearance B between the internal gear and drive gear and the pump body with a straight edge and feeler gauges.30 to 0. A Item Top clearance A A B Side clearance B Clearance C between pump boss and drive gear A B: Repair or service limit Unit: mm (in.18 (0.00157 to 0.150 (0.

POWERSHIFT TRANSMISSION Reassembly Pump Assembly 2 3 1 3 3 204832 Sequence 1 2 Stator shaft. Spring. Snap ring Pump body. Oil seal 3 Internal gear. install the oil seal to the pump body.05300 Oil seal 204833 5-10 . Washer. O-ring. Drive gear. Relief valve. Washer Suggestions for Reassembly 1. Special tools needed Installer 91268 . Bolt. Installing oil seal Using installer (special tool).

Friction plates. Ball bearing Thrust washer. Snap ring Belleville spring. Pressure plate. Ball bearing. 5-11 . Needle roller bearing REVERSE gear Thrust washer. Spring retainer.POWERSHIFT TRANSMISSION 2. Needle roller bearing. FORWARD gear 5 6 7 8 Thrust washer. Inspection after reassembly Turn the drive gear by hand to make sure the pump gears rotate smoothly. Mating plates. Drive gear 209927 6 7 1 3 2 4 5 8 207124 Sequence 1 2 3 4 Input shaft. 3. Seal ring Clutch spring. coat automatic transmission fluid to the pump body interior. Seal ring Seal ring NOTE Reassembly of the clutch spring and plates on the REVERSE gear side is the same as that on the FORWARD gear side. internal gear and drive gear. Installing pump Internal gear Oil pump body When installing the pump. Clutch piston. Snap ring Thrust washer.

Special tools needed Piston tool 91268 . Number of plates 1 ton class Friction plate Mating plate 3 4 2. Installing piston assembly When installing the piston assembly to the input shaft. 2. Reassembling input shaft To install the snap ring.POWERSHIFT TRANSMISSION Suggestions for Reassembly 1. (3) The friction plates and the mating plates should be replaced as a set. 3 ton classes 5 6 Mating plate (6) Friction plate (5) Belleville spring (1) Drum Pressure plate (1) 207125 (2) Coat the mating plates and friction plates with automatic transmission fluid when installing them. Belleville spring Piston 207126 5-12 .07100 207160 3. compress the clutch spring with a special tool or an arbor press. coat to the seal ring automatic transmission fluid. Installing plate (1) Make sure that the combination and number of plates are correct.

use installer (special tool).POWERSHIFT TRANSMISSION 4. Installing FORWARD gear and REVERSE gear Make sure that the oil groove side of the thrust washer faces the gear when installed. Testing clutch piston FORWARD side REVERSE side After reassembling the input shaft. FORWARD REVERSE 207128 5-13 . Installing bearing To install the ball bearing to the input shaft. Special tools needed Installer 91268 . 200213 5. apply air to the clutch piston through oil hole on the FORWARD gear side to make sure that the piston moves freely.04100 207127 6.

Gasket.POWERSHIFT TRANSMISSION Transmission Assembly 10 9 8 14 4 5 3 7 12 11 13 1 2 6 207129 Sequence 1 2 3 4 5 6 7 8 Torque converter housing. O-ring 9 10 11 12 13 14 Gasket. Ball bearing Gasket. Eyebolt. Ball bearing. Gasket Output flange Magnet strainer. Ball bearing Idler shaft. Control valve. Oil seal Pump assembly. Sender unit Torque converter assembly 5-14 . Snap ring Input shaft assembly Idler gear. Baffle plate Output gear. O-ring Transmission housing. Filter case Drain plug. O-ring Oil pipe.

follow the reverse of disassembly sequence. Reassembling sequence To reassemble. 2. Mounting the transmission housing Set the transmission housing to a hoist with slings and eye bolts. Installing pump assembly (1) Lay the transmission housing in a normal position. 4. and install the pump assembly to the torque converter assembly. 204839 5. Be sure to install the O-ring in the oil inlet port. 204830 6. (4) Put the O-ring on the pump assembly. 3. Lower the housing onto the torque converter housing by aligning the input shaft with the transmission.POWERSHIFT TRANSMISSION Suggestions for Reassembly 1. Placing the torque converter housing Lay the torque converter housing with its engine side down. (2) Drive the input shaft (which has not been inserted into the transmission yet) into position with a copper rod from the torque converter side. 5-15 . (3) Tighten two torque converter housing mounting bolts. Apply grease to the O-ring. Applying grease Apply grease to the lips of the oil seals of the pump assembly and transmission housing. Applying oil on seal ring Coat to the input shaft seal ring with automatic transmission fluid.

(2) Make sure that the distance between the end face of torque converter housing and the mating face of flexible plate is 50 to 52 mm (1.POWERSHIFT TRANSMISSION 7.97 to 2. after 1 minute. (3) Support the flexible plate to the torque converter housing with a wire to prevent the torque converter from slipping out of position until the torque converter is coupled to the engine.05 in. Filling torque converter with AFT Fill the torque converter after the transmission has been mounted on the truck and the engine is ready to be started. 5-16 .) 204840 8.). Run the engine at idle speed for a while.05 in. 50 to 52 mm (1. Installing torque converter (1) Install the torque converter in position by mating the splines of stator shaft and by positioning the groove of pump drive gear correctly. Stop the engine and. check the oil level in the transmission with the oil level gauge in 15 minutes.97 to 2.

(2) Check each spool for sign of wear.POWERSHIFT TRANSMISSION Control Valve Disassembly 3 10 4 9 2 5 1 8 6 8 6 7 206450 Sequence 1 2 3 4 5 Solenoid valve Plug. damage or seizure. 200220 5-17 . Gasket Inspection after disassembly (1) Check oil ways and passages for clogging. Slug. O-ring 7 Oil seal 8 Plug. Spring seat. Strainer Cover. O-ring Accumulator piston. O-ring. Stopper pin. Clutch valve. Plug 6 Clutch valve plunger. Spring Main regulator valve. O-ring. (3) Check oil seals for damaged lips. Main regulator spring. O-ring 9 Accumulator spring seat. O-ring 10 Drain plug. Bearing roller. Valve spring. also check the valve spring for fatigue or damage. Pin. Return spring. (4) Check the orifice in the main regulator valve for cleanliness.

O-ring. Spring seat 7 8 9 10 11 Accumulator piston. Main regulator spring. Cover Drain plug. Valve spring. Plug Solenoid valve assembly Start by: Thoroughly clean the oil ways and passages in the valve. O-ring. Bearing roller Oil seal Clutch valve plunger. Gasket Strainer. Slug.POWERSHIFT TRANSMISSION Reassembly 9 8 Section A-A 1 7 2 A 6 A 5 9 4 Section B-B C 4 3 B B C 10 Section C-C 11 206451A Sequence 1 2 3 4 5 6 Accumulator spring seat. Pin Plug. O-ring. 5-18 . Stopper pin Clutch valve. Spring O-ring. O-ring. Return spring Main regulator valve. Slug. O-ring.

stop the engine. Stop the engine and. Run the engine at idle speed for a while. after one minute check the oil level in the transmission with the oil level gauge in 15 minutes. e Lube oil pressure 5. Raise the front wheels.8 ton classes 650 (650) 2600 (2300) 2 to 3. or place wood blocks under the outer mast and tilt the mast forward.5 ton classes 650 (650) 2600 (2300) 4. Warm up until the transmission oil temperature rises. Unit: rpm Truck Model Item No-load minimum speed No-load maximum speed ( ). b Clutch pressure d Torque converter outlet pressure 207130 5-19 . c Torque converter inlet pressure a Main pressure ! CAUTION The front wheels will rotate when the clutch pressure is tested.POWERSHIFT TRANSMISSION Inspection and Adjustment Testing Hydraulic Pressure 1. If the speeds are not correct. 3. jack the front axle housing. After checking the engine speeds. make an adjustment by referring to SERVICE MANUAL for the engine. 2. The pressure taps are located as shown. Diesel model 1. To do this.0 to 1. Connect a pressure gauge to the tap for a pressure to be tested. Check the no-load minimum and maximum speeds of the engine.

5) [14 to 21] b Clutch pressure Torque converter inlet pressure Torque converter outlet pressure A c A d A e Lube oil pressure Engine speed: 1500 ± 100 rpm A 5-20 . Connector 91268 .02300 *Gauge 64309 . torque converter outlet pressure and lube oil pressure. and test the main pressure.17331 For gauge Remarks M14 × 1.5 thread R(PT)1/8 thread M14 × 1.17733 Connector 91268 .17713 *Hose 64309 . Move the transmission shift lever to the FORWARD and REVERSE position.5 to 3) [21 to 43] 98 to 147 (1 to 1. 8.04400 *Connector 64309 . and test the clutch pressure. A: Standard value Unit: kPa (kgf/cm2) [psi] a Main pressure A 883 to 1079 (9 to 11) [128 to 156] 883 to 1079 (9 to 11) [128 to 156] 196 to 490 (2 to 5) [28 to 71] 147 to 294 (1.5 thread 600 kPa (6 kgf/cm2) [90 psi] 2000 kPa (20 kgf/cm2) [300 psi] — — — — Pressure taps a b — c — d.e — — — — — Remark: The asterisked tools are included in the gauge kit (64309 .17701). torque converter inlet pressure. Start the engine.17714 *Gauge 64309 . 7. Move the transmission shift lever to the neutral position.17722 *Connector 64309 . Use the following tools when testing the oil pressure: Tool name/ Tool No.POWERSHIFT TRANSMISSION 6.

7 ± 0.2 (4.03) 49 to 95 (1.06 in.01 to 0. To adjust the clutch pedal.).0 (0.74) 5-21 . Do not adjust the clearance by setting the pushrod length.04) 40 to 61 (1. abnormal temperature rise or clutch disc seizure. (2) Set the master cylinder pushrod length E to 103. proceed as follows: 1.5 ton classes 0.2 to 0.7 (0.) Truck Model Item Drum-to-lining clearance Stroke for brake application 1. the transmission clutch will not disengage or grab.POWERSHIFT TRANSMISSION Adjusting Inching Pedal ctu at ing Free play a ke ra ke B ro st A E Push rod length 207323 The inching pedal is interlocked with the brake pedal so that. Unit: mm (in. Unit: mm (in.).2 mm (4.06) (3) Adjust and confirm the brake drum-to-lining clearance.93 to 3.02 to 0. when this pedal is depressed.57 to 2.4) 2 to 3. resulting in poor braking. hydraulic pressure acting on the transmission is reduced to zero before the brake is applied to bring the transmission into neutral condition.8 ton classes 0.1 in.0 to 1.5 to 1. Adjusting the brake (1) Adjust the released height A of the brake pedal to 220 ± 3 mm (8.) Pushrod length E 103. If this linkage is out of adjustment.

7) Clearance between inching 9 to 9. Under this condition. Set the clearance B between the inching pedal and brake pedal connecting parts to 9 to 9.9 mm (0. mm (in.5 B pedal and brake (0.5 ton classes .004 to 0.236 to 0.5 mm (0.5 mm (0.354 to 0. Adjusting (1) Connect a pressure gauge to the clutch pressure tap. and block the rear wheels.5 C plunger stroke (0.004 to 0. (4) Release the inching pedal.020 in.20) [85] Clutch valve plunger stroke. (3) Start the engine.9 mm (0. Make an adjustment by means of the inching cable. raise the front wheels.) .354 to 0.) for the 1 ton class or 5.5 mm (0.5 (0.374) (0.374) Plunger D projection when brake is applied 5-22 16.) for the 1 ton class or 0. and make sure that clutch valve plunger stroke (C) is 9 to 9. the drum-to-lining clearance is too large.) by the stopper bolt.374) (0.531) (0.232 in. If the plunger stroke is less than 8.354 to 0.POWERSHIFT TRANSMISSION 2.5 0.374 in.350 in.65 in. the drum-to-lining clearance is too small.6 mm (0.374 in.) 200244 Truck Model Item Released height 220 A pedal (8.) for the 1 ton class or 6 to 9. Adjusting the inching pedal Start by: Warm up the transmission oil.5 6 to 9.5 mm (0.7 in.5 5 (0. readjust the brake and brake pedal.65) 1.236 to 0.378 in. and repeat the adjustment.) for the 2 to 3 ton classes at 883 to 1079 kPa (9 to 11 kgf/cm 2) [128 to 156 psi] read on the pressure gauge.1 to 0. If the plunger stroke is out of specification. kPa (kgf/cm2) [psi] 2 to 3.) for the 2 to 3 ton classes.354 to 0. • • If the plunger stroke is more than 9.1 to 0.8 ton classes Clutch pressure. and release the brake pedal.5 mm (0.) at 0 kgf/cm2 hydraulic pressure. make an adjustment by means of the push rod so that the clutch valve plunger stroke (D) is 16. (2) Adjust the released height A of the inching pedal to 220 mm (8.020) pedal connecting parts Clutch valve 9 to 9.374 in.) for the 2 to 3 ton classes.0 to 1. Depress the inching pedal until the brake starts to be applied (the pedal encounters resistance). A B 207131A D C 981 (10) [142] 588 (6) 13.

and move the transmission shift lever to the FORWARD position. Check to make sure that the transmission oil level is correct.POWERSHIFT TRANSMISSION Testing Clutch Valve 1. 1. 1. mm (in. Clutch pressure. do not allow the engine to keep on running at the highest speed attained or the torque converter may suffer damage. Gradually depress the accelerator pedal all the way by the right foot. Stall-speed running of the engine is limited to 30 seconds or less. 6.39) 206468 Clutch valve plunger stroke.) 2. kPa (kgf/cm2) [psi] 981 (10) [142] 588 (6) [85] 0 5 (0. 2. and plot the hydraulic pressure curve relative to the clutch valve plunger stroke.20) 10 (0. (See the topic. Move the lever to the FORWARD position. Warm up until the transmission oil temperature reaches 40 °C to 60 °C (104 °F to 140 °F). read the stall speed with an electric or stroboscopic tachometer.) Testing Stall Speed ! WARNING Make tests in a clear level area only. Run the engine at idle speed. 3. Block the front and rear wheels. 3. There must be one operator. Depress the inching pedal. Testing hydraulic pressure. 5. Also. and apply the parking brake. ! CAUTION Do not depress the inching pedal. Check the no-load maximum speed of the engine. Keep all other personnel away from the lift truck. Make sure that the plotted pressure curve is identical with the curve shown. Gradually pull out the clutch valve plunger from its fully pushed position. Under this condition. 4. 5-23 . Start the engine. Check the operation of the brakes before the tests are made. Connect a pressure gauge to the clutch pressure tap.

Stand ready to start with the engine idling and the transmission shift lever in the neutral position. 2. When the engine or the torque converter is changed. 2. 3. too. depress the accelerator pedal all the way. shift into forward and. Measure for reverse. the stall speed will vary as it is determined by the engine and torque converter combination. maximum 5-24 . 10-m (33-ft) Start Acceleration Test 1. at the same time. 3. Measure the amount of time that the truck elapses to travel 10 meters (33 feet) by using a watch. LPG models will show stall speed about 100 rpm lower than the specified speed. Time required for 10 m (33 ft) travel (no load) 5 seconds. 4. At the signal. Similarly read the stall speed for reverse drive.POWERSHIFT TRANSMISSION 7. Unit: rpm Truck Model Item Stall speed (tolerance: ± 100) 1870 GP15K GP18K GP20K GP20K-HP GP25K GP25K-HP 1791 GP30K GP35K DP20K DP25K DP30K DP35K 2095 1971 NOTE 1. Any stall speed within ±100 rpm of the specified speed is allowed.

Repair or replace. Readjust. Replace. defective Snap ring fitted to clutch drum broken Oil way for supplying oil pressure to clutch piston clogged Shaft splines worn Broken parts in reduction differential or front axle No power flow Transmission Power train 5-25 . Torque converter Not enough output power Transmission Road wheels Torque converter Flexible plate broken Not enough oil Oil pump drive defective Turbine shaft broken Main pressure too low Not enough oil Inching pedal link maladjusted Seal ring worn in servo case O-rings on input shaft worn Plug on input shaft loose or slipped off. Repair or replace. resulting in oil leaks Clutch seized Shafts broken Clutch drum. Replace. Replace oil. Refill. Clean or replace. Replace. Repair. Check pump gears for wear or replace. resulting in reduced capacity Magnet strainer clogged Seal rings or O-rings worn Stator freewheel seized Impeller damaged or rubbing Air being sucked in on suction side Water in oil Oil level too low Pedal linkage maladjusted (brake shift and forward reverse) Main pressure too low. Replace. Replace shafts. Readjust. Refill. particularly snap ring groove. Replace.POWERSHIFT TRANSMISSION Troubleshooting Engine Engine lacks power Poor performance of engine Oil level too low Air being sucked in on suction side Faulty action of spool in main regulator valve Weakened spring in main regulator valve Worn gears in oil pump. Check and adjust brake system Replace. Readjust. Replace. Replace gasket and retighten. Replace. Replace. Tune up engine. resulting in slipping clutches Seal rings or O-rings worn Clutch piston damaged Friction plate seized or dragging High mechanical resistance in road wheels Tune up engine. Overhaul and check or replace defective parts. Refill. Replace. Clean or replace. Replace torque converter assembly. Replace. Retighten or replace. Replace. Replace. Replace torque converter assembly. Refill. Replace.

Replace. Refill. Replace. Replace packing and retighten. Retighten or replace packing. Retighten or replace. Clean or replace. Replace. Retighten or replace. Transmission Abnormal noise Loud noise Low noise Oil leaks Leaking drain plug Cracks or blowholes in case Oil blowing out of transmission housing (1) Water in oil (2) Air being sucked in suction side (3) Oil leaks from air breather Oil level too high 5-26 . Repair or replace pipe. Replace. gasket and O-rings. Replace oil. Retighten and replace gasket.torque converter. Replace. Replace oil. Lower oil level. Replace. Check lips and sliding surfaces for wear. Replace friction plate. Replace seals. Repair or replace. Replace. Wash or replace. Replace. Replace. Repair. Replace. Clean or replace. Repair or replace. Retighten or replace packing.POWERSHIFT TRANSMISSION Torque converter Flexible plate broken Bearings damaged Rubbing blades of running member Bolts loose Splines worn Oil pump noisy Friction plates seized and dragging Bearings worn or seized Gears broken Bolts loose Splines worn Magnet strainer clogged Main regulator valve defective Restriction in oil pipe Oil too viscous in cold weather Instruments faulty Wrong kind of oil used Magnet strainer clogged Oil pump defective Excessive oil leaks (1) Main regulator valve spring broken or fatigued (2) Main regulator valve spool defective Air being sucked in Oil level too low Leaking oil seals Leaking joint of case Leaking pipe connection or joint Replace. Replace oil. Replace.

Clean or replace. Replace. Repair or replace. Refill. Repair or replace. Replace oil. Replace. Replace. Replace friction plates. Repair or replace. Transmission Others Main pressure is too low Clutch pressure is too low 5-27 . Retighten or replace O-ring. Repair or replace. Replace. Urge user to operate properly. Repair or replace. Replace. Retighten or replace packing.POWERSHIFT TRANSMISSION Oil level too high or too low Magnet strainer clogged Impeller rubbing Stator freewheel defective Torque converter Air being sucked in Water in oil Restriction in oil pipe (resulting in reduced circulation flow) Bearings worn or seized Instruments out of order Friction plates dragging Bearings worn or seized Control linkage defective Truck not operated properly Others (1) Cooling fan belt damaged (2) Oil cooler clogged (3) Brakes grabbing Main regulator valve defective Main pressure is too high Oil viscosity too high because of low temperature Wrong kind of oil used Magnet strainer clogged Oil pump failure Coil spring defective in main regulator valve Faulty movement of main regulator valve spool Air being sucked in Not enough oil Control linkage defective Clutch valve out of order Magnet strainer clogged Oil pump worn or otherwise defective Coil spring defective in main regulator valve Faulty movement of main regulator valve spool Air being sucked in Not enough oil Control linkage out of order Inching valve defective Seal ring broken in servo case Clutch piston seal rings broken Oil temperature is too high Refill or drain. Clean or replace. Repair or replace. Clean or replace. Repair or replace. Replace torque converter assembly. Clean or replace. Repair or replace valve assembly. Retighten or replace packing. Check and readjust. Refill. Replace oil. Replace oil. Replace. Repair or replace. Repair or replace. Replace. Replace torque converter assembly. Repair or replace. Replace.

5-28 . or friction plates slipping if the speed is too high Tune up engine. Repair or replace.POWERSHIFT TRANSMISSION Stall speed out of specification Lack of engine power if the speed is slightly low in both forward and reverse drive Stator and freewheel damaged if the speed is excessively low in both forward and reverse drive Inching pedal linkage defective. Replace stator assembly.

118) 2.2 + 0.0 (0.098 + 0.5 to 3) [21.004 3.1] 49 to 343 (0.5 to 3.3] Within 5 90 (3.3 to 43] 49 (0.5) [7.4 to 71.54 − 0 0.90 (3.POWERSHIFT TRANSMISSION Service Data A: Standard value Truck Model GP15K GP18K Item Stall speed (tolerance ± 100 rpm) rpm A 1870 GP20K GP20K-HP GP25K GP25K-HP B: Repair or service limit Unit: mm (in.008 ) + 0.0020) 2.2 to 85] 147 to 245 (1.1 to 50] 98 to 147 (1 to 1.5 + 0. A A B A B Pump boss Width of seal ring groove 3 A B Outside diameter of sliding surface to oil seal 1 Width or seal ring 2 (0.5394) 2.05 (0.5 ± 0.079) 2.1] 98 (1) [14] 98 to 588 (1 to 6) [14.1 0 − 0.5) [14.) DP20K DP25K GP:1971 DP: 2095 GP/DP30K GP/DP35K Main pressure Clutch pressure Engine at 1500 ± 100 rpm A kPa (kgf/cm2) [psi] Engine at 800 ± 50 rpm B kPa (kgf/cm2) [psi] Engine at 2500 ± 100 rpm B kPa (kgf/cm2) [psi] Engine at 1500 ± 100 rpm A kPa (kgf/cm2) [psi] Engine at 800 ± 50 rpm B kPa (kgf/cm2) [psi] Engine at 2500 ± 100 rpm B kPa (kgf/cm2) [psi] Engine at 1500 ± 100 rpm A kPa (kgf/cm2) [psi] 883 to 1079 (9 to 11) [128 to 156] 785 (8) [144] 785 to 1177 (8 to 12) [114 to 171] 883 to 1079 (9 to 11) [128 to 156] 785 (8) [144] 785 to 1177 (8 to 12) [114 to 171] 196 to 490 (2 to 5) [28. 3 1 204984 5-29 .098 ± 0.0 (0.5) [7.030 Torque converter inlet pressure Engine at 800 ± 50 rpm B kPa (kgf/cm2) [psi] Engine at 2500 ± 100 rpm B kPa (kgf/cm2) [psi] Engine at 1500 ± 100 rpm A kPa (kgf/cm2) [psi] Torque Engine at 800 ± 50 rpm B converter kPa (kgf/cm2) [psi] outlet pressure Engine at 2500 ± 100 rpm B kPa (kgf/cm2) [psi] Lubricating Engine at 1500 ± 100 rpm A oil pressure kPa (kgf/cm2) [psi] 10-m (33 ft) starting acceleration (no load) sec.00138) 89.2 to 21.

00157 to 0.012 to 0.1 to 0.0059) 0.POWERSHIFT TRANSMISSION A: Standard value Truck Model GP15K GP18K Item Diameter 1 A B GP20K GP20K-HP GP25K GP25K-HP B: Repair or service limit Unit: mm (in.18 (0.004 to 0.00327) 0.)/min B 2 3 1 204831 5-30 .00024 ) − 0.024 − 0.083 (0.1 to 0.00094 14.3 to 0.006 (0.4 (0.0130) 0.040 to 0.012) DP: 33 [2014] at 2200 rpm GP: 36 [2197] at 2400 rpm DP: 23 [1404] at 2200 rpm GP: 26 [1587] at 2400 rpm Oil pump Capacity liter (cu.004 to 0.15 (0.) DP20K DP25K GP/DP30K GP/DP35K 15− 0.3 (0.95 (0.0071) 0.016) 0.33 (0.5886) Pilot boss 1 200411 Top clearance 1 Side clearance 2 Clearance between pump boss and drive gear 3 Gear backlash A A B A A B A 0.in.59 − 0.

5 (2.157 ± 0.3 ± 0.060) 2.85) 5 6 207132 5-31 .05 (0.6 ± 0.20) 200412 Thickness of mating plate 1 Thickness of friction plate 2 Thickness of pressure plate 3 Backlash between friction plate and gear 4 Width of seal ring 5 Clutches Width of piston seal ring groove 6 Free length of clutch spring 7 Spring constant: k = N/mm (kgf/mm) [lbf/in] 4 3 7 2 A B A B A B A A B A B A B 1 1.2 (0.063 ± 0.5 (0.476 (1.004) 1.091 ± 0.3 (0.008) 0.1023 ± 0.087) 4.884) [105.6 ± 0.5 (2.417]] 72.POWERSHIFT TRANSMISSION A: Standard value Truck Model GP15K GP18K Item Face runout 1 (in free state) Clearance between engine flywheel and flexible plate mounting surface on torque converter 2 (to be measured before bolts are torqued) Flexible plate 1 2 B: Repair or service limit Unit: mm (in.2 (0.051) 2.13 to 0.1 (0.97) [k = 18.1 (0.13) 0.0051 to 0.1 (0.0020) 2.020) 1 to 5 (0.012) 3.098) 75.004) 1.) DP20K DP25K GP/DP30K GP/DP35K GP20K GP20K-HP GP25K GP25K-HP A B A 0.5 (0.01122) 2 ± 0.3 (0.285 (0.3 (0.004) 2.08 ± 0.04 to 0.5 (0.0 ± 0.

189) 2.05 (0. 4 8 207133 5-32 .0020) 2.098 +0.5 ± 0.0020) 3.5 ± 0.087) 3.2 +0.0020) 2.098 +0.004 +0.0 (0.5 (0.110 ± 0.2 (0.0 (0.079) +0.05 (0.118) 2.098 ± 0.05 (0.00083 ) 5.098 ± 0.079) 2.0 (0.106) 1.098) 2.) DP20K DP25K GP/DP30K GP/DP35K 2.0 (0.5 ± 0. 2 +0.7 (0.8 ± 0.2 (0.1 3.021 (1.18 +0 +0 30.POWERSHIFT TRANSMISSION A: Standard value Truck Model GP15K GP18K Item Width of stator shaft seal ring 1 Width of piston seal ring groove in stator shaft 2 Width of clutch piston seal ring 3 Width of clutch piston seal ring groove 4 Width of transmission housing seal ring 5 Input shaft and servo case Width of transmission housing seal ring groove 6 Inside diameter in transmission housing for seal ring 7 Thickness of input shaft thrust washer 8 Thickness of input shaft thrust washer 9 A B A B A B A B A B A B A B A B A B 2.05 (0.118) 2.0 (0.118) 30 +0.0 (0. 6 7 8 9 3.004 ) 3.079) 2.0 (0.098 ± 0.008 (0.2 (1.0020) 2.008 ) +0.5 GP20K GP20K-HP GP25K GP25K-HP B: Repair or service limit Unit: mm (in.118) 2.1 +0.5 +0.

12 to 0.730]] 26.0110) 0.0488) [2.2154) [12.0055) Output shaft 1 204988 Gear backlash Free length of clutch spring 1 Spring constant: k = N/mm (kgf/mm) [lbf/in] Free length of clutch spring 2 Spring constant: k = N/mm (kgf/mm) [lbf/in] Free length of clutch spring 3 Spring constant: k = N/mm (kgf/mm) [lbf/in] Free length of clutch spring 4 Spring constant: k = N/mm (kgf/mm) [lbf/in] A B A B A B A B A B 0.97) [k = 0.0855) [4.020) 75 (2.59]] 35.95) [k = 2.) DP20K DP25K GP/DP30K GP/DP35K GP20K GP20K-HP GP25K GP25K-HP A 0.5 (0.04) Control valve 5-33 .5 (1.6003) [33.45) [k = 5.0047 to 0.883 (0.POWERSHIFT TRANSMISSION A: Standard value Truck Model GP15K GP18K Item Free movement of idler gear (looseness of mating splines) 1 Measuring point B: Repair or service limit Unit: mm (in.00213 to 0.8 (1.40) 28 (1.28 (0.010) Idler gear 1 shaft 204987 Free movement of output flange gear (looseness of mating splines) 1 Measuring point A 0.054 to 0.478 (0.89) 36.12 to 0.26 (0.0525]] 72 (2.5 (1.838 (0.10) [k = 0.14 (0.784]] 48 (1.112 (0.0047 to 0.83) 50 (1.

669]] 89 (3.2 (4.354 to 0.94) 130 (5.236 to 0.98) [k = 4.303 (0.5 (0.5 (0.020) 6 to 9.POWERSHIFT TRANSMISSION A: Standard value Truck Model GP15K GP18K Item Free length of torque converter outlet and inlet regulator valve springs 5 Spring constant: k = N/mm (kgf/mm) [lbf/in] Free length of accumulator valve spring (inner) 6 Spring constant: k = N/mm (kgf/mm) [lbf/in] Free length of accumulator valve spring (outer) 7 Spring constant: k = N/mm (kgf/mm) [lbf/in] 6 7 2 1 3 4 B: Repair or service limit Unit: mm (in.892]] 24 (0.408]] 128 (5.) DP20K DP25K GP/DP30K GP/DP35K GP20K GP20K-HP GP25K GP25K-HP A B A B A B 25 (0.5 A (0.7447) [41.50) Control valve 5 206451 200418 Height of inching pedal 1 Clearance in pedal linkage 2 Plunger projection 3 Plunger projection when brake starts to apply 4 Push rod length 5 Inching pedal control A 9 to 9.58) [k = 7.1 to 0.04) 91 (3.12) 0.5 A (0.374) 16.427) [23.5 (0.004 to 0.06) 1 3 4 200419 2 5 207131A 5-34 .374) 9 to 9.650) 103.0609) [3.12) [k = 0.187 (0.7 ± 0.374) A A 220 ± 3 (8.354 to 0.597 (0.

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