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b
4 (30) 3
a
(33) 2
5
6
1
c
(32) No. 2 shaft
7
d No. 1 shaft
(30)
No. 3 shaft
e
(61)
Truck type
This transmission consists of one forward gear and
one reverse gear. The forward-reverse changeover is Item 2 ton class
1 ton class
accomplished by a powershift mechanism that uses 3 ton class
hydraulically controlled multiple-disc clutches. Three-element, single-stage,
Type
The transmission housing and torque converter hous- two-phase
ing can be separated from each other. Range Power path
The torque converter shell is constructed of steel- F (Forward) a→cd→e
plates welded in one body. For this reason, torque R (Reverse) b→e
converter parts can be replaced as an assembled unit
only.
Transmission reduction ratio
32 61
F (Forward) × = 1.972
33 30
61
R (Reverse) = 2.033
30
6-1
POWERSHIFT TRANSMISSION
4 3
1
7
5
8
9
213642
3
F
N
R
213643
6-2
POWERSHIFT TRANSMISSION
Torque
converter
Torque converter inlet pressure relief valve
0.10 to 0.50 MPa
Oil cooler (1.02 to 5.1 kgf/cm2)
PL PO [14.5 to 72.53 psi]
(Valve top surface marked with "M")
Selector valve
CF CR
Forward clutch Reverse clutch
213644
6-3
POWERSHIFT TRANSMISSION
2.2 Installation
(1) Couple the torque converter and transmission to
the engine.
To do this, push the torque converter toward the
transmission as far as it goes so that the distance
between the end surface of the torque converter
housing and the flywheel connecting face of the
flexible plate is 50 mm (1.97 in.).
When the assembly is coupled with the engine,
the clearance between the flywheel and flexible
plate should be 1 to 5 mm (0.039 to 0.197 in.).
A zero clearance indicates that the torque con-
verter is in improperly engaged with the oil pump
gear or any of the splines. In this case, reassem-
ble the torque converter and oil pump properly.
(2) Connect the flexible plate to the flywheel with the
bolts through the access hole in the torque con-
verter housing.
Note: Tighten the bolts evenly and progressively.
Avoid giving strain to the flexible plate.
Unit: N·m (kgf·m) [lbf·ft]
24 ± 2.4
Tightening torque (2.45 ± 0.24)
[17.7 to 1.77]
6-4
POWERSHIFT TRANSMISSION
3. Outline
3.1 Overall View of Powershift Transmission
Serial No.
214910
Left side of lift truck
Speed sensor
Engine side
Output flange
214911
Right side of lift truck
6-5
POWERSHIFT TRANSMISSION
Control valve
215210
Overall view of control valve
6-6
POWERSHIFT TRANSMISSION
214912
4.1.2 Transmission, setting on the stand
Place the transmission on the special tool (stand,
91A68-03500). Special tool
(Stand,91A68-03500)
Part name Part number
Stand 91A68-03500
214913
Control valve
6-7
POWERSHIFT TRANSMISSION
Speed sensor
Output flange
Oil temperature
switch
214915
4.2.5 Output flange, Removal
4.2.6 Oil strainer, Removal
Remove oil strainer together with O-ring.
Oil strainer assembly
214916
6-8
POWERSHIFT TRANSMISSION
214917
Eye bolt
Bolt
214918
214919
Eye bolt
Bolt
214920
6-9
POWERSHIFT TRANSMISSION
214921
214922
Oil pump
214924
6-10
POWERSHIFT TRANSMISSION
O-ring
214926
214927
6-11
POWERSHIFT TRANSMISSION
214928
O-ring
Seal ring
Shim
214929
214930
214931
6-12
POWERSHIFT TRANSMISSION
214932
Transmission
gasket
O-ring
214934
6-13
POWERSHIFT TRANSMISSION
214935
Guide bolt
214936
(2) Wrap wire around input shaft and idler shaft, and
lift the housing slightly.
Idler shaft
assembly Input shaft
assembly
214937
6-14
POWERSHIFT TRANSMISSION
214938
Idler shaft
assembly
214939
214940
6-15
POWERSHIFT TRANSMISSION
214942
214943
6-16
POWERSHIFT TRANSMISSION
214944
Drain plug
214946
Special tool
(Bolt, 67281-15400)
214947
6-17
POWERSHIFT TRANSMISSION
Baffle plate
Torque converter
relief cover
Torque converter
relief plate
214948
Special tool
(2) Using a screw driver, remove bearing. (Stand, 91A68-01300)
214949
6-18
POWERSHIFT TRANSMISSION
Special tool
(Stand, 91A68-01300) 214950
Special tool
(Puller, 91A68-01800)
214951
6-19
POWERSHIFT TRANSMISSION
Input spacer
214953
(3) Using the special tool (puller, 91A68-01800),
remove bearing together with input spacer.
Special tool
Part name Part number (Puller,91A68-01800)
Puller 91A68-01800
Input spacer
214954
6-20
POWERSHIFT TRANSMISSION
Snap ring
214955
(5) Using a screw driver, raise forward gear assem-
bly.
Forward gear
assembly
214956
(6) Using the special tool (puller, 91A68-01800),
remove forward gear assembly.
Special tool
(puller, 91A68-01800)
214957
6-21
POWERSHIFT TRANSMISSION
214958
Special tool
(Installer, 91268-04100)
Special tool
(Stand, 91A68-01700) 214959
214960
Friction plate
Mating plate
214961
6-22
POWERSHIFT TRANSMISSION
Input shaft
214962
(4) Using clutch pack special tool (stand kit, 91A68-
00010), retract clutch spring together with spring
retainer, and remove snap ring.
Clutch piston
Spring retainer
CAUTION
Exposed thread of the bolt under the nut should be
60 mm or more.
Special tool
(Plate2, 91A68-01500)
Special tool
(Stand kit,91A68-01300) 214965
Special tool
(Plate1,91A68-01400)
Bolt
Snap ring
214966
6-23
POWERSHIFT TRANSMISSION
214967
Clutch piston
Piston ring
214968
6-24
POWERSHIFT TRANSMISSION
6-25
POWERSHIFT TRANSMISSION
6-26
POWERSHIFT TRANSMISSION
Special tool
(Stand, 91A68-01700) 214969
Stator shaft
Internal gear
Pump drive gear
O-ring
Special tool
(Remover, 91A68-01900) 214972
6-27
POWERSHIFT TRANSMISSION
214975
6-28
POWERSHIFT TRANSMISSION
Torque converter
relief plate
214976
Baffle plate
214977
6-29
POWERSHIFT TRANSMISSION
214979
Clutch piston
214980
6-30
POWERSHIFT TRANSMISSION
5.5.3 Gear
Inspect gear and spline for wear and damage.
5.5.4 Drum
Inspect sliding area of clutch piston for wear and dam-
age.
6-31
POWERSHIFT TRANSMISSION
Clutch piston
214984
(4) Apply oil to piston ring and sliding area of clutch
piston.
(5) Install input shaft to clutch piston.
Wood bar
214986
6-32
POWERSHIFT TRANSMISSION
Stand 91A68-01300
Plate 1 91A68-01400 Special tool
(Plate 2, 91A68-01500)
Plate 2 91A68-01500
Special tool
(Stand, 91A68-01300) 214988
Special tool
(Plate 1,
91A68-01400)
Snap ring
214989
6-33
POWERSHIFT TRANSMISSION
214991
(3) Install snap ring.
Mating plate
214992
Snap ring
Special tool
(Stand, 91A68-01300)
214993
6-34
POWERSHIFT TRANSMISSION
Forward gear
214995
Spacer
Input shaft
214996
6-35
POWERSHIFT TRANSMISSION
214997
Special tool
(Installer, 91268-04100)
214998
Forward gear
215000
6-36
POWERSHIFT TRANSMISSION
Snap ring
215001
215002
Special tool
(Installer, 91268-04100)
215003
Angular bearing
Input spacer
215004
6-37
POWERSHIFT TRANSMISSION
Bearing
215005
Forward gear
215006
6-38
POWERSHIFT TRANSMISSION
215009
6-39
POWERSHIFT TRANSMISSION
6-40
POWERSHIFT TRANSMISSION
Unit: mm (in.)
UUu
44 (1.7)
9
22 (0.9) (0.4)
0
21 -0.5
0
(0.8 -0.02) 0 to 1.0 (0 to 0.04) POSITION OF BUSHING
PUMP BODY
BUSHING
ø0.025 S X
ø0.025 S Y
)
+0.025 )
ø60H7 (+0.030
ø42F7 (+0.050
+0
5
5
0.
0.
C
BUFFING
*
*
3.2S
SYMBOL
(SEE NOTE(2)) X
215011
6-41
POWERSHIFT TRANSMISSION
Oil seal
(2) Apply grease to lip portions.
215012
(5) Install guide bolt, and then install stator shaft. Stator shaft
Guide bolt
O-ring 215014
(6) Tentatively install the oil pump assembly mounting
bolts from stator shaft side, and remove guide
Oil pump assembly bolt
bolt.
(7) Tighten the hexagon cap bolt. Hexagon
cap bolt
(8) Remove the oil pump assembly mounting bolts
that were tentatively installed.
215015
6-42
POWERSHIFT TRANSMISSION
215017
215018
6-43
POWERSHIFT TRANSMISSION
215020
5.9.2 Input shaft gear assembly and idler gear assembly, Installation
(1) Tentatively install input shaft gear assembly.
(2) Tentatively install idler gear assembly. Input shaft gear
assembly
Note: The gear having 30 teeth should be on the
torque converter housing side, and the gear
having 32 teeth should be on the transmission
housing side.
215021
Idler gear
assembly
Z=30
215022
6-44
POWERSHIFT TRANSMISSION
215023
215024
215025
Transmission gasket
O-ring
Oil seal
215026
6-45
POWERSHIFT TRANSMISSION
215027
Control valve
attaching point
215029
6-46
POWERSHIFT TRANSMISSION
215030
Special tool
(Installer, 91A68-02200)
215033
6-47
POWERSHIFT TRANSMISSION
215034
(2) Using a depth micro gauge, measure the height
of fitting protrusion on servo case assembly.
(The measured value = B)
Depth micro gauge
Servo case
assembly
B
215035
(3) Use the following formula to obtain the play in the
thrusting direction of input shaft gear assembly.
C (play) = A - B Input shaft gear assembly
Install shims on the top of outer race so that the
play meets the standard.
Unit: mm (in.) Shims
Play in the thrusting 0.3 to 0.4
direction (0.012 to 0.016)
215036
6-48
POWERSHIFT TRANSMISSION
O-rings
215037
(2) Apply oil to seal ring of input shaft gear assembly,
and install servo case assembly with bolts tighten-
ing to the specified torque.
Unit: N·m (kgf·m) [lbf·ft]
39.2 ± 3.9
Servo case assembly (4.00 ± 0.40)
Servo case assembly
[28.9 ± 2.88]
215038
215039
215040
6-49
POWERSHIFT TRANSMISSION
Eye bolts
215041
(4) As you rotate idler gear with a screwdriver from
control valve attaching portion, install torque con-
verter assembly.
Note: Be careful when installing so that your hands
will not be caught between transmission hous-
ing and flexible plate or torque converter.
Idler gear
215042
Torque converter
Oil pump
Stator shaft
Oil pump
Pump drive gear
Input shaft
215043
6-50
POWERSHIFT TRANSMISSION
215044
50 mm
(2.0 in.)
215045
215046
5.12.2 Control valve, Installation
(1) Remove special tool (stand kit, 91A68-00200)
from transmission, and set the transmission in the Guide bolts
special tool (stand, 91A68-03500).
6-51
POWERSHIFT TRANSMISSION
O-rings
215048
215049
Stopper
215051
6-52
POWERSHIFT TRANSMISSION
215052
6-53
POWERSHIFT TRANSMISSION
Vise
215054
Breather
215055
Breather cover
215056
6-54
POWERSHIFT TRANSMISSION
Plugs
215057
Plug
215058
Flat tip
screwdriver
215059
Main orifice
215060
6-55
POWERSHIFT TRANSMISSION
215061
215062
(2) Remove main spring seat together with O-ring.
215063
6-56
POWERSHIFT TRANSMISSION
Slug
215064
Slug
Accumulator
spring seat
215067
6-57
POWERSHIFT TRANSMISSION
Inner spring
215068
Special tool
(Stand, 91A68-02801)
Pin remover
6-58
POWERSHIFT TRANSMISSION
Snap ring
Accumulator plug
215074
6-59
POWERSHIFT TRANSMISSION
215075
(2) Remove snap ring from inching valve section.
Snap ring
215076
6-60
POWERSHIFT TRANSMISSION
2 1 3 4 6 5 7 8
11
12
10
14
9
15
13 23
24
16
22
25
F R
17 19 18 20 21
213654
Reassembly sequence
1 Main relief plug, O-ring 10 Snap ring 19 Inching valve
2 Snap ring 11 Accumulator piston 20 Inching valve spring
3 Slug 12 Outer spring 21 Inching stopper, Spring pin
4 Regulator valve 13 Inner spring 22 Inching spring
5 Main relief spring (thick) 14 Accumulator spring seat, O-ring 23 Inching stopper
6 Main relief spring (thin) 15 Snap ring 24 Inching plug, O-ring
7 Main spring seat, O-ring 16 Oil seal 25 Strainer, O-ring
8 Snap ring 17 Snap ring
9 Accumulator plug, O-ring 18 Inching rod
6-61
POWERSHIFT TRANSMISSION
215077
215078
Regulator valve
215079
6-62
POWERSHIFT TRANSMISSION
215081
Snap ring
Oil seal
215083
6-63
POWERSHIFT TRANSMISSION
215086
6-64
POWERSHIFT TRANSMISSION
215087
n
lever directio
Inching
Outer spring
Accumulator piston
Inner spring
215088
6-65
POWERSHIFT TRANSMISSION
Lo
regulator valve so that the side to which slug is
ng
sid
fitted is facing to the lever side.
e
Regulator valve section
Direction of In
ching lever
6-66
POWERSHIFT TRANSMISSION
Valve body
215093
Special tool
(Stand, 91A68-02701)
Pin remover
215094
Note: 1. When installing spring pin, be sure to use the
special tool. If not, it can result in damage to
Spring pin Inching lever
the inching rod and valve body.
2. When installing spring pin, orient it so that its
notch faces to the end of inching rod.
6-67
POWERSHIFT TRANSMISSION
Flat-blade
215098
6-68
POWERSHIFT TRANSMISSION
215099
215100
Plugs Plugs
Plugs
215101
Breather cover
215102
6-69
POWERSHIFT TRANSMISSION
Breather
215103
215104
215105
6-70
POWERSHIFT TRANSMISSION
6-71
POWERSHIFT TRANSMISSION
Torque con-
Special tool/ part Lubrication oil
Remark Main pressure Clutch pressure verter inlet pres-
number pressure
sure
Connector
M14 × 1.5 thread ٤ -— — —
91268-04400
*Connector
R (PT) 1/8 thread — ٤ ٤ ٤
64309-17733
Connector
M14 × 1.5 thread — — — ٤
91268-02300
*Gauge
600 (6) [87] — — ٤ ٤
64309-17714
*Gauge
2000 (20) [290] ٤ ٤ — —
64309-17713
*Hose
64309-17722
٤ ٤ ٤ ٤
*Connector For gauge
64309-17731 connection ٤ ٤ ٤ ٤
Torque converter 600 ± 50 min-1 (rpm) A 0.16 ± 0.02 (1.63 ± 0.20) [23.2 ± 2.9]
c Neutral
inlet oil pressure 1600 ± 100 min-1 (rpm) A 0.40 ± 0.02 (4.08 ± 0.20) [58.0 ± 2.9]
Lubrication oil 600 ± 50 min-1 (rpm) A 0.02 ± 0.02 (0.20 ± 0.20) [2.9 ± 2.9]
d Neutral
pressure 1600 ± 100 min-1 (rpm) A 0.05 ± 0.02 (0.51 ± 0.20) [7.3 ± 2.9]
A: Standard value
6-72
POWERSHIFT TRANSMISSION
Brake
ineffective Play
stroke
2
213672
6-73
POWERSHIFT TRANSMISSION
6-74
POWERSHIFT TRANSMISSION
Adjusting procedure
(1) Run the engine at idle speed to raise the tempera-
ture of the transmission oil.
Inching pedal
(2) Shift the direction lever into the forward position.
Inching cable play stopper
(3) Gradually press the inching pedal to retract the
inching rod 2. Make sure that the oil pressure is 0
(zero) when the projection of the inching rod
Inching cable
becomes 26.9 mm (1.06 in.) or less.
Inching pedal
stopper bolt
213674
6-75
POWERSHIFT TRANSMISSION
9. Troubleshooting
Engine lacks power Tune up engine.
Engine
Poor performance of engine Tune up engine.
Oil level too low Refill.
Air being sucked in Retighten or replace O-ring.
Faulty action of spool in main regulator
Repair or replace.
valve
Settling of spring in main regulator valve Replace the spring.
Torque converter Worn gears in oil pump, resulting in Disassemble and inspect and if defect
reduced capacity is found, replace the defective parts.
Magnet strainer clogged Replace.
Worn seal rings or O-rings Inspect, and if defective, replace.
Seizure of stator freewheel Replace torque converter assembly.
Not
Damage or rubbing of impeller Replace torque converter assembly.
enough
output Air being sucked on suction side Retighten or replace.
power
Outlet pressure too low to suppress inter-
Readjust pressure.
nal foaming
Water in oil Change oil.
Oil level too low Refill.
Pedal linkage maladjusted (brake shift and
Transmission Adjust.
forward reverse)
Main oil pressure too low, resulting in slip-
Adjust.
ping clutches
Worn seal rings or O-rings Inspect, and if defective, replace.
Damaged clutch piston Replace.
Friction plate seized or dragging Replace.
High mechanical resistance in road
Road wheels Check and adjust brake system.
wheels
Flexible plate broken Replace.
Oil level too low Refill.
Oil pump drive defective Replace.
Torque converter
Turbine shaft broken Replace.
Check pump gears for wear or
Main pressure too low
replace.
Oil level too low Refill.
Inching pedal link maladjusted Adjust.
Seal ring worn in servo case Replace.
O-rings on input shaft worn Replace.
No power
Plug on input shaft loose or slipped off,
flow Repair.
resulting in oil leaks
Clutch seized Replace.
Transmission
Shafts broken Replace.
Clutch drum, particularly snap ring groove,
Replace.
defective
Snap ring fitted to clutch drum broken Replace.
Oil way for supplying oil pressure to clutch
Clean or replace.
piston clogged
Shaft splines worn Replace shafts.
Broken parts in reduction differential or
Power train Repair or replace.
front axle
6-76
POWERSHIFT TRANSMISSION
6-77
POWERSHIFT TRANSMISSION
6-78
POWERSHIFT TRANSMISSION
10.Service Data
Unit: mm (in.)
Truck type
Item
1 ton class 2 ton class 3 ton class
Main oil pressure,
MPa (kgf/cm2) [psi] A Forward: 1.25 ± 0.03 (12.75 ± 0.31) [181.3 ± 4.4]
Engine at 1600 ± 100 rpm
Clutch oil pressure, Forward: 1.21 ± 0.03 (12.34 ± 0.31) [175.5 ± 4.4]
MPa (kgf/cm2) [psi] A
Engine at 1600 ± 100 rpm Reverse: 1.18 ± 0.03 (12.03 ± 0.31) [171.2 ± 4.4]
Torque converter inlet oil pressure,
MPa (kgf/cm2) [psi] A Forward:0.39 ± 0.02 (3.98 ± 0.20) [56.6 ± 2.9]
Engine at 1600±100 rpm
Lubrication oil pressure,
MPa (kgf/cm2) [psi] A Forward:0.05 ± 0.02 (0.51 ± 0.20) [7.3 ± 2.9]
Engine at 1600 ± 100 rpm
Travel time for 10m starting acceleration
sec. A 5 seconds, maximum
(no load)
K21: 1930 ± 100 min-1
Stall speed in theory K25: 2008 ± 100 min-1
S4S: 2100 ± 100 min-1
Pump boss A -0.085 -0.0033
42 -0.035 (1.65 -0.0014)
Diameter of fitting surface in contact with oil
seal 1
B 41.85 (1.65)
1
213675
213676
6-79
POWERSHIFT TRANSMISSION
Unit: mm (in.)
Truck type
Item
1 ton class 2 ton class 3 ton class
Oil pump A 0.040 to 0.083 (0.00157 to 0.00327)
Side clearance 1
B 0.15 (0.0059)
A 0.3 to 0.33 (0.0118 to 0.0130)
Top clearance 2
B 0.35 (0.0138)
Backlash A 0.1 to 0.18 (0.00394 to 0.00709)
213677
214081
6-80
POWERSHIFT TRANSMISSION
Unit: mm (in.)
Truck type
Item
1 ton class 2 ton class 3 ton class
Clutch A 1.6 ± 0.1 (0.063 ± 0.0039)
Thickness of mating plate 1
B 1.3 (0.0512)
A 2.6 ± 0.1 (0.1024 ± 0.0039)
Thickness of friction plate 2
B 2.2 (0.0866)
A 0.1 to 0.3 (0.0039 to 0.0118)
Backlash of friction plate and gear 3
B 0.5 (0.0197)
A 2 ± 0.1 (0.0787 ± 0.0039)
Width of seal ring 4
B 1.5 (0.0591)
A 2.3 ± 0.05 (0.0906 ± 0.002)
Width of piston seal ring groove 5
B 2.5 (0.0984)
Free length of clutch return spring 6 56.3 (2.22)
A
(Spring constant: k = N/mm (kgf/mm) [lbf/in.]) K=38.3 (3.905) [218.7]
2 1 3
5 213679
6-81
POWERSHIFT TRANSMISSION
Unit: mm (in.)
Truck type
Item
1 ton class 2 ton class 3 ton class
Input shaft A 2.5 ± 0.05 (0.0984 ± 0.002)
Turbine shaft seal ring width 1
B 2.0 (0.0866)
+0.2 +0.0079
A 2.5 +0.1 (0.0984+0.0039)
Turbine shaft piston seal ring groove width 2
B 3.0 (0.1181)
+0.021 +0.0008
Stator shaft inside diameter contacting seal A 30 0 (1.1811 0 )
ring 3
B 30.2 (1.189)
A 2.5 ± 0.05 (0.0984 ± 0.002)
Clutch piston seal ring width 4
B 2.0 (0.0866)
A 2.8 ± 0.05 (0.1102 ± 0.002)
Clutch piston seal ring groove width 5
B 3.0 (0.1181)
A 2.5 ± 0.05 (0.0984 ± 0.002)
Clutch shaft seal ring width 6
B 2.0 (0.0866)
+0.2 +0.0079
A 2.5 +0.1 (0.0984 +0.0039)
Clutch shaft seal ring groove width 7
B 3.0 (0.1181)
+0.021 +0.0008
Servo case inside diameter contacting seal A 30 0 (1.1811 0 )
ring 8 B 30.2 (1.189)
1, 2
6, 7
㧲 㧾
8 3
4, 5
213680
6-82