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 5
Reassembly .................................................................................................................... 5 - 10
Pump Assembly ...................................................................................................... 5 - 10
Transmission Assembly .......................................................................................... 5 - 14
Control Valve........................................................................................................................ 5 - 17
Disassembly .................................................................................................................. 5 - 17
Reassembly .................................................................................................................... 5 - 18

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 - 31

 POWERSHIFT TRANSMISSION

Description

a b
(36) (31)
F
• •

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 for-
ward 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 parts, except for torque con-
verter, clutch valve, the output flange and uni-
versal joints, are common to all models.
1.0 to 1.8 ton models 2 to 3.5 ton models
Model 66H7 66H8
Type Three-element, single-stage, two-phase

The transmission housing and the torque con- Range Powerflow

verter housing can be separated from each other.
F (FORWARD) a → c d e
The pump, turbine and stator can be removed as R (REVERSE) b → e
one assembled unit from the startor shaft and
from the input shaft. Transmission reduction ratio
F 35 70
The torque converter is of one-piece construc- × = 2.195
(FORWARD) 36 31
tion fabricated by welding and is meant to be
replaced as one assembled unit. R 70
= 2.258
(REVERSE) 31

5-1
 Torque converter inlet pressure
Lube oil
d Oil cooler
c
Hydraulic Circuit

Accumulator
valve

F R Main regulator
valve
POWERSHIFT TRANSMISSION

Clutch valve

F ←→ R
Selector
valve
F
b

5-2
b

a
Filter (100 mesh)
with magnet Unit: kPa (kgf/cm2) [psi]
930 to 1180
a Main pressure (9.5 to 12.0)
[135.1 to 170.7]
930 to 1180
b Clutch pressure (9.5 to 12.0)
[135.1 to 170.7]
100 to 490
c Torque converter inlet (1.0 to 5.0)
pressure [14.2 to 71.1]
Oil pump 30 to 290
Actual capacity : 36 liters (2197 cu. in.)/2400 rpm (Gasoline models) d Lube oil pressre (0.3 to 3.0)
33 liters (2014 cu. in.)/2200 rpm (Diesel models) [4.27 to 42.7]
Engine speed: 1600±100 rpm

204869
 POWERSHIFT TRANSMISSION

Control

R
N 1
F

6 2
5

207136

1 Transmission shift lever 5 Clutch valve plunger

2 Clutch (inching) pedal 6 Solenoid valve assembly
3 Bracket (inching) (for forward-reverse)
4 Control valve assembly

Removal and Installation

Removal face of the housing and the mating face of
(1) Remove the engine and transmission as an flexible plate is 50 to 52 mm (1.97 to 2.05
assembly from the truck. in.). The clearance between the flywheel
and flexible plate should be 1 to 5 mm (0.04
NOTE to 0.20 in.) when the torque converter is
For the removal and installation of the coupled to the engine. If this clearance is
engine and transmission, refer to POWER zero, it is an indication that the torque con-
TRAIN. Drain oil from the transmission verter is improperly coupled to the engine;
housing recouple the converter to the engine proper-
ly.
(2) Tighten the bolts securing the flexible plate
(2) Unscrew the bolts securing the flexible
to the flywheel through the access hole in
plate through the access hole in the torque
the converter housing.
converter housing.
(3) Separate the torque converter and transmis- NOTE
sion from the engine. Tighten the bolts in a diagonal sequence.
Installation
(1) Couple the torque converter and transmis-
sion to the engine. To do this, place the
torque converter in the transmission hous-
ing so that the distance between the end
5-3
POWERSHIFT TRANSMISSION

Disassembly and Reassembly

Transmission Assembly
Disassembly

20
16
17 19 10

18 5 3 9
15
14
1
21

12
Bracket (inching)

2
8 11
4

5 24 2
23

22
6 Mount bracket

11
7
207119

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

NOTE
1) Remove the pump as an assembly includ-
ing 9 and 10.
2) Remove the input shaft as an assembly
including 14 thru 20, and disassemble it in
the order shown.

Start by:
1. Remove two mount brackets from the trans-
mission housing.
2. Remove the brackets (inching) and springs.
Suggestions

1. Removing torque converter assembly

Remove the torque converter assembly complete
with the flexible plate.
Prepare a container to catch the oil that flows out
of the converter.

204829

5-5
POWERSHIFT TRANSMISSION

2. Removing pump assembly Bolt hole

Unscrew the pump mounting bolts and screw two
bolts (special tool) into the M8 × 1.25 holes in the

(2.2 in.)
55 mm
pump body to remove the pump assembly. Be sure
to tighten the bolts equally, or the threads will suf-
fer damage. Use M8 × 1.25 bolts having an effec-
tive thread length of 55 mm (2.2 in.)
Special tool needed
Bolt 91268-05100 M8 × 1.25
Bolt hole
3. Removing transmission housing bolts
After removing the pump assembly, unscrew two
transmission housing bolts (F1805-10025) from
the torque converter housing side.

4. Removing transmission housing

Lay the transmission and torque converter assem-
bly with transmission housing down. Unscrew the
transmission housing bolts. Hang the transmission
housing to a hoist, 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.

204830

5. Removing input shaft ball bearing

Using a special tool, remove the ball bearing from 1
the input shaft.

Special tool needed

Ref ••
Part name Part No. Q’ty •
No.
1 Puller 91268-13810 2
2 Plate 91268-13820 1 4 2 3
207120
3 Bolt F1035-10020 2
4 Gear puller T-24
— 1
[Banzai make]

5-6
 POWERSHIFT TRANSMISSION

6. Disassembling input shaft

Using a special tool or an arbor press, compress
the clutch spring, and remove the snap ring.
Special tool needed
Piston tool 91268-07100

NOTE
1) Do not remove steel balls and sealing caps
from the transmission housing and torque
converter housing.
2) Do not remove oil seals from the pump 207160
body and transmission housing unless they
are defective.

Inspection after disassembly

1. Input shaft
(1) Check the splines for wear or damage. Seal ring grooves
(2) Check the width of each seal ring groove for
wear; also check the groove for damage.
(3) Check to be sure that oil grooves and passages
•
are open and clean, free from sign of clogging. •

2. Gears Oil passages

Check the gears and splines for wear or defects.
207121
3. Clutch drums
(1) Check the sliding surfaces of mating and fric-
tion plates for wear or damage.

5-7
POWERSHIFT TRANSMISSION

4. Friction plates and mating plates

(1) Check for sign of seizure, uneven contact,
warpage or excessive wear.
(2) Check the splines for wear or damage. Mating plate
A = Assembly standard
B = Repair or service limit Unit: mm (in.) Friction
1.6 ± 0.10 plate
Thickness of mating A
(0.063 ± 0.0039)
plate
B 1.3 (0.051)
207122
2.6 ± 0.1
Thickness of friction A
(0.1023 ± 0.004)
plate
B 2.2 (0.087)

5. Clutch pistons Seal ring

(1) Shake each piston, make sure that the balls
Plug
move freely in it. When piston is overhauled
and cleaned, screw the plug until its head gets
into piston end face, and caulk the plug.

NOTE
Do not disassemble the piston unless it is
defective.
Seal ring 207123
(2) Check the seal rings and their grooves for
wear or damage.

6. Transmission housing
Check the seal ring contact surfaces for wear or
damage.

7. Magnet strainer
Check for clogging or breakage.

8. Idler shaft
Check the splines for wear or damage.

9. Output flange
Check the splines for wear or damage. Also,
check the oil seal contact surface for defects.

5-8
 POWERSHIFT TRANSMISSION

10. Oil pump B

(1) Check top clearance A between the drive gear
and pump body with feeler gauges.
(2) Check side clearance B between the internal A
gear and drive gear and the pump body with C
a straight edge and feeler gauges.
(3) Check the backlash between the drive gear and
internal gear with feeler gauges.
(4) Put the drive gear on the torque converter
pump impeller, and check clearance C Drive gear 204831
between the gear and pump boss.

A = Assembly standard
B = Repair or service limit Unit: mm (in.)
0.30 to 0.33
A Top clearance A
(0.0118 to 0.0130)
0.040 to 0.083
A
B Side clearance (0.00157 to 0.00327)
B 0.150 (0.00591)
Clearance
between pump 0.1 to 0.4
C A
boss and (0.004 to 0.016)
drive gear
0.10 to 0.18
A
Gear backlash (0.0039 to 0.0071)
B 0.30 (0.0118)

5-9
POWERSHIFT TRANSMISSION

Reassembly
Pump Assembly

3
204832

Sequence
1 Stator shaft, Relief valve, Spring, Washer, 3 Internal gear, Drive gear, O-ring, Bolt,
Snap ring Washer
2 Pump body, Oil seal

Suggestions

1. Installing oil seal

Using installer (special tool), install the oil seal to
the pump body.
Oil seal
Special tool needed
Installer 91268-05300

204833

5-10
 POWERSHIFT TRANSMISSION

2. Installing pump
When installing the pump, coat automatic trans-
mission fluid to the pump body interior, internal
gear and drive gear.

3. Inspection after reassembly

Turn the drive gear by hand to make sure the pump
gears rotate smoothly.

7
1
3

5
8

207124

Sequence
1 Input shaft, Clutch piston, Seal ring
2 Clutch spring, Spring retainer, Snap
ring
3 Belleville spring, Mating plates,
Friction plates, Pressure plate, Snap
ring
4 Thrust washer, Needle roller bearing,
FORWARD gear
5 Thrust washer, Ball bearing
6 Thrust washer, Needle roller bearing
REVERSE gear
7 Thrust washer, Ball bearing, Seal ring
8 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.

5-11
POWERSHIFT TRANSMISSION

Suggestions
1. Installing piston assembly
When installing the piston assembly to the input
shaft, coat to the seal ring automatic transmission
fluid.

2. Reassembling input shaft

To install the snap ring, compress the clutch spring
with a special tool or an arbor press.
Special tool needed
Piston tool 91268-07100

207160

3. Installing plate
Friction plate (5) Mating plate (6) Drum
(1) Make sure that the combination and number of
plates are correct. •
• •
Belleville •
Number of plates spring (1)
•
1 ton class model 2, 3 ton class models
Friction plate 3 5
Mating plate 4 6 Pressure
plate (1)
207125

Belleville spring Piston

(2) Coat to the mating plates and friction plates
with automatic transmission fluid when
installing them. •
(3) The friction plates and the mating plates •
should be replaced as a set.

207126

5-12
 POWERSHIFT TRANSMISSION

4. Installing FORWARD gear and REVERSE

gear
Make sure that the oil groove side of thrust wash-
er faces the gear when installed.

200213

5. Installing bearing
To install the ball bearing to the input shaft, use
installer (special tool).
Special tool needed
Installer 91268-04100

207127

6. Testing clutch piston FORWARD side

After reassembling the input shaft, apply air to the
clutch piston through oil hole on the FORWARD REVERSE side
gear side to make sure that the piston moves freely.

FORWARD

REVERSE

207128

5-13
POWERSHIFT TRANSMISSION

Transmission Assembly

8
10

9
• 14
4 •
• •

• •

• •
5 •
•

•
3
12 7 •
• •
11
13
• • • •
•
1
2 •
•
•
6
207129

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

5-14
 POWERSHIFT TRANSMISSION

Suggestions

1. Reassembling sequence
To reassemble, follow the reverse of disas-
sembly sequence.

2. Placing the torque converter housing

Lay the torque converter housing with its
engine side down.

3. Applying grease
Apply grease to the lips of the oil seals of the
pump assembly and transmission housing.

4. Applying oil on seal ring

Coat to the input shaft seal ring with automat-
ic transmission fluid.
204839

5. Mounting the transmission housing

Set the transmission housing to a hoist with
slings and eye bolts. Lower the housing onto
the torque converter housing by aligning the
input shaft with the transmission.

204830

6. Installing pump assembly

(1) Lay the transmission housing in a normal posi-
tion.
(2) Drive the input shaft (which has not been
inserted into the transmission yet) into posi-
tion with a copper rod from the torque con-
verter side.
(3) Tighten two torque converter housing mount-
ing bolts.
(4) Put the O-ring on the pump assembly. Apply
grease to the O-ring, and install the pump
assembly to the torque converter assembly. Be
sure to install the O-ring in the oil inlet port.

5-15
POWERSHIFT TRANSMISSION

7. Installing torque converter

(1) Install the torque converter in position by mat-
ing the splines of stator shaft and by position-
ing the groove of pump drive gear correctly. 50 to 52 mm
(2) Make sure that the distance between the end (1.97 to 2.05 in.)
face of torque converter housing and the mat-
ing face of flexible plate is 50 to 52 mm (1.97
to 2.05 in.).
(3) Support the flexible plate to the torque con-
verter housing with a wire to prevent the
torque converter from slipping out of position
until the torque converter is coupled to the
engine.
204840

8. 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.
Run the engine at idle speed for a while. Stop the
engine and, after 1 minute, check the oil level in
the transmission with the oil level gauge in 15
minutes.

5-16
 POWERSHIFT TRANSMISSION

Control Valve
Disassembly
3

10
4

9
2
5
1

8 6

7
206450

Sequence
1 Solenoid valve
2 Plug, O-ring, Strainer
3 Cover, O-ring
4 Accumulator piston, Spring
5 Main regulator valve, Spring seat,
O-ring, Main regulator spring, Plug
6 Clutch valve plunger, Valve spring, Clutch valve,
Return spring, Slug, Stopper pin, O-ring
7 Oil seal
8 Plug, Bearing roller, O-ring
9 Accumulator spring seat, Pin, O-ring
10 Drain plug, Gasket

Inspection after disassembly

(1) Check oil ways and passages for clogging.
(2) Check each spool for sign of wear, damage or
seizure.
(3) Check oil seals for damaged lips.
(4) Check the orifice in the main regulator valve
for cleanliness; also check the valve spring for
fatigue or damage.

200220

5-17
POWERSHIFT TRANSMISSION

Reassembly

8 1
Section A-A 7

2 6

A A
4 B B 5
4 3
Section B-B 9
C

10 11
Section C-C
206451A

Sequence
1 Accumulator spring seat, O-ring, Pin 7 Accumulator piston, Spring
2 Plug, O-ring, Bearing roller 8 O-ring, Cover
3 Oil seal 9 Drain plug, Gasket
4 Clutch valve plunger, O-ring, Stopper pin 10 Strainer, O-ring, Plug
5 Clutch valve, Valve spring, Slug, Return 11 Solenoid valve assembly
spring
6 Main regulator valve, Slug, Main regula-
tor spring, O-ring, Spring seat

Start by:
Thoroughly clean the oil ways and passages in the
valve.

5-18
 POWERSHIFT TRANSMISSION

Inspection and Adjustment

Testing Hydraulic Pressure
1. Run the engine at idle speed for a while.
Stop the engine and, after one minute check
the oil level in the transmission with the oil
level gauge in 15 minutes.
2. Warm up until the transmission oil temper-
ature rises.
3. Check the no-load minimum and maximum
speeds of the engine. If the speeds are not
correct, make an adjustment by referring to
SERVICE MANUAL for the engine.
Unit: rpm
1.0 to 1.8 ton 2 to 3.5 ton
models models
No-load 650 650
minimum (650) (650)
speed
No-load 2600 2600
maximum (2300) (2300)
speed
( ); Diesel model
4. After checking the engine speeds, stop the
a Main pressure c Torque converter
engine. Raise the front wheels. To do this, inlet pressure
jack the front axle housing, or place wood
blocks under the outer mast and tilt the mast
forward.
CAUTION
The front wheels will rotate when the
•
clutch pressure is tested.
•
•
•
5. Connect a pressure gauge to the tap for a
pressure to be tested. The pressure taps are d Lube oil pressure
located as shown.
b Clutch pressure

207130

5-19
POWERSHIFT TRANSMISSION

6. Use the following tools when testing the oil

pressure:
Tool name Pressure taps
Tool No. Remarks
a b c d
Connector M14 x 1.5
— — —
91268-04400 thread
*Connector R(PT)1/8
—
64309-17733 thread
Connector M14 x 1.5
— — —
91268-02300 thread
600 kPa
*Gauge
(6 kgf/cm2) — —
64309-17714 [90 psi]
2000 kPa
*Gauge
(20 kgf/cm2) — —
64309-17713 [300 psi]

*Hose
64309-17722
*Connector
For gauge
64309-17331
Remark: The asterisked tools are included in the
gauge kit (64309-17701).

7. Start the engine. Move the transmission shift

lever to the neutral position, and test the main
pressure, torque converter inlet pressure and
lube oil pressure.

8. Move the transmission shift lever to the FOR-

WARD and REVERSE position, and test the
clutch pressure.

A = Assembly standard Unit: kPa (kgf/cm2) [psi]

930 to 1180
a Main pressure A (9.5 to 12.0)
[135.1 to 170.7]
930 to 1180
b Clutch pressure A (9.5 to 12.0)
[135.1 to 170.7]
100 to 490
c Torque converter inlet A (1.0 to 5.0)
pressure [14.2 to 71.1]
30 to 290
d Lube oil pressure A (0.3 to 3.0)
[4.27 to 42.7]
Engine speed: 1600 ± 100 rpm

5-20
 POWERSHIFT TRANSMISSION

Adjusting Inching Pedal

g
in
uat Free play
ct
kea
a e
Br rok
st
A

E
Push rod length 207323

The inching pedal is interlocked with the brake

pedal so that, when this pedal is depressed,
hydraulic pressure acting on the transmission is
reduced to zero before the brake is applied to
bring the transmission into neutral condition. If
this linkage is out of adjustment, the transmis-
sion clutch will not disengage or grab, resulting
in poor braking, abnormal temperature rise or
clutch disc seizure. To adjust the clutch pedal,
proceed as follows:

1. Adjusting the brake

(1) Adjust the released height A of the brake
pedal to 220 ± 3 mm (8.7 ± 0.1 in.).
(2) Set the master cylinder pushrod length E to
103.2 mm (4.06 in.).
Unit: mm (in.)
Pushrod length E 103.2 (4.06)

(3) Adjust and confirm the brake

drum-to-lining clearance. Do not adjust the
clearance by setting the pushrod length.
Unit: mm (in.)
1.0 to 1.8 ton 2 to 3.5 ton
models models
Drum-to-lining 0.5 to 1.0 0.2 to 0.7
clearance (0.02 to 0.04) (0.01 to 0.03)
Stroke for brake 40 to 61 49 to 95
application (1.57 to 2.4) (1.93 to 3.74)

5-21
POWERSHIFT TRANSMISSION

2. Adjusting the inching pedal

Start by:
Warm up the transmission oil, raise the front
wheels, and block the rear wheels.
Adjusting
(1) Connect a pressure gauge to the clutch pres-
sure tap.
(2) Adjust the released height A of the inching pedal
to 220 mm (8.7 in.) by the stopper bolt. Set the
clearance B between the inching pedal and brake A
pedal connecting parts to 9 to 9.5 mm (0.354 to
0.374 in.) for the 1 ton models or 0.1 to 0.5 mm
(0.004 to 0.020 in.) for the 2 to 3 ton models.
(3) Start the engine, and release the brake pedal.
Depress the inching pedal until the brake starts
to be applied (the pedal encounters resistance). B
Under this condition, make an adjustment by
means of the push rod so that the clutch valve
207131A
plunger stroke (D) is 16.5 mm (0.65 in.) at 0
kgf/cm2 hydraulic pressure.
(4) Release the inching pedal, and make sure that D C
clutch valve plunger stroke (C) is 9 to 9.5 mm
(0.354 to 0.374 in.) for the 1 ton models or 6
to 9.5 mm (0.236 to 0.374 in.) for the 2 to 3
ton models at 883 to 1079 kPa (9 to 11

kPa (kgf/cm2)[psi]
kgf/cm2) [128 to 156 psi] read on the pressure

Clutch pressure,
gauge. Make an adjustment by means of the
inching cable. If the plunger stroke is out of 981
(10)
specification, readjust the brake and brake [142]
pedal, and repeat the adjustment. 588
• If the plunger stroke is more than 9.6 mm (6)
13.5 5 [85]
(0.378 in.) , the drum-to-lining clearance is too
(0.531)(0.20)
small.
Clutch valve plunger stroke, mm (in.)
• If the plunger stroke is less than 8.9 mm 200244
(0.350 in.) for the 1 ton models or 5.9 mm
(0.232 in.) for the 2 to 3 ton models, the drum- Unit: mm (in.)
to-lining clearance is too large. 1 to 1.8 ton 2 to 3.5 ton
models models

A Released height 220

pedal (8.7)
Clearance
between inching 9 to 9.5 0.1 to 0.5
B pedal and brake (0.354 to 0.374) (0.004 to 0.020)
pedal connecting
parts

C Clutch valve 9 to 9.5 6 to 9.5

plunger stroke (0.354 to 0.374) (0.236 to 0.374)
Plunger
D projection when 16.5 (0.65)
brake is applied

5-22
 POWERSHIFT TRANSMISSION

Testing Clutch Valve

1. Connect a pressure gauge to the clutch pres-
sure tap. 981
(10)

kPa (kgf/cm2) [psi]

2. Start the engine, and move the transmission [142]

Clutch pressure,
shift lever to the FORWARD position. 588
3. Depress the inching pedal. Gradually pull out (6)
the clutch valve plunger from its fully pushed [85]
position, and plot the hydraulic pressure curve
relative to the clutch valve plunger stroke.
Make sure that the plotted pressure curve is
0 5 10
identical with the curve shown. (0.20) (0.39)
Clutch valve plunger stroke, mm (in.)
206468

Testing Stall Speed

WARNING
Make tests in a clear level area only. There
must be one operator. Keep all other per-
sonnel away from the lift truck. Check the
operation of the brakes before the tests are
made.

1. Check to make sure that the transmission oil

level is correct. (See the topic, 1. Testing
hydraulic pressure.)
2. Warm up until the transmission oil tempera-
ture reaches 40 °C to 60 °C (104 °F to 140 °F).
3. Block the front and rear wheels, and apply the
parking brake.
4. Check the no-load maximum speed of the
engine.
5. Run the engine at idle speed.
6. Move the lever to the FORWARD position.
Gradually depress the accelerator pedal all the
way by the right foot. Under this condition,
read the stall speed with an electric or strobo-
scopic tachometer.
CAUTION
Do not depress the inching pedal. Also, do not
allow the engine to keep on running at the
highest speed attained or the torque converter
may suffer damage. Stall-speed running of
the engine is limited to 30 seconds or less.

5-23
POWERSHIFT TRANSMISSION

7. Similarly read the stall speed for reverse drive.

Unit: rpm
GP15K/18K GP20K/25K GP30K/35K
(DP15K/18K) (DP20K thru 35K)
Stall speed
1870 1791 1971
(tolerance:
(2084) (2095)
± 100)

NOTE
1. Any stall speed within ±100 rpm of the
specified speed is allowed.
2. LPG models will show stall speed about
100 rpm lower than the specified speed.
3. When the engine or the torque converter is
changed, the stall speed will vary as it is
determined by the engine and torque con-
verter combination.

10-m (33-ft) Start Acceleration Test

1. Stand ready to start with the engine idling and
the transmission shift lever in the neutral posi-
tion.
2. At the signal, shift into forward and, at the
same time, depress the accelerator pedal all
the way.
3. Measure the amount of time that the truck
elapses to travel 10 meters (33 feet) by using a
watch.
4. Measure for reverse, too.
Time required for 10 m (33 ft) 5 seconds,
travel (no load) maximum

5-24
 POWERSHIFT TRANSMISSION

Troubleshooting

Following is a planned method of procedure for investigation and correction of the defects of the pow-
ershift transmission. The chart includes some of the most common complaints that may be encoun-
tered during the service life of the powershift transmission.
1) Too high an oil level results in abnormal oil
Step 1: Check oil level in temperature rise; NOTE
transmission.
2) Too low an oil level causes air to be sucked If oil is changed, run
in, resulting in reduced main pressure. engine for a few
See oil level.
Maladjusted inching pedal reduces clutch pressure, minutes, allowing oil
Step 2: Check inching pedal link- to flow into torque
resulting in slippage in clutches.
age.
See page 5-12. converter and cooler
and recheck oil level.
Step 3: Measure mast extending When mast lifting speed is normal, engine and
speed. mast hydraulic are in sound condition.
See page 10-38.

NO
OK
Step 4-1 : Remove oil pump for mast and
Step 4: Measure oil pressure.
measure stall speed.
See page 5-24.

930 to 1180 kPa (9.5 to 12.0 kgf/cm2)

Measure main pressure. [135.1 to 170.7 psi]
NO
Repair by referring to 1 of the
OK next page. NO
The same as main pressure
Measure clutch pressure. OK
NO
Repair by referring to 2. Replace oil pump for mast, Tune-up
OK or re-adjust flow divider. engine
Measure torque converter 100 to 490 kPa (1.0 to 5.0 kgf/cm2) See page 10-32.
inlet pressure. [14.2 to 71.1 psi]
NO
Repair by referring to 3.
OK
30 to 290 kPa (0.3 to 3.0 kgf/cm2)
Measure lube oil pressure. [4.27 to 42.7 psi] NO Powershift transmission is in
NO trouble; follow Step 4 and
Repair by referring to 4. subsequent steps.
OK
see page 5-24
OK
Step 5: Measure stall speed. In case where stall speed is
out of the specification after
NO engine and oil pump have
Repair by referring to 5. been turned up.

OK
Step 6: 10-m (33-ft) starting 5 seconds, maximum
acceleration test.
NO
Repair by referring to 6.
OK
Finish

5-25
POWERSHIFT TRANSMISSION

Check items Possible causes Remedies

1 Main pressure Low a) Oil pump sucking air Replace gaskets and O-rings.
(Sucking sound heard and oil
emulsified)
b) Suction strainer clogged Clean or replace strainer.
(No delivery of oil)
c) Main regulator valve spring Replace spring.
fatigued (Slight pressure drop)
d) Flexible plate broken Replace.
*e) Oil pump worn Replace.
High a) Main regulator valve seized Replace.
b) Discharge side pipe clogged Replace.
2 Clutch pressure Low a) Clutch valve not pushed in enough Adjust inching pedal linkage,
(Push in clutch valve) see page 5-21.
b) Main orifice clogged Clean.
c) Accumulator piston sticking Repair or replace.
Low with transmission shift lever in forward or
reverse position (accompanying abnormal oil
temperature rise)
a) Solenoid valve malfunction Replace.
*b) Clutch piston seal rings damaged Replace.
(Only F or R pressure)
*c) Input shaft seal ring damage Replace.
*d) O-ring damage Replace.
3 Torque converter Low a) Inlet relief valve spring fatigued Replace.
inlet pressure b) Not enough oil from oil pump Same as for low main pressure.
(Air being sucked in and strainer
clogged)
High Pipe clogged Clean.
4 Lube oil pressure Low a) Cooler clogged Remove cooler and check oil
pressure.
*b) Transmission housing worn Replace.
*c) Outlet relief valve leaky
5 Stall speed High Clutches slipping Replace.
(If clutch pressure is normal)
Low Torque converter defective Replace.
(If engine and gear pump are in
sound condition)
6 10-m (33-ft) start *a) Clutches seized (If slow in starting) Replace.
acceleration *b) Clutch slipping Wrong kind of oil? Check.
*c) Stator seized Replace.
(Abnormal oil temperature rise)
*d) Bearing and bushing seized Replace.
(Abnormal noise)
e) Brake dragging For adjusting method,
see page 8-12.
Footnote: * indicates items needing transmission removal.

5-26
 POWERSHIFT TRANSMISSION

Troubleshooting
Complaints Possible causes Remedies
Not enough output Engine a) Not enough power from engine Tune-up engine.
power b) Poor performance of engine Tune-up engine.
Torque a) Oil lever too low Refill.
converter b) Air being sucked in on suction side Replace gasket and
retighten.
c) Faulty action of spool in main Repair or replace.
regulator valve
d) Fatigued spring in main regulator Replace.
valve
e) Worn gears in oil pump, resulting in Overhaul and check or
reduced capacity replace defective parts.
f) Magnet strainer clogged Replace.
g) Seal rings or O-rings worn Replace.
h) Stator freewheel seized Replace assembly.
i) Blades of rotating members damaged Replace as an assembly.
or rubbing
Transmission a) Air being sucked in on suction side Retighten or replace.
b) Outlet pressure too low to suppress Readjust.
internal foaming
c) Water in oil Replace oil.
d) Oil level too low Refill.
e) Pedal linkage maladjusted (brake Readjust,
shift) see page 5-21
f) Main pressure too low, resulting in a Readjust
slipping clutches 930 to 1180 kPa (9.5 to
12.0 kgf/cm2) [135.1 to
170.7 psi]
g) Seal rings or O-rings worn Replace.
h) Clutch piston damaged Replace.
i) Friction plate seized or dragging Replace.
Wheels High mechanical resistance in road Check and adjust brake
wheels system, see page 8-12
No power flow Torque a) Flexible plate broken Replace.
converter b) Not enough oil Refill.
c) Oil pump drive defective Replace.
d) Turbine shaft broken Replace as an assembly.
e) Main pressure too low Check pump gears for
wear or replace.
Transmission a) Not enough oil Refill.
b) Inching pedal link maladjusted Readjust, see page 5-22
c) Both clutches on main shaft remain Readjust inching pedal
disengaged linkage or replace
clutches, see page 5-22

5-27
POWERSHIFT TRANSMISSION

Complaints Possible causes Remedies

No power flow Transmission d) Seal ring worn in servo case Replace.
e) O-rings on input shaft worn Replace.
f) Plug on input shaft loose or slipped Repair.
off, resulting in oil leaks
g) Clutch seized Replace.
h) Shaft broken Replace.
i) Clutch drum, particularly snap ring Replace.
groove, broken
j) Snap ring fitted to clutch drum Replace.
broken
k) Oil way for supplying oil pressure Clean or replace.
to clutch piston clogged
l) Shaft splines worn Replace shafts.
Drive line Broken parts in downstream side of Repair or replace.
transmission
Abnormal noise Torque a) Flexible plate broken Replace.
converter b) Bearings damaged Replace as an assembly.
c) Gears damaged Replace as an assembly.
d) Rubbing blades of running member Replace as an assembly.
e) Bolts loose Retighten or replace.
f) Splines worn Replace.
g) Oil pump noisy Repair or replace.
Transmission a) Clutch seized and dragging Replace clutch plate.
b) Bearings worn or seized Replace.
c) Gears broken Replace.
d) Bolts loose Retighten or replace.
e) Splines worn Replace.
Loud noise a) Oil filter clogged on outlet side Clean.
b) Main regulator valve spool defective Wash or replace.
c) Restriction in oil pipe Replace.
d) Oil too viscous in cold weather Replace oil.
e) Instruments out of order Replace.
f) Improper oil used Replace oil.
Low noise a) Oil filter clogged Clean or replace.
b) Oil pump out of order Replace.
c) Excessive oil leaks Repair.
d) Main regulator valve spring broken Replace.
or fatigued
e) Main regulator valve spool defective Repair or replace.
f) Air being sucked in Retighten or replace
packing.
g) Oil level too low Refill.

5-28
 POWERSHIFT TRANSMISSION

Complaints Possible causes Remedies

Oil leaks a) Leaking oil seals Check lips and sliding
surfaces for wear.
Replace seals.
b) Leaking joint of case Retighten or replace
packing.
c) Leaking pipe connection or joint Repair or replace pipe
and gasket.
d) Leaking drain plug Retighten and replace
gasket.
e) Cracks or blowholes in case Replace.
f) Oil blowing out of transmission case
• Water in oil Replace oil.
• Air being sucked in suction side Replace packing and
retighten.
• Oil leaks from air breather Repair.
g) Too much oil Lower oil level.
Oil temperature is Torque a) Oil level too high or too low Keep correct oil level.
too high converter b) Oil filter clogged Clean or replace.
c) Rubbing blades of running members Replace as an assembly.
d) Stator freewheel defective Replace as an assembly.
e) Air being sucked in Retighten or replace
gasket.
f) Water in oil Replace oil.
g) Restriction in oil pipe (resulting in Repair or replace.
reduced circulation flow)
h) Bearings worn or seized Replace as an assembly.
i) Instruments out of order Replace.
Transmission a) Clutches dragging Replace clutch plate.
b) Bearings worn or seized Repair or replace.
c) Control linkage defective Repair or replace.
Others a) Truck driven improperly Advice user to drive
truck properly.
b) Drive line or road wheels defective
• Cooling fan belt damaged Replace.
• Oil cooler clogged Clean or replace.
• Brakes grabbing Check and readjust,
see page 8-12
Main pressure is too a) Regulator valve defective Repair or replace valve
high assembly.
b) Restriction in oil pipe (resulting in reduced Repair or replace.
circulation flow)
c) Oil viscosity too high because of low temperature Replace oil.
d) Improper oil used Replace oil.

5-29
POWERSHIFT TRANSMISSION

Complaints Possible causes Remedies

Main pressure is a) Magnet screen clogged Clean or replace.
too low b) Gear pump worn Replace.
c) Coil spring defective in main regulator valve Replace.
d) Incorrect movement of main regulator valve spool Repair or replace.
e) Air being sucked in Retighten or replace
packing.
f) Not enough oil Refill.
g) Control linkage defective Repair or replace.
h) Clutch valve out of order Repair or replace.
Clutch oil pressure is a) Magnet screen clogged Clean or replace.
too low b) Gear pump worn or otherwise defective Replace.
c) Coil spring defective in main regulator valve Replace.
d) Erratic movement of main regulator valve spool Repair or replace.
e) Air being sucked in Retighten or replace
packing.
f) Oil level too low Refill.
g) Control linkage out of order Repair or replace.
h) Clutch valve defective Repair or replace.
i) Seal ring broken in servo case Replace.
j) Clutch seal rings broken Replace.
Stall speed out of a) Lack of engine power if the speed is slightly low Tune up engine.
specification in both forward and reverse drive
b) Stator and freewheel damaged if the speed is Replace torque converter
excessively low in both forward and reverse drive assembly.
c) Inching pedal linkage defective, or clutch slipping if Repair or replace.
the speed is too high

5-30
 POWERSHIFT TRANSMISSION

Service Data
A = Assembly standard B = Repair or service limit
Unit: mm (in.)
Truck Models GP/DP15K GP/DP20K GP/DP30K
Items GP/DP18K GP/DP25K GP/DP35K
Stall rpm (tolerance ±100 rpm) A GP: 1870 GP: 1971
DP: 2084 DP: 2095
At 1600 ± 100 engine rpm,
Main pressure kPa (kgf/cm2) [psi] A 930 to 1180 (9.5 to 12.0) [135.1 to 170.7]

At 1600 ± 100 engine rpm,

Clutch pressure kPa (kgf/cm2) [psi] A 930 to 1180 (9.5 to 12.0) [135.1 to 170.7]

Torque converter At 1600 ± 100 engine rpm,

inlet pressure kPa (kgf/cm2) [psi] A 100 to 490 (1.0 to 5.0) [14.2 to 71.1]

Lubricating oil At 1600 ± 100 engine rpm,

pressure kPa (kgf/cm2) [psi] A 30 to 290 (0.3 to 3.0) [4.27 to 42.7]

10-m (33 ft) starting acceleration (no load), sec. A Within 5

–0 –0
A 90 –0.030 (3.54 –0.00138)
Outside diameter of sliding surface to oil seal 1
B 89.90 (3.5394)
2.5 ± 0.05
A (0.098 ± 0.0020)
Width or seal ring 2
B 2.0 (0.079)
+0.2 +0.008
Width of seal ring groove 3 A 2.5 (0.098 +0.004 )
Pump boss

+0.1

B 3.0 (0.118)

2, 3 1 204984

5-31
POWERSHIFT TRANSMISSION

A = Assembly standard B = Repair or service limit

Unit: mm (in.)
Truck Models GP/DP15K GP/DP20K GP/DP30K
Items GP/DP18K GP/DP25K GP/DP35K
–0.00024
A 15 –0.006
–0.024 (0.59 –0.00094 )
Diameter 1
B 14.95 (0.5886)
Pilot boss

200411
Top clearance 1 A 0.3 to 0.33 (0.012 to 0.0130)
A 0.040 to 0.083 (0.00157 to 0.00327)
Side clearance 2
B 0.15 (0.0059)
Clearance between pump boss and drive gear 3 A 0.1 to 0.4 (0.004 to 0.016)
A 0.1 to 0.18 (0.004 to 0.0071)
Gear backlash
B 0.3 (0.012)
DP: 33 (2014) at 2200 rpm
A
GP: 36 (2197) at 2400 rpm
Capacity, liter (cu.in.)/min
DP: 23 (1404) at 2200 rpm
Oil pump

B
GP: 26 (1587) at 2400 rpm

204831

5-32
 POWERSHIFT TRANSMISSION

A = Assembly standard B = Repair or service limit

Unit: mm (in.)
Truck Models GP/DP15K GP/DP20K GP/DP30K
Items GP/DP18K GP/DP25K GP/DP35K
A 0.2 (0.008)
Face runout 1 (in free state)
B 0.5 (0.020)
Clearance between engine flywheel and flexible
1 to 5
plate mounting surface on torque converter 2 A
(0.04 to 0.20)
Flexible plate

(to be measured before bolts are torqued)

1 2

200412

A 1.6 ± 0.1 (0.063 ± 0.004)

Thickness of mating plate 1
B 1.3 (0.051)
A 2.6 ± 0.1 (0.1023 ± 0.004)
Thickness of friction plate 2
B 2.2 (0.087)
A 4.0 ± 0.3 (0.157 ± 0.012)
Thickness of pressure plate 3
Clutches

Backlash between friction plate and gear 4
Width of seal ring 5
Width of piston seal ring groove 6
B 3.3 (0.13)
A 0.13 to 0.285 (0.0051 to 0.01122)
A 2 ± 0.1 (0.08 ± 0.004)
B 1.5 (0.060)
A 2.3 ± 0.05 (0.091 ± 0.0020)
B 2.5 (0.098)

Free length of clutch spring 7 A 75.5 (2.97) [k = 18.476 (1.884) [105.417]]

Spring constant [k = N/mm (kgf/mm) [lbf/in]] B 72.5 (2.85)

2 1
3 4
5
7 • 6
•
•
•
•

207132

5-33
POWERSHIFT TRANSMISSION

A = Assembly standard B = Repair or service limit

Unit: mm (in.)
Truck Models GP/DP15K GP/DP20K GP/DP30K
Items GP/DP18K GP/DP25K GP/DP35K
A 2.5 ± 0.05 (0.098 ± 0.0020)
Width of stator shaft seal ring 1
B 2.0 (0.079)
A 2.5 +0.2
+0.1 (0.098 +0.008
+0.004 )
Width of piston seal ring groove in stator shaft 2
B 3.0 (0.118)
A 2.5 ± 0.05 (0.098 ± 0.0020)
Width of clutch piston seal ring 3
B 2.0 (0.079)
A 2.8 ± 0.05 (0.110 ± 0.0020)
Width of clutch piston seal ring groove 4
B 3.0 (0.118)
A 2.5 ± 0.05 (0.098 ± 0.0020)
Width of transmission housing seal ring 5
B 2.0 (0.079)
Input shaft and servo case

+0.008
A 2.5 +0.2
+0.1 (0.098 +0.004 )
Width of transmission housing seal ring groove 6
B 3.0 (0.118)

Inside diameter in transmission housing for A 30 +0.021

seal ring 7
Thickness of input shaft thrust washer 8
Thickness of input shaft thrust washer 9
+0 (1.18 +0.00083
+0 )
B 30.2 (1.189)
A 2.5 (0.098)
B 2.2 (0.087)
A 3.0 (0.118)
B 2.7 (0.106)

1, 2

5, 6 7 8 9 3, 4 8
207133

5-34
 POWERSHIFT TRANSMISSION

A = Assembly standard B = Repair or service limit

Unit: mm (in.)
Truck Models GP/DP15K GP/DP20K GP/DP30K
Items GP/DP18K GP/DP25K GP/DP35K
Free movement of idler gear
A 0.12 to 0.26 (0.0047 to 0.010)
(looseness of mating splines) 1
Idler gear shaft

Measuring point
1

204987
Free movement of output flange gear
A 0.054 to 0.14 (0.00213 to 0.0055)
(looseness of mating splines) 1
Measuring point
Output shaft

204988
A 0.12 to 0.28 (0.0047 to 0.0110)
Gear backlash
B 0.5 (0.020)

Free length of main relief valve spring (inner) 1 A 75 (2.95) [k = 2.112 (0.2154) [12.0525]]
Spring constant [k = N/mm (kgf/mm) [lbf/in]] B 72 (2.83)
A 50 (1.97) [k = 0.838 (0.0855) [4.784]]
Control valve

Free length of main relief valve spring (outer) 2

Spring constant [k = N/mm (kgf/mm) [lbf/in]] B 48 (1.89)

Free length of clutch valve spring 3 A 36.8 (1.45) [k = 5.883 (0.6003) [33.59]]
Spring constant [k = N/mm (kgf/mm) [lbf/in]] B 35.5 (1.40)

Free length of clutch valve spring 4 A 28 (1.10) [k = 0.478 (0.0488) [2.730]]

Spring constant [k = N/mm (kgf/mm) [lbf/in]] B 26.5 (1.04)

5-35
POWERSHIFT TRANSMISSION

A = Assembly standard B = Repair or service limit

Unit: mm (in.)
Truck Models GP/DP15K GP/DP20K GP/DP30K
Items GP/DP18K GP/DP25K GP/DP35K
Free length of torque converter outlet and A 25 (0.98) [k = 4.187 (0.427) [23.892]]
inlet regulator valve springs 5
Spring constant [k = N/mm (kgf/mm) B 24 (0.94)

Free length of accumulator valve spring (inner) 6 A 130 (5.12) [k = 0.597 (0.0609) [3.408]]
Spring constant [k = N/mm (kgf/mm) [lbf/in]] B 128 (5.04)

Free length of accumulator valve spring (outer) 7 A 91 (3.58) [k = 7.303 (0.7447) [41.669]]
Spring constant [k = N/mm (kgf/mm) [lbf/in]] B 89 (3.50)
6

7
Control valve

2
1

206451 200418
Height of inching pedal 1 A 220 ± 3 (8.7 ± 0.12)
9 to 9.5 0.1 to 0.5
Clearance in pedal linkage 2 A
(0.354 to 0.374) (0.004 to 0.020)
Plunger projection 3 A 9 to 9.5 6 to 9.5
(0.354 to 0.374) (0.236 to 0.374)
Plunger projection when brake starts to apply 4 A 16.5 (0.650)
Push rod length 5 A 103.2 (4.06)
Inching pedal control

3
2
4

200419 5 207131A
5-36