Cat DP150 Forklift Service Manual 1

Service Manual
Chassis & Mast

DP100 3DP-10011-up
DP115 4DP-10011-up
DP135 5DP-10011-up
DP150 6DP-10011-up
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99799-80120
FOREWORD
This service manual is a guide to servicing of Cat® Lift Truck’s 10 ton to 15 ton pneumatic
models. The instructions are grouped by systems to serve the convenience of your ready
reference.
Long productive life of your lift trucks depends to a great extent on correct servicing – the
servicing consistent with what you will learn from this service manual. We hope you read the
respective sections of this manual carefully and know all the components you will work on
before attempting to start a test, repair or rebuild job.
The descriptions, illustrations and specifications contained in this manual were of the trucks of
serial numbers in effect at the time it was approved for printing. Cat lift truck reserves the right
to change specifications or design without notice and without incurring obligation.
These lift trucks are powered by Mitsubishi 6D16TL diesel engine. For the items of the engine,
refer to the following service manual:
6D16 '7/Diesel Engine Service Manual (Pub. No. 99709-68130)%HJLQVRQSDJH
Safety Related Signs
The following safety related signs are used in this service

manual to emphasize important and critical instructions:
Indicates a specific potential hazard

WARNING
resulting in serious bodily injury or
death.
Indicates a specific potential hazard

CAUTION
resulting in bodily injury, or damage
to, or destruction of, the machine.
NOTE Indicates a condition that can cause

damage to, or shorten service life of,
the machine.
Pub. No. 99799-80120

WARNING
SAFETY
WARNING 4. Lower the forks or other implements to the ground
before performing any work on the truck. If this
The proper and safe lubrication and
cannot be done, make sure the forks or other
maintenance for this lift truck, recommended
implements are blocked correctly to prevent them
by Cat lift truck, are outlined in the
from dropping unexpectedly.
OPERATION & MAINTENANCE MANUAL for
these trucks. WARNING
Improper performance of lubrication or Do not operate this truck unless you have
maintenance procedures is dangerous and read and understand the instructions in the
could result in injury or death. Read and OPERATION & MAINTENANCE MANUAL.
understand the OPERATION & Improper truck operation is dangerous and
MAINTENANCE MANUAL before performing could result in injury or death.
any lubrication or maintenance.
5. Use steps and grab handles (if applicable) when

The serviceman or mechanic may be unfamiliar with mounting or dismounting a truck. Clean any mud
many of the systems on this truck. This makes it or debris from steps, walkways or work platforms
important to use caution when performing service before using. Always face truck when using
work. A knowledge of the system and/or components steps, ladders and walkways. When it is not
is important before the removal or disassembly of any possible to use the designed access system,
component. provide ladders, scaffolds, or work platforms to
Because of the size of some of the truck components, perform safe repair operations.
the serviceman or mechanic should check the weights 6. To avoid back injury, use a hoist when lifting
noted in this Manual. Use proper lifting procedures components which weigh 23 kg (50 lb.) or more.
when removing any components. Make sure all chains, hooks, slings, etc., are in
Following is a list of basic precautions that should good condition and are of the correct capacity. Be
always be observed. sure hooks are positioned correctly. Lifting eyes
1. Read and understand all warning plates and decals are not to be side loaded during a lifting
on the truck before operating, lubricating or operation.
repairing the product. 7. To avoid burns, be alert for hot parts on trucks
2. Always wear protective glasses and protective which have just been stopped and hot fluids in
shoes when working around trucks. In particular, lines, tubes and compartments.
wear protective glasses when pounding on any 8. Be careful when removing cover plates.
part of the truck or its attachments with a hammer Gradually back off the last two bolts or nuts
or sledge. Use welders gloves, hood/goggles, located at opposite ends of the cover or device and
apron and other protective clothing appropriate to pry cover loose to relieve any spring or other
the welding job being performed. Do not wear pressure, before removing the last two bolts or
loose-fitting or torn clothing. Remove all rings nuts completely.
from fingers when working on machinery. 9. Be careful when removing filler caps, breathers
3. Do not work on any truck that is supported only and plugs on the truck. Hold a rag over the cap or
by lift jacks or a hoist. Always use blocks or jack plug to prevent being sprayed or splashed by
stands to support the truck before performing any liquids under pressure. The danger is even greater
disassembly. if the truck has just been stopped because fluids
can be hot.
10. Always use tools that are in good condition and 17. Always support the mast and carriage to keep
be sure you understand how to use them before carriage or attachments raised when maintenance
performing any service work. or repair work is performed, which requires the
11. Reinstall all fasteners with same part number. mast in the raised position.
Do not use a lesser quality fastener if 18. Loose or damaged fuel, lubricant and hydraulic
replacements are necessary. Do not mix metric lines, tubes and hoses can cause fires. Do not
fasteners with standard nuts and bolts. bend or strike high pressure lines or install ones
12. If possible, make all repairs with the truck which have been bent or damaged. Inspect lines,
parked on a level, hard surface. Block truck so it tubes and hoses carefully. Do not check for
does not roll while working on or under truck. leaks with your hands. Pin hole (very small)
leaks can result in a high velocity oil stream that
13. Disconnect battery and discharge any capacitors
will be invisible close to the hose. This oil can
(electric trucks) before starting to work on truck.
penetrate the skin and cause personal injury. Use
Hang “Do not Operate” tag in the Operator’s
cardboard or paper to locate pin hole leaks.
Compartment.
19. Tighten connections to the correct torque. Make
14. Repairs, which require welding, should be
sure that all heat shields, clamps and guards are
performed only with the benefit of the
installed correctly to avoid excessive heat,
appropriate reference information and by
vibration or rubbing against other parts during
personnel adequately trained and knowledgeable
operation. Shields that protect against oil spray
in welding procedures. Determine type of metal
onto hot exhaust components in event of a line,
being welded and select correct welding
tube or seal failure, must be installed correctly.
procedure and electrodes, rods or wire to provide
a weld metal strength equivalent at least to that 20. Relieve all pressure in air, oil or water systems
of parent metal. before any lines, fittings or related items are
disconnected or removed. Always make sure all
15. Do not damage wiring during removal
raised components are blocked correctly and be
operations. Reinstall the wiring so it is not
alert for possible pressure when disconnecting
damaged nor will it be damaged in operation by
any device from a system that utilizes pressure.
contacting sharp corners, or by rubbing against
some object or hot surface. Do not connect 21. Do not operate a truck if any rotating part is
wiring to a line containing fluid. damaged or contacts any other part during
operation. Any high speed rotating component
16. Be sure all protective devices including guards
that has been damaged or altered should be
and shields are properly installed and functioning
checked for balance before reusing.
correctly before starting a repair. If a guard or
shield must be removed to perform the repair
work, use extra caution.
HOW TO READ THIS MANUAL
1. Service data in the text

Example:
A: Standard value B: Repair or service limit
Unit: mm (in.)
0.020 to 0.105
A
Clearance between cylinder (0.00079 to 0.00413)
and piston
B 0.15 (0.0059)
2. Symbols or abbreviations
OP ....................... Option
R1/4 .................... Taper pipe thread (external) 1/4 inch (formerly PT1/4)
Rc1/8................... Taper pipe thread (internal) 1/8 inch (formerly PT1/8)
G1/4A ................. Straight pipe thread (external) 1/4 inch (formerly PF1/4-A)
Rp1/8 .................. Straight pipe thread (internal) 1/8 inch (formerly PS1/8)
GROUP INDEX
GROUP INDEX Items

Model View, Truck Models Covered, Serial Number Locations,
GENERAL INFORMATION
Technical Data, Dimensions
1
COOLING SYSTEM Removal and Installation, Fan Belt Adjustment 2
Console Box, Major Components, Lamp Bulb Specifications,

ELECTRICAL SYSTEM Batteries, Electrical System Schematic 3
2-speed Transmission, 3-speed Transmission, Gear Ratios, Removal

POWER TRAIN and Installation, Engine and Transmission Unit 4
Torque Converter, Transmission, Power Flow, Control Valve, Main
2-SPEED POWERSHIFT Regulator Valve, Hydraulic Controls, Speed Selector System, Control
TRANSMISSION
5
System
Torque Converter, Transmission, Power Flow, Control Valve, Main
3-SPEED POWERSHIFT Regulator Valve, Hydraulic Controls, Speed Selector System, Control
TRANSMISSION
6
System
FRONT AXLE AND Front Wheels (Tires), Front Axle and Reduction Differential
REDUCTION DIFFERENTIAL
7
REAR AXLE Rear Axle, Power Cylinder, Minimum Turning Radius 8
Wheel Brake System, Brake Control Valve, Air Master, Air Governor,
BRAKE SYSTEM Air Dryer, Parking Brake, Testing and Adjusting 9
STEERING SYSTEM Steering Control Valve, Tilt Steering Assembly 10

Hydraulic System, Hydraulic Tank, Gear Pump, Priority Valve,
HYDRAULIC SYSTEM Control Valve, Flow Regulator Valve, Down Safety Valve, Lift and Tilt 11
Cylinders
MASTS AND FORKS Simplex Mast 12

Applicable Attachment Models, Specifications, Structure, Removal and
HYDRAULIC FORK Installation, Removal, Installation, Fork Positioner Assembly, Fork
POSITIONER
13
Positioner Cylinder, Inspection and Adjustment, Troubleshooting, etc.
HYDRAULIC SIDE SHIFTERS Side Shifter Assembly, Hydraulic Cylinder 14

Maintenance Chart, Tightening Torque for Standard Bolts and Nuts,
SERVICE DATA Periodic Replacement Parts, Lubrication Instructions, Weight of Major 15
Components, Special Tools
GENERAL INFORMATION
1
Model View ................................................................................................ 1–1
Truck Models Covered ........................................................................... 1–1
Serial Number Locations ....................................................................... 1–2
Technical Data .......................................................................................... 1–3
Dimensions (Approximate) .................................................................... 1–4
GENERAL INFORMATION
Model View
210310
Truck Models Covered
This Service Manual furnishes servicing and maintenance

information for the following trucks:
Truck model Transmission Designation – Serial number Engine mounted
DP100 Powershift 3DP – 10011- up Mitsubishi 6D16TL diesel engine
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1-1
GENERAL INFORMATION
Serial Number Locations
Name plate Chassis serial number
Mast serial number Transmission serial number Diesel engine serial number
210311
1-2
GENERAL INFORMATION
Technical Data
Truck Model
DP100 DP115 DP135 DP150
Item
Designation 3DP 4DP 5DP 6DP
Type Standard (with 3-speed powershift transmission)
Capacity/load center 10000/600 11500/600 13500/600 15000/600
kgf/mm (lbf/in.) (22000/24) (25000/24) (30000/24) (33000/24)
Lift mm (in.) 3000 (120) 3300 (130)
Lift speed (unloaded/loaded) 360/300 360/340 310/290 310/280
General mm/sec (fpm) (71/65) (71/67) (61/57) (61/55)
Lowering speed (unloaded/loaded)
500/450 (98/89) 420/380 (83/75)
mm/sec (fpm)
Tilt angle (forward – backward) 15° – 12°
Free lift mm (in.) 0
Travel speeds (unloaded/ Forward
loaded) 31.5/24.5 (20/15) 33.0/22.0 (20/14)
km/h (mph) Reverse
Minimum turning radius 4000 4060 4160 4550
mm (in.) (157) (160) (164) (179)
Performance Turning angle Inside 78°27’
Outside 51°14’
Minimum intersecting aisle 3550 3590 3680 3830
mm (in.) (140) (141) (145) (151)
Gradeability At 1.6 km/h (1 mph) 32% 29% 23%
(rated load) At 2 km/h (1.2 mph) 21% 19% 15% 14%
Tires Size of tires (front and rear) 10.00-20- 10.00-20-
12.00-20-18PR (I)
14PR (I) 16PR (I)
Inflation pressure of tires 700 (7.0) 800 (8.0)
800 (8.0) [116]
(front and rear) kPa (kgf/cm2) [psi] [101] [116]
Weight 14450 15330 17320 17760
kg (lb) (31860) (33800) (38190) (39160)
Weight and Front axle loading 7090 6950 7460 7940
axle loading kg (lb) (15630) (15320) (16450) (17510)
(unloaded)
Rear axle loading 7360 8380 9860 9820
kg (lb) (16230) (18480) (21740) (21650)
1-3
GENERAL INFORMATION
Dimensions (Approximate)
G I J
E
E
A
H
D
M
L K
B F
210312
1-4
GENERAL INFORMATION
Unit: mm (in.)
Ref. Truck Model

DP100 DP115 DP135 DP150
No. Item
A Lift 3300 (130)
B Fork length 1220 (48)
C Fork width 180 (7.1)
D Fork thickness 70 (2.8) 90 (3.5)
E Tilt angle (forward – backward) 15° – 12°
F Overall length 4293 (169) 4371 (172) 4528 (178) 4830 (190)
G Overall width (outside of tires) 2514 (99) 2599 (102)
H Overall height (to top of mast lowered) 3137 (124) 3483 (137)
I Tread (front) 1900 (75) 1906 (75)
J Tread (rear) 1930 (76) 1890 (74)
K Wheelbase 2800 (110) 3100 (122)
L Front overhang 754 (29.7) 759 (29.9) 792 (31.2) 794 (31.3)
M Ground clearance (at frame) 340 (13.4) 380 (15.0)
N Minimum turning radius 4000 (157) 4060 (160) 4160 (164) 4550 (179)
1-5
COOLING SYSTEM
Specifications .......................................................................................... 2 – 1
Description ............................................................................................... 2 – 2 2
Removal and Installation ...................................................................... 2 – 3
Radiator and Intercooler ........................................................................... 2 – 3
Troubleshooting ...................................................................................... 2 – 6
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COOLING SYSTEM
Specifications
Truck Model
DP100 DP115 DP135 DP150
Item
Type Forced circulation
Corrugated fin with pressure cap

Radiator type
(with built-in transmission oil cooler)
Oil cooler type Plate fin type
Capacity (complete system)

23 (6.1)
liter (U.S. gal.)
2-1
COOLING SYSTEM
Description
Detail of transmission oil cooler
2 4
9 6
3
8
5
To torque converter
From torque converter
210313
1. Intercooler 6. Drain cock

2. Intake hose (intercooler) 7. Upper hose (radiator)
3. Outlet hose (intercooler) 8. Lower hose (radiator)
4. Radiator 9. Reserve tank
5. Transmission oil cooler
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and has eight blades to provide high cooling efficiency. (PDLO
The lower tank has a built-in transmission oil cooler which, (QJLQH3DUWV#+HDY\(TXLSPHQW5HVWRUDWLRQ3DUWVFRP
in operation, is constantly removing heat from the :HEVLWH
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2-2
COOLING SYSTEM
Removal and Installation
Radiator and Intercooler

Removal
11
2
1 11
12
13
1 9
4 3
10
7
5
10 9
13 14
8
210314
Sequence
1. Engine cover, Gas spring 8. Radiator hose (lower)
2. Radiator cover 9. Clamp
3. Reserve tank hose 10. Oil cooler pipe
4. Fan guard 11. Intercooler mount, Grommet, Collar, Washers
5. Intercooler intake hose 12. Intercooler
6. Intercooler outlet hose 13. Radiator mount, Grommet, Collar, Washers
7. Radiator hoses (upper) 14. Radiator
Start by:
Loosen the radiator drain cock to drain coolant from the
radiator.
WARNING
Make sure the coolant temperature is cool before

opening the drain cock.
2-3
COOLING SYSTEM
Suggestions for Removal
1. Intercooler
(1) Install eyebolts in the bracket mounting bolt holes.
(2) Hitch a sling into the eyebolts and lift the intercooler
with a crane to remove.
Weight of intercooler 9 kg (20 lb)
210139
2. Radiator
(1) Hitch a sling to the radiator and support the radiator.
Weight of radiator 30 kg (66 lb)
(2) Remove the radiator mounts (at 4 places) and lift off
the radiator.
206547
Inspection
1. Intercooler
(1) Replace the mounting rubber if it lacks elasticity or if it
is hardened.
(2) If foreign substances such as insects or dust adhere to
the core fins, blow compressed air from the opposite
direction to remove them, taking care not to damage
the fins.
(3) Replace the intercooler if corrosion and rusting are
remarkable or if the fins are unrepairable.
(4) Check the intercooler hoses (upper and lower) for
expansion and damage to the hose clamp. Replace
them if any abnormality is found.
2. Radiator
(1) Blow dirt and bugs, if any, from the radiator fins with
compressed air. Be careful not to bend the fins because
this will decrease cooling efficiency.
2-4
COOLING SYSTEM
(2) Replace the radiator if the fins are damaged beyond

repair.
(3) Check the rubber cushions of the radiator mounts and
replace them if damaged or deteriorated.
(4) Check the radiator hoses, upper and lower, and replace
them if damaged or deteriorated.
Installation
To install, follow the reverse of removal sequence and do
the following steps:
1. Intercooler
Lower the intercooler, aligning the lower mount with the
mounting pin of the frame mount.
Mount
210315
2. Hose
When connecting a hose to the intercooler or radiator,
insert it fully to the base. Securely tighten the clamp and
make sure that it stops at the flair of the base and that it
does not come out.
3. Antifreeze and Coolant

(1) Mix antifreeze with distilled water to the specified
concentration and fill the mixed solution to the radiator
neck.
(2) Likewise, fill the mixed solution to the specified level
in the reserve tank. 101641
(3) Start the engine and warm it up with attention to noise.
(4) If coolant in the reserve tank decreases, fill the mixed
solution to the specified level.
Fill within
this range.
101465B
2-5
COOLING SYSTEM
Troubleshooting
Radiator corroded Repair or replace.
Hose clamps loose Retighten or replace.
Coolant leaks from Upper or lower hose deteriorated due to aging Replace.
radiator
Drain cock defective Replace.
Cracks in coolant passage in engine Check and repair.
Debris in radiator fin Clean.
Radiator fins distorted Repair or replace.

Cooling system
overheats Water pump belt loose Readjust. Check for elongation
or cracks due to aging and
replace if necessary.
Thermostat defective Repair or replace.
Hose clamps loose Retighten or replace.

Oil leaks from oil
cooler hose
Oil cooler corroded Repair or replace.
2-6
ELECTRICAL SYSTEM
Specifications .......................................................................................... 3 – 1
Location of Components ..................................................................... 3 – 2
Harness A.................................................................................................. 3 – 4
Harness B.................................................................................................. 3 – 8 3
Harness C.................................................................................................. 3 – 10
Description ............................................................................................... 3 – 12
Console Box ............................................................................................. 3 – 12
Major Components ................................................................................... 3 – 15
Lamp Bulb Specifications .......................................................................... 3 – 18
Console Box ............................................................................................. 3 – 19
Disassembly and Reassembly ............................................................ 3 – 20
Console Box ............................................................................................. 3 – 20
Components in Console Box .................................................................... 3 – 21
Combination Meter ................................................................................... 3 – 22
Sub-Meter ................................................................................................. 3 – 23
Batteries ................................................................................................... 3 – 26
Starter System .......................................................................................... 3 – 27
Gauges ..................................................................................................... 3 – 27
Lighting System ........................................................................................ 3 – 28
Alarm Unit ................................................................................................. 3 – 28
Batteries ................................................................................................... 3 – 29
Electrical System Schematic .............................................................. 3 – 31
ELECTRICAL SYSTEM
Specifications
Truck Model
DP100 DP115 DP135 DP150
Item
Model nomenclature – No. of batteries 95E41R – 2
Battery Voltage V 12
Capacity Ah 80
Transmission shift lever Electric
Console box With OK monitor
Automatic transmission controller Electronic Control Unit (ECU)
Starter switch Anti-restart type
Lamps See “Lamp Bulb Specifications.”
3-1
ELECTRICAL SYSTEM
Location of Components
Front combination light
Harnass A
Right side
Seat frame
Heater cable
To air heater
relay
Engine
Left side
To battery relay
To engine coolant
temperature gauge unit
Harness C
Rear combination light
Harness B
210316
For the components to which harnesses A, B and C are connected, see the pages which follow.
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or sharp edges. Repair a frayed harnesses with (PDLO
vinyl tape. (QJLQH3DUWV#+HDY\(TXLSPHQW5HVWRUDWLRQ3DUWVFRP
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3-2
ELECTRICAL SYSTEM
Memo
3-3
ELECTRICAL SYSTEM
Harness A (located under the seat frame) Part 1
2
13
1 3
6 21
4
1
16
12 8
5 23
10
12 9
11
17
18
19
20
15
22
14
14
See page 3-6.
14
210317
3-4
ELECTRICAL SYSTEM
1. Console box
2. Sub-meter
3. Steering column
4. Horn switch
5. Transmission shift lever
6. Turn signal switch
7. Stop lamp switch
8. RH front combination lamp
9. RH high beam
10. LH front combination lamp
11. LH high beam
12. Diode
13. Ground point
14. To harness B
15. To transmission harness
16. Junction connector
17. RH working lamp (option)
18. LH working lamp (option)
19. Cab power supply (option)
20. Front revolving light (option)
21. High beam (option)
22. Air conditioner/car heater power supply
(option)
23. Option terminal
3-5
ELECTRICAL SYSTEM
Harness A (located under the seat frame) Part 2
4 7
5 8
1 2 3
11
10
210318
3-6
ELECTRICAL SYSTEM
1. ECU
2. Relay for battery relay
3. Relay for air dryer
4. F signal relay
5. R signal relay
6. Battery fuse
7. Fuse holder A
8. Fuse holder B
9. Speedometer power supply (option)
10. Speedometer signal (option)
11. Option terminal
3-7
ELECTRICAL SYSTEM
Harness B (located at the left of engine compartment)
16
8
2
9 6
10
7
12
15
11
14 13
210319
3-8
ELECTRICAL SYSTEM
1. To harness A
2. To harness C
3. Glow plug
4. Electronic horn
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6. Fuel tank unit &RQWDFWSKRQH
7. Battery relay (PDLO(QJLQH3DUWV#+HDY\(TXLSPHQW5HVWRUDWLRQ3DUWVFRP
8. M5 terminal
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9. Battery side terminal
10. Frame side terminal
11. Battery
12. Starter relay
13. Alternator
14. Engine coolant temperature gauge unit
15. Ground point
16. Earphone switch (option)
3-9
ELECTRICAL SYSTEM
Harness C (located at the right of engine compartment)
1
2
4
5
12
7 11
13
14
10 9
210320
3-10
ELECTRICAL SYSTEM
1. To harness B
2 Low air pressure switch
3. Air dryer
4. Air pressure gauge unit
5. Engine stop control timer &DW)RUNOLIW0LWVXELVKL'LHVHO(QJLQH3DUWV
6. Engine stop solenoid &RQWDFWSKRQH
7. Oil bypass alarm switch (PDLO(QJLQH3DUWV#+HDY\(TXLSPHQW5HVWRUDWLRQ3DUWVFRP
8. Engine oil pressure switch :HEVLWHZZZ+HDY\(TXLSPHQW5HVWRUDWLRQ3DUWVFRP
9. RH rear combination lamp ZZZ'3FRP
10. LH rear combination lamp
11. Ground point
12. Air cleaner dust indicator (option)
13. Working and license plate lamp (option)
14. Back-up buzzer (option)
3-11
ELECTRICAL SYSTEM
Description
Console Box 1 5 4 3
1. Engine coolant temperature gauge
2. Travel speed select switch
3. Fuel gauge
4. Service hourmeter
5. OK monitor
6. Starter switch
7. Lighting switch 7
8. Fuse box
6
8
2
207464
OK Monitor
1 2 3 4 5 6 7 8 9
207465
Function
No. Indicator light OFF ON or flickering Remarks

1 Powershift transmission oil temp. indicator light Normal Overheating
2 Air cleaner element indicator light Normal Clogged Option
3 Brake fluid level indicator light Normal Low
4 Engine oil pressure indicator light Normal Low
5 Alternator not charging indicator light Normal Abnormal
6 Glow plug indicator light Heating completed Heating
7 Turn signal indicator light Turn signal OFF Turn signal ON
8 Engine coolant level indicator light Normal Low Option
9 Headlamp beam indicator light Low High Option
How to check indicator light bulbs
The bulbs are normal if the indicator lights 1, 2, 3 and 8 come ON when the starter switch key is turned to
(ON) position. (The indicator lights will go OFF when the engine starts.)
3-12
ELECTRICAL SYSTEM
Components
9
6
3
2
1
7
207176
1. Power relay 4. Glow plug relay 7. Starter switch

2. Power relay 5. Glow plug timer 8. Fuses
3. Turn signal relay 6. Lighting switch 9. Travel speed select switch
Spare Terminals
The spare terminal cord extends from the fuse box in the
console box. (Another spare terminal is in the chassis-side
main harness.)
Color code Lg (light green)
Removing the console box rear panel will permit you to

gain access to this spare terminal which is taped to the
harness protector.
Spare terminal 207209
3-13
ELECTRICAL SYSTEM
Side Instrument Panels
7 8 5
1
2 4 6
3
210321
1. Working lamp switches (option) 5. Brake air pressure gauge

2. Working lamp indicators (option) 6. Battery switch
3. Windshield wiper switches (option) 7. Powershift transmission oil temperature gauge
4. Brake lining wear indicator 8. Speedometer (option)
3-14
ELECTRICAL SYSTEM
Major Components
Electronic Control Unit (ECU)
Failure indicator lights
LED (green)
LED (red)
Rear (mounting) face

205509
The Electronic Control Unit (ECU) has a built-in 1- systems so that failure of power, control circuit, or
chip microcomputer. This computer processes signals other components will not endanger the operator.
from the travel speed sensor for actuating the 2-speed
automatic transmission. NOTE
The ECU has “self-diagnostic” failure indicator lights The failure indicator lights are located on the rear
which come on when any problem occurs in the (mounting) face of the ECU. This makes it
electrical system, thereby allowing the operator to necessary to remove the ECU from the truck to
locate the problem. It has the following fail-safe observe these lights.
Fail-safe Systems
Failure Function
Solenoid output signal circuit Turns OFF the power line and causes an indicator light to
open come on when the solenoid output signal circuit is open.
Travel speed sensor circuit Allows the truck to run at the present travel speed but
open causes an indicator light to come on.
Failure Indicator Light Flashing Patterns
Failure Flashing pattern
Travel speed sensor circuit

open
2-speed automatic transmission

control circuit open 204697
NOTE: The failure indicator lights come ON and go OFF as shown below:
ON
OFF 204668
3-15
ELECTRICAL SYSTEM
Starter Switch (Anti-restart Type) running) to help prevent damage to the starter pinion or
flywheel ring gear. The (ON) position of the switch is
This switch has a built-in mechanical lockout. This
for energizing the glow plugs.
lockout restrains the key from turning to (START)
position from (ON) position (as when the engine is
(OFF)
(ON)
B M
(START)
203561A
Connection Chart
Terminal B M S
Component Fuse box, batteries, Fuse box, engine stop Transmission shift
Key alternator, glow plugs control timer, glow lever, glow plug timer
position plug timer and relay
(OFF) {
(ON) { {
(START) { { {
Lighting Switch
OFF 1st 2nd Knob position

8 8 Stroke
(0.3) (0.3) [Unit: mm (in.)]
206481
Connection Chart
Terminal B T H P
Tail lamps, license
Component Batteries plate lamp (option), Headlamps Front combination
Knob (fuses) instrument panel lamps
position lamp
(OFF)
1st position { { {
2nd position { { { {
3-16
ELECTRICAL SYSTEM
Fuse Box
Symbol Capacity Circuit
A 10 A Transmission shift lever
B 10 A Instrument panel lamp,

A
turn signals
B
C C 10 A Spare terminal
D
E D 15 A Lamps
F
E 10 A Horn
G
H F 10 A Spare
J
G 10 A Transmission controller,
vacuum buzzer, stop lamps
H 10 A Back-up lamps
J 15 A Spare
101441F
Optional fuses
Fuse Capacity Circuit Fuse

Battery fuse 15 A holder B
Fuse
15 A Working lamps holder A
Fuse holder A 10 A Revolving lamp
10 A Air dryer relay
15 A Air conditioner Battery fuse
5A Car heater
Fuse holder B
20 A Windshield wiper
210322
10 A Cab
3-17
ELECTRICAL SYSTEM
Lamp Bulb Specifications

Item Bulb
Quantity Color of
of bulbs lens For 24V Remarks
Type of lamp system Schematic drawing
Headlamps 2 Frosted 60W 60/60W

(option)
Turn signal lamps 2 Amber 25W

Standard
Combination (mounted on
lamps (front) overhead guard)
Clearance lamps 2 Frosted 12W
Stop and tail lamps 2 Red 10W/25W
Combination Turn signal lamps 2 Amber 25W

lamps (rear)
Back-up lamps 2 Frosted 25W
Working lamps (front) 2 Frosted 60W/60W Option
Working lamps (rear) 2 Frosted 60W/60W Option
License plate lamp 1 Frosted 12W Option
Instrument panel lamps 2 Frosted 3W

For combination
meter
OK monitor indicator lamps 5 Frosted 3W
207466
3-18
ELECTRICAL SYSTEM
Console Box
Removal
6 5
5
4
1
207539A
Start by: 5. Disconnect the electrical wires at connectors, and

(a) Turn off the starter switch, and disconnect the remove transmission shift lever and turn signal
negative (grounding) cable from the battery. lever 5.
(b) Remove nut and washer on steering wheel, and 6. Remove bolts on console box assembly 6, and
remove the steering wheel. remove the console box assembly.
Suggestions for Removal Installation
1. Disconnect the electrical wires at connectors 1. To install, follow the reverse of removal sequence.
2. Remove screws on cover 2 using a flat-tip
screwdriver, and remove the cover.
3. Remove screws on cover (U-RE) 3, and remove the
cover.
4. Remove screws on cover (U-FR) 4, and remove the
cover.
3-19
ELECTRICAL SYSTEM
Disassembly and Reassembly
Console Box
Disassembly
3 207175
Suggestions for Disassembly Reassembly

1. Remove two screws 1 securing the cover. (Use a To reassemble the console box, follow the reverse of
flat-tip screwdriver.) disassembly sequence.
2. Remove six screws 2 and separate the front and
rear panels.
3. Remove four screws 3 securing the instrument
panel.
NOTE
To replace the instrument panel bulbs, remove screws
2 and 3.
3-20
ELECTRICAL SYSTEM
Components in Console Box

Disassembly
10
7
4
3
2
8
9
1
207558
Sequence
1. Harness 6. Glow plug timer
2. Power relay 7. Lighting switch
3. Power relay 8. Starter switch
4. Turn signal relay 9. Fuses
5. Glow plug relay 10. Travel speed select switch
Reassembly
To reassemble the console box, follow the reverse of
disassembly sequence.
3-21
ELECTRICAL SYSTEM
Combination Meter
Disassembly
2
3
8
9
206480
Sequence
1. Instrument panel 6. Meter case
2. Dial 7. Printed circuit plate
3. Engine coolant temperature gauge 8. Bulb
4. Service hourmeter 9. Socket
5. Fuel gauge
CAUTION Bulb replacement
Be careful not to damage the printed circuit For bulb replacement, remove the socket from the
plate when disassembling the combination printed circuit plate by turning it counterclockwise.
meter. For configuration of the indicator lights, refer to “OK
Monitor.”
Reassembly
To reassemble the combination meter, follow the
reverse of disassembly sequence.
3-22
ELECTRICAL SYSTEM
Sub-Meter
Disassembly
7
4
3 9
10
11 2
12
210323
Sequence
1. Disconnect the harness at connectors 1.
2. Remove three bolts 2 that hold the side instrument
panel, and remove the instrument panel from the seat
frame.
3. Remove four screws 3 and separate panel 4 from cover
5.
4. Remove the following components:
6. Brake air pressure gauge
7. Battery switch
8. Brake lining wear indicator
9. Powershift transmission temperature gauge
10. Low air pressure buzzer
11. Power relay
12. Brake lining wear buzzer
3-23
ELECTRICAL SYSTEM
Reassembly
Follow the reverse of disassembly sequence.
NOTE
Connect the air pressure gauge harness to the correct
terminal.
(Green/red)
Air pressure
(Black)
gauge terminal
(Green)
(Blue)
To brake lining
wear indicator
To battery switch
To low air
To power relay pressure buzzer
To brake lining
wear buzzer
210324
3-24
ELECTRICAL SYSTEM
Precautions for installing other parts

1. Engine stop solenoid installation
(1) Before installing the solenoid, push the plunger all the 0 0
L=26-1.5 mm (1.02 -0.063 in.)
way into it to make sure that the plunger stroke
coincides with the standard value.
0 0
Stroke L 26 – 1.6 mm (1.02 – 0.063 in.)
Note: Record the measured value of plunger stroke.

210325
(2) After installing the solenoid, connect a lamp (or tester)

and power supply to it. V
Testa
(3) Energize the solenoid to see if the lamp is lit. (Check
voltage when the tester is used.) Lamp
NOTE
When testing the solenoid -
(1) Do not energize any longer than 5 seconds. DC24V
(2) Do not energize any more than 5 times.
AUX 210326
3-25
ELECTRICAL SYSTEM
Batteries
1. Electrolyte specific gravity (S.G.) reading and battery condition
Electrolyte S.G. reading

Battery condition Adjustment
at 20°C (68°F)
1.280 to 1.265 Battery is fully or well Check each cell for S.G.
charged.
1.260 to 1.225 Battery is half charged. Recharge the battery. Make sure there is neither faulty
component, short-circuited cord nor corroded connection in
the system.
1.220 or lower Battery is discharged. Recharge the battery. If difference in S.G. among the cell is
large, adjust the S.G. during recharging.
When S.G. difference A cell with a low S.G. Recharge until voltage and S.G. stabilize and have remained
among cells is more is in shorted condition. constant for at least 2 hours.
than 0.040 Some electrolyte has During recharging, adjust the S.G. to anywhere between
been lost. Too much 1.280 and 1.265.
electrolyte, or water in If difference in S.G. among the cells is more than 0.040 and
electrolyte, too. a low S.G. is found in certain cells only, replace the battery.
2. Relationship between electrolyte specific (3) During charging, adjust the charging current to
gravity and charging rate prevent the battery electrolyte temperature from
rising beyond 45°C (113°F).
To check the battery for charging, take hydrometer
readings on its electrolyte: the battery may be deemed (4) When connecting the cables to the battery, begin
to be fully charged if the readings are between 1.280 with the cable for the positive (+) terminal. When
and 1.265 at normal temperature. The tendency of the disconnecting them from the battery, begin with the
charging system can be told from the way the cable for the negative (-) terminal.
electrolyte level goes down to expose cell plates. If
refilling (with distilled water) is necessary every month CAUTION
or so, the system is tending to over-charge the battery.
If refilling is not required for over 3 months, it is likely Be sure to turn off the starter switch and
that the system is inadequately charging. lighting switch before disconnecting or
connecting the battery cables to prevent the
3. Precautions for battery charging
IC regulator from suffering damage.
(1) In slow-charging a dead battery, the charging
current should be about 1/10 the capacity of the
battery to be charged.
(2) In quick-charging the battery, the battery capacity
in ampere should not be exceeded.
3-26
ELECTRICAL SYSTEM
Troubleshooting
Starter System
Dead or weak battery Recharge or replace.
Starter circuit defective Repair or replace.
Starter will not crank
engine Poor continuity in starter switch Replace.
Starter or starter relay defective Replace.
Transmission shift lever not in neutral Move the lever to
Starter switch position neutral position.
Turning off starter Open or short circuit Repair or replace.

switch will not stop Engine stop solenoid defective Replace or readjust.
engine Control timer defective Replace.
Gauges
Open or short circuit Repair or replace.
Will not indicate at all Gauge internally defective Replace.
Gauge unit defective Replace.
Temperature Will not indicate Wrong type of gauge or gauge unit Replace.
gauges accurately Loose terminal connection Repair.
Will indicate higher than Circuit between gauge and gauge unit Repair.
grounded
actual temperature
Gauge internally defective Replace.

Will not indicate at all Gauge internally defective Replace.
Will not indicate Gauge or gauge unit not of the type Replace.
called for
accurately
Loose terminal connection Repair.
Fuel gauge Circuit between gauge and gauge unit Repair.

Will indicate “Full” grounded
regardless of fuel level
in tank Gauge internally defective Replace.
Circuit between gauge and gauge unit Repair.

Will indicate “Empty” open or short
regardless of fuel level
in tank Gauge unit defective Replace.
Gauge internally defective Replace.
Will not indicate Open or short circuit Repair or replace.

(even if air pressure is Gauge defective Replace.
acting on gauge unit) Gauge unit defective Replace.
Air pressure
gauge
Indication will not Circuit between gauge and gauge unit Repair.
return to 0 (when air grounded
pressure is 0 kPa Gauge defective Replace.
(0 kgf/cm2) [0 psi]) Gauge unit defective Replace.
3-27
ELECTRICAL SYSTEM
Lighting System
Dead or weak battery Recharge or replace.
Fuses blown out Check and replace.
Will not light Open or short circuit Repair or replace.
Poor grounding Clean ground spot and re-make
connection.
Bulbs burnt out Replace.
Lamps –
general
Dead or weak battery Check and recharge.
Burned contact points in switches Repair or replace.
Loose terminals Repair.
Will light dimly
Dirty lenses Clean.
Waterdrops inside lenses Dry and replace packings.
Bulbs expired in service life Replace.
Light switch defective Replace.

Headlamps Will not light

Will not flash
Turn signal relay defective Replace.

Will not go out
Turn signal switch defective Replace.
Turn signal
lamps Wrong wattage of bulbs Replace.
Will flash too slow Weak battery Recharge or replace.
Turn signal relay detective Replace.
Wrong wattage of bulbs Replace.

Will flash too fast
Back-up lamps Back-up lamp switch defective Correct if improperly installed:

replace if internally defective.
will not lights
Other lamps
License plate
Lighting switch defective Replace.
lamp will not
lights Bulb burnt out Replace.
Alarm Unit
Fuse blown out Check and replace.
Will not give blast
of sound Horn switch defective Repair or replace.
Horn defective Replace.
Horn Horn button defective Replace.
Will give abnorm- Horn switch defective Replace.

al blast of sound Horn defective Replace.
3-28
ELECTRICAL SYSTEM
Batteries
Alternator belt slipping Readjust.
* Alternator
Stator coil grounded or open-circuited Repair or replace.
Rotor coil open Replace.
Brushes poorly seating on slip rings Replace brushes if worn.
Clean holder and polish
slip rings.
Diode ruptured Replace.
* Regulator
Regulated voltage setting too low Readjust.
Tends to run down rapidly
* Batteries
Not enough electrolyte or wrong proportion of Refill and check
acid to water specific gravity: 1.280
Battery cell plates deteriorated Replace.
(possibly internal short-circuit)
Terminal connections loose Clean and retighten.
* Wiring
Open or loose connection between starter switch Repair.
and regulator IC terminal
Fuse blown, or loosely set in holder Replace and repair.
Open or loose connection between F terminals of Repair.
regulator and alternator
* Wiring
Circuit between regulator IC and F terminals Repair.
shorted or miswired
Poor grounding of regulator F terminal Repair.
Tends to get overcharged
* Regulator
Pressure coil open-circuited Replace.
Regulated voltage too high Readjust.
3-29
ELECTRICAL SYSTEM
Memo
3-30
ELECTRICAL SYSTEM
Electrical System Schematic
3-31
CONSOLE BOX LITING SWITCH STARTING SWITCH CORD,AIR DRYER ENGINE STOP DUST INDICATOR
TURN SIGNAL CONNECTION CHART CONNECTION CHART CONTROL TIMER SWITCH (OP.)
RELAY LIGHTING TERMINAL NO. CORD OFF 1 2 B G1 G2 M S (INTAKE SYSTEM)
B AV1.25B TORQUE-CONVERTER AIR PRESSURE BRAKE LINING WEAR BRAKE LINING WEAR LOW AIR PRESSURE
SWITCH OFF COOLANT LEVEL
T OIL THERMO GAGE GAGE POWER RERAY BATTERY SWITCH WARNING LAMP WARNING BUZZER BUZZER
P ON SUBMETER ASSY AIR DRAYER SENSOR (OP.)
B P H T H AV1.25B START
WORNING SWITCH REAR WORKING FRONT WORKING (BRAKE LINE) HARNESS, INDICATOR DUST (COOLING SYSTEM)
(OP.) SWITCH (OP.) SWITCH (OP.)
3Y
RW 8B E E 27 28
3BY T B T B
GB
RW
GB
HOUR METER
WATER TEMP FUEL 10A 66 228 HARNESS, INDICATOR RADIATOR
+
10A 229
10A
23
LR
B
Y
GR
GW
GW
YB
BW
LG
LG
R
YR
BR
B
L
2B
230 352
B
L
L
L
15A
10A 355 356 24 22 24 119 202 54 36 95 38 68 67
RG 10A 357 23 106 201 106 37 39 40 66
110 110 AIR HORN SWITCH (OP.)
10A
2Y
(BRAKE LINE)
LW
BACK LAMP 10A 201
B
0.75fG
0.75fB
15A 202
2R
POWER RELAY
2L
352
5BW
37
R
LOW AIR PRESSURE AIR PRESSURE
8B
WL 230
LR
B
SOL
BAT
SWITCH GAGE UNIT
ON
228 230
1 1 2 68
1 2 229
BY
2R
2L
B
2 5 54 67
2RW
2BW
WR
5 4 3
SPEED SELECT
2BY
YG
YR
GLOW 95
5BW
8B
336 313 334 320 332 312 3

TIMER
6 4 SWITCH 38 69
R
2 39 70
2 SPEED 3 SPEED 2 5 66 85 71 76
B
36 LR
G 228
Y 66
22 24 54 38 66 R 23
357 23 119 95 39 36 85 230
2R
69
BW
GR
YR
BR
BY
LG
YB
2B
G
R
L
GROW RELAY 70
YB
46 REAR COMBINATION LAMP (24V)
2B
RL 22 22
GY 82 GY
GL 18 18 B TURN SIGNAL LAMP (25W)
22 24 54 38 66 HARNESS,SUBMETER G 20 101 101 G
GW
GW
WR
RW
WR
6 5 18 19
BW
WB
65 23 119 95 39 36 92 92
GR
LW
WL
TAIL & STOP LAMP (10/25W)

YG
GB
YR
RY
RB
W
YB
BY
GL
GL
Lg
G
LR
RL
YL
BL
R
B
L
GR GR
3 16 17 51 51 51
GW
BW
GR
51 50
YR
BR
GL
GL
2B
GL
Y
L
8 7 23 26 75 75 BACKUP LAMP (12W)

3 6 7 8 12 13 14 83 90 5
13 12
9 10 11 15 16 17 18 19 20 21 22 23 61 62 72 36 26 50 51 WORK LAMP SWITCH 15B 340
34 43 46 72 31 121 230 228 15 50 8 52 79 57 55 70 75 218 217 219 36 3 74 200 72 36 22
83 14 21 20 (OP.)(24V) 341
RW
LW
WR
BW
WB
230
BW
GR
GR
GR
YW
YW
RB
GR
BY
GL
BR
YG
GL
YB
62 61
LR
F-N-R LEVER
R
R
B
2B
82
R
B
90 22 15 71
34 43 72 230 15 8 79 55 75 218 219 3 200 182 53
Br GL 46 31 121 (WHITE) 228 50 52 57 70 (GREEN) 217 36 74 25 HARNESS,C 20 52
46
GR
74 22 99 91 77
RL
R 47
B
F
LgR GY
73 24 BACK BUZZER (OP.)(24V)
GB
GR
BW BW
GL
G
B
4 119
YB
YB
N
BR BR
B1
L L 3 38 2L
B2 200 23
66
54 GROW PLUG
HORN SWITCH GR SHIFT LEVER CHART 95
5BW 182 53 HARNESS, I
121 36 5 82
ENGINE STOP
GR
GR
TERMINAL B1 B2 F N R 39 CODE SOLENOIDO
GR
LEVER
RL
SOLENOID
B
GB
21 121 221 OIL BYPASS OIL PRESSURE
FORWARD F
NEUTRAL N ALARM SWITCH
224 223 REVERSE R (ENGINE GROUP) (ENGINE GROUP)
TURN SIGNAL LEVER
GR
GY
Y GY GY
R
B GL 17 GL 17 222 34 43 72 230 15 8 79 55 75 2B WORKING LAMP (OP.)(24V)
L
G GR 19 19 73 31 228 4 50 52 57 65 65
15 CORD
RL
83 B
341
TURN SIGNAL LAMP LEVER CHART
B
TERMIMAL F L R 336 15 21 339 M6 STEERING COLUMN
LEVER 313 121
LEFT L
RELAY FOR AIR DRYER F SIGNAL R SIGNAL 28
NEUTRAL N 27
RW
RIGHT BATTERY RELAY FUSE HOLDER RELAY RELAY RELAY 228

R
GB
121 218 219 126 70 22 66 2 5 95 66

LR
15 39 217 114 46 23 25 54 23
85
G
21 15A
69
G
70 GR
R
53
2R
RW 230 182
13 B
BY
LW
GW
WORKING LAMP(OP.)(24V)
2BY
CORD
RY 46 92
GW
LW
GY
BR
GL
RL
GR
BR
338
B
22
B
B
L
51
YB
82 75
G
203 226 94 54 314 127 112 111 116 117 18

2B
GR
95 225 126 85 110 113 114 115 5

RL
20
GL
FRONT COMBINATION LAMP 230

5BW
GY
95
GL
LW
GL
GR
226 WORKING LAMP (OP.)(24V)
B
225
99 94
54 RL
314 82 B
HEAD LAMP(24V) 126
127
R
85 X Y Z W
24V-60W 110
112 HARNESS,B
111 SEAT FRAME SIDE FRAME SIDE (R.H.)
114
116 60B
115 M10 M10
338 18 4 43 51 57 225 94 230 46 23 85 301 5
20 21 34 31 39 91 75 228 70 22 66 82 2 CORD
R R
FUSE HOLDER A FUSE HOLDER
11 8
8BW
5BW
RW
BW
YW
YW
GR
LW
2BY
GY
GB
YG
BR
GL
GL
GL
YB
BY
LR
RL
2BR
2B
8B
G
G
G
R
BR
314 2BY
a
2BY 306 CIRCUIT FUSE CAPACITY
313 313 2BW
b
2BW
305
312 312 c 304 a AIR DRYER(STD.)
18 301
8BW 10A 28
20 WL b WORNING LAMP 27
17 317 317 2LW
2L
d
2WB 309 228
316 316 2WR 308
c FRONT & REAR
12 49 e
2WR 15A 66
315 f 307
GR
WORKING LAMP 23
GL
R
HARNESS,HEAD LAMP 85
FUSE HOLDER B FRONT WORKING d ROOM LAMP(OP.) 10A 69
70
338 13 19 316 YR LAMP (OP.) e WIPER 15A 46
13 11 17 317 336 332 332 22
RY
12 49 POWER SOURSE FOR 82

17 RY 15A 18
14 R 335 335 AIR CONDITIONER 20
11 INPUT FOR WORKING LAMP (OP.) f 91 REAR COMBINATION LAMP (24V)
RW RW
GR
50 RW 50 YG POWER SOURSE FOR 51
13 334 334 5A 75
17 GY
REAR WORKING LAMP (OP.) CAR HEATER
GL 5
13
19 GL 230 77 GB BACKUP LAMP (12W)
19 220 BACK SIGNAL (OP.) 52 GR
11 50 91 G TAIL & STOP LAMP (10/25W)
GL
RB POWER SOURCE FOR 20
79 99 B TURN SIGNAL LAMP (25W)
RL REAR WORKING LAMP (OP.) 34
82 YR
130
HARNESS,HEAD LAMP 43
GR
GL
BY
POWER SOURCE FOR
R
323 B HARNESS, 1 2B B
324 SPEED METER (OP.) 98 98 6
11 50 ECU FUSE 4
19 327
B
328
W
SPEED METER SIGNAL (OP.)
327
327
55 210
91 211 (3) Termimal of marks show arrangemant of electrical apparatus side.
335 336 116
112
RW
WR
YR
GL 25 219 (2) Phenomenon line show circuits for optional parts.
GY 222 217
1
25 RG
215
73
215
218
94 NOTES (1) Unless otherwise specified. wire size shall be 1.25mm2.
BR
216 216
YR
HEAD LAMP(24V) RY
2BY
222 73 B 212 212

214 214 B
R RB
24V-60W 213 213
GY
GL
B 2 130
8W
209 CABLE,STARTER 44 43
RB
RY
335 GY 215 HARNESS,T/M

208 216
2B
8B
FRONT COMBINATION LAMP BW

207 CORD,HEATER 212 340 RY
60B 60B 6
98
YW
TERMINAL MUST BE TIGHTEN M

YR
GR RB B 34
91 BR
206 213 341
RG
BR
GL
55 WITH BOLT FOR VALVE COVER. 57 M
0.85R
CABLE,BATTERY B S
B
21
FLW
B 43 130 CAT
98 215 216 212 ECU FUSE S
222 73 214 31 32 L B E L R
Schematic No. Used for Truck Model Serial No.
TORQUE-CONVERTER 2WR LR
CABLE,BATTERY
0.85R
213 315 SW P
FLW
0.5R
L
FLW
60B
GY
OIL THERMO UNIT

GL
WORKING LAMP(OP.)(24V)
RW
GB
DP 100 3DP10011-up
YW
YG
90
B
213 M10 ENGINE

(TRANSMISSION GROUP) SR 214 39 60B CABLE,BATTERY
0.5
RW 4DP10011-up
R
G
SF DP 115
335 212
60B
RY
RB
CABLE,BATTERY
RY
341 340 215 217 112 211 327 ES099 - 80120 99799 - 80120
GL
IC REGULATOR
B
CORD 18 4 43 52 57 225 94 230 46 23 85 301 5 STARTER(24V-5kW)

B
317 SH S1 S2 HARNESS, A 20 21 34 31 39 91 75 228 70 22 66 82 2 214 216 218 219 116 210 DP 135 5DP10011-up
BW
60B
2LW FORWARD-REVERSE HEATER (OP.) 44 (ENGINE GROUP)

8BW
5BW
WR
RW
BW
WB
60B
RW
BW
YW
YW
RG
LW
GR
GR
LW
2BY
GY
GB
YG
RB
RY
BR
317
GL
GL
GL
YB
BY
RL
LR
RL
2B
8B
G
B
R
Y
POWER SOURCE FOR CAB 2L

316 SOLENOID M 225 4 DP 150 6DP10011-up
2LW
322 213 214 212 216 215 218 217 219 112 116 211 210 327 HORN (24V)
4 15 3 14 13 7 6 8 10 11 2 1 16 BR
STOP LAMP SWITCH (TRANSMISSION GROUP)
TRAVEL SPEED SOLENOID TRAVEL SPEED SOLENOID
CORD (2 SPEED) (3 SPEED) M5 M10
WORNING LAMP(OP.) FUEL TANK UNIT
WR
TRAVEL SPEED SENSOR (TRANSMISSION GROUP) (TRANSMISSION GROUP) X Y Z W TRANSMISSION
BRAKE LINING WEAR (FUEL SYSTEM) BATTERY RELAY INSIDE OF FRAME (LH.) ENGINE THERMO UNIT
336 (TRANSMISSION GROUP) HEATER SWITCH (OP.) CONTROLLER ALTERNATOR(24V-40A) Pub. No. 99799 - 80120
DETECTING SWITCH
(ENGINE GROUP) 3 - 31
(AIRMASTER)
POWER TRAIN
Specifications .......................................................................................... 4 – 1
Description ............................................................................................... 4 – 2
2-speed Transmission ............................................................................... 4 – 2
3-speed Transmission ............................................................................... 4 – 3
Gear Ratios (2-speed Transmission) ........................................................ 4 – 4
Gear Ratios (3-speed Transmission) ........................................................ 4 – 5 4
Engine and Transmission Unit Removal .................................................... 4 – 6
Installation ................................................................................................ 4 – 16
Refill Capacities (Approximate) ................................................................. 4 – 19
Service Data ............................................................................................ 4 – 20
POWER TRAIN
Specifications
Truck Model
DP100 DP115 DP135 DP150
Item
Type 3-element, 1-stage, 2-phase
Torque
Model MI 16
converter
Stall torque ratio 2.88
Direction control Electric, column shift

Control
Speed control Automatic
2-speed transmission
Transmission Forward 1st: 1.556
2nd: 0.685
Gear ratio 3-speed transmission
1st: 2.402
Reverse 2nd: 1.010
3rd: 0.532
Gear type Hypoid

Reduction
bevel gear
Gear ratio 5.571
Type Planetary gear

Final drive
Gear ratio 4.167
Housing type Banjo
Differential bevel gear, type –

Straight bevel – 2
Differential No. of gears
Differential bevel pinion, type –

Straight bevel – 4
No. of pinions
Type Full-floating, tubular

Front axle
Mounting method Fixed
4-1
POWER TRAIN
Description
2-speed Transmission
10
9
15
4 3 2 1
16
13 14 12 11 7 8
205488A
1. Diesel engine 9. Pump drive gear

2. Flywheel 10. Hydraulic pump
3. Torque converter 11. Universal joint
4. Transmission 12. Parking brake
5. Input shaft 13. Front axle
6. Countershaft 14. Reduction and differential
7. Output shaft 15. Final drive
8. Travel speed sensor gear 16. Wheel brake
Power from the diesel engine is sent through the (4) Reduction and differential 14
following components to the front wheels: Receives power from the universal joint and splits
(1) Torque converter 3 it through two rear axles to the final drive. The
Is a hydrokinetic device serving as a variable differential allows the front wheels to turn
torque amplifier. different amounts when the truck goes around a
curve.
(2) Transmission 4
(5) Final drive 15
Has two forward and two reverse speeds. It has
four hydraulic multi-disc clutches. Has a planetary gear and drives the front wheels.
(3) Universal joint (propeller shaft) 11

Transmits power from the transmission to the
reduction and differential.
4-2
POWER TRAIN
3-speed Transmission
11
12
3 2 1
17 4 5
8
18
15 16 14 13 9 10
205670A
1. Diesel engine 10. Travel speed sensor gear

2. Flywheel 11. Pump drive gear
3. Torque converter 12. Hydraulic pump
4. Transmission 13. Universal joint
5. Input shaft 14. Parking brake
6. FORWARD clutch shaft 15. Front axle
7. REVERSE clutch shaft 16. Reduction and differential
8. 1ST-SPEED/3RD-SPEED clutch shaft 17. Final drive
9. Output shaft 18. Wheel brake
Power from the diesel engine is sent through the (3) Universal joint (propeller shaft) 13
following components to the front wheels: Transmits power from the transmission to the
(1) Torque converter 3 reduction and differential.
Is a hydrokinetic device serving as a variable (4) Reduction and differential 16
torque amplifier. It is one of two related devices, Receives power from the universal joint and splits
hydraulic coupling and converter. it through two rear axles to the final drive. The
(2) Transmission 4 differential allows the front wheels to turn
Has three forward and three reverse speeds. It has different amounts when the truck goes around a
five hydraulic multi-disc clutches. curve.
(5) Final drive 17
Has a planetary gear and drives the front wheels.
4-3
POWER TRAIN
Gear Ratios (2-speed Transmission)
Figures in ( ) indicate number of gear teeth.
(39)
(60)
(18) (57)
(54)
(52)
(36)
(54)
(36)
(42)
(7) (52)
(39)
(37)
(56)
210327
Speed Transmission Reduction bevel gear Final drive Total gear ratio
52 56
1st 1.556 ( 52 x 36 ) 36.111
Forward
52 37
2nd 0.685 ( 52 x 54 ) 5.571 4.167 15.906
56 36 57
1st 1.556 ( 36 ) ( ) ( +1) 36.111
7 18
Reverse
37
2nd 0.685 ( 54 ) 15.906
60 39
PTO gear ratio: 0.929 ( 42 x 60 )
PTO: For driving hydraulic pump (standard)
Above + For driving air conditioner compressor
(option)
4-4
POWER TRAIN
Gear Ratios (3-speed Transmission)

(39)
(60)
(58)
(18) (57) (54) (35)
(34)
(58)
(42)
(60) (35)
(24)
(7) (58)
(39)
(31)
(53) (56)
210328
Speed Transmission Reduction bevel gear Final drive Total gear ratio
35 58 58 56
1st 2.402 ( 34 x 58 x 58 x 24 ) 55.760
35 53
Forward 2nd 1.010 ( 34 x 54 ) 23.455
35 58 58 31
3rd 0.532 ( 34 x 58 x 58 x 60 ) 5.571 4.167 12.347
35 58 56 39 57
1st 2.402 ( 34 x 58 x 24 ) ( ) ( + 1) 55.760
7 18
35 58 53
Reverse 2nd 1.010 ( 34 x 58 x 54 ) 23.455
35 58 31
3rd 0.532 ( 34 x 58 x 60 ) 12.347
60 39
PTO gear ratio: 0.929 ( 42 x 60 )
PTO: For driving hydraulic pump (standard)
Above + For driving air conditioner compressor
(option)
4-5
POWER TRAIN
Engine and Transmission Unit Removal

Start by:
(a) Disconnect the negative (ground) battery cable.
(b) Drain the coolant [approximately 23 liters (6 U.S. gal.)]
from the radiator and from the engine.
(c) Open the air tank drain plug to release air from the
tank.
1. Overhead guard or cab
A. Overhead guard
1. Disconnect the harnesses of the head lamps and
combination lamps from the connectors.
2. Remove the four bolts (M16) that hold the overhead
guard.
3. Hitch a sling to the overhead guard and remove the
guard.
NOTE 210329
Hitch slings with balancing at the center-of-gravity

position duly in mind.
B. Cab (when so equipped)

1. Disconnect the harness of the head lamps, combination Seat frame
lamps, warning lamps, windshield wiper and washer
and pump from the connectors.
2. Remove the covers at the four lower corners of the cab.
Remove the four bolts (M16) that hold the cab.
3. Hitch a sling to the cab and remove the cab.
NOTE Frame
(1) For head guard-equipped or cab-equipped truck, 210330
the subsequent steps of work are the same when

removal has been done this far.
(2) If the truck is equipped with a cab and a car heater,
disconnect the engine coolant hose and the heater
harness.
4-6
POWER TRAIN
2. Removal of Covers and Plates
3
1
11
6
2 12
4
8
5
7
10
Seat frame
9
210331
Sequence
1. Gas spring (LH, RH) 7. Floor plate A (LH)
2. Engine cover 8. Cover (brake pedal)
3. Radiator cover 9. Cover (front)
4. Front cover B, Air cleaner 10. Toe board
5. Front cover A 11. Floor plate D
6. Floor plate A (RH) 12. Floor plate C

(1) Leave the seat bracket attached to the seat frame.
(2) Leave the accelerator pedal, brake pedal, inching pedal,
brake control valve, etc. attached to the seat frame.
(3) Disconnect the air cleaner hose at the engine side, then
remove the hose and air cleaner attached to the front
cover B.
4-7
POWER TRAIN
3. Removal of Seat Frame and Associated Parts
4
7
3
10
To transmission
2
To harness B 9
210332
Sequence
1. Engine control cable 6. Brake reserve tank
2. Seat frame harness A 7. Hydraulic control cable
3. Inching pedal cable 8. Steering control valve
4. Brake control valve hose 9. Body grounding cable
5. Parking brake lever 10. Seat frame
4-8
POWER TRAIN
(1) Engine control cable

Disconnect the cable at the engine side. Coil it up at
the front side of the seat frame.
(2) Inching pedal cable

Disconnect the cable from the clevis pin of the inching
lever under the seat frame.
(3) Parking brake lever

Remove the lever mounting bolt with the lever in the
brake applied position.
210333
(4) Hydraulic control cable

Remove the cable from the clevis pin at the foot of the
control lever.
(5) Brake reserve tank

Remove the mounting bolt and drain oil from the tank.
(6) Seat frame harness A

Disconnect the harness at the following connectors.
(a) Connectors (3 places) to harness B
(b) Connector of transmission harness 210334
(7) Body grounding cable

Disconnect the cable at the seat frame side.
4-9
POWER TRAIN
(8) Brake control valve hose

Disconnect the two hoses from the valve at
connectors.
210335
(9) Steering control valve

Disconnect the five hoses from the valve at
connectors.
210336
Seat frame
(10)Seat frame
Bolt
(a) Remove the mounting bolts from the seat frame.
This must be done by at least two persons. Cushions
(b) Hitch slings to the bolt holes located at four

corners of the
NOTE Frame
Hitch the slings with balancing at the center-of-gravity
position duly in mind. Nut
210337
seat frame and hoist the seat frame to move out of

place.
4-10
POWER TRAIN
4. Electrical Parts Removal
(1) Harness B disconnecting points (see page 3-8.)

1. Glow plug terminal
2. Joint with harness C
3. Lining wear detection switch connector
4. Alternator connector
5. Engine coolant temperature gauge unit terminal
Note: Disconnect the harness B from the right-hand side

of the truck. Then, unclip the harness at two mid-
points and put it aside to the left-hand side of the
truck.
(2) Harness C disconnecting points (see page 3-10.)

1. Engine stop solenoid connector
2. Oil bypass alarm switch terminal
3. Engine oil pressure switch terminal
(3) Starter cable

Disconnect the cable at the starter relay side connector.
(4) Engine grounding cable

Remove the bolt securing the cable to the frame.
210338
4-11
POWER TRAIN
5. Pipes and Hoses Removal
8
6
7 11
3 9
3
5
10
9
10
12
2
4
1 12
1
1
1
210339
Sequence
1. Fuel hose 7. Hydraulic suction hose
2 Cross member 8. Fan guard
3 Air compressor hose 9. Intercooler hose
4 Exhaust pipe 10. Radiator hose
5. Air master 11. Intercooler
6. Hydraulic high pressure hose 12. Transmission cooler hose
&RQWDFWSKRQH
(PDLO(QJLQH3DUWV#+HDY\(TXLSPHQW5HVWRUDWLRQ3DUWVFRP 4-12
ZZZ'3FRP
POWER TRAIN
(1) Fuel hose

Two pipes remain attached to the underside of the
cross member. Disconnect the hoses to the engine and
truck body at pipe connectors.
(2) Air compressor hoses

Leave the two hoses connected at the suction side.
(3) Air master

(a) Disconnect the pipe between the air master and
wheel brake.
(b) With the brake reserve tank and pipe behind left
connected, remove the air master together with
bracket.
(4) Hydraulic high pressure hose

Disconnect the hose at the oil pump and priority valve
sides.
(5) Hydraulic suction hose

Disconnect the hose from the suction pipe on the
underside of the oil pump and the suction hose
connector. (Place a dip pan to receive the oil that flows
out.)
(6) Intercooler
(a) Unclip the harness C (at three points) ahead of the
intercooler and slacken it forward to prevent
breaking.
(b) Remove the bolts securing the intercooler and lift
the intercooler off the frame.
Intercooler weight Approx. 9 kg (19.8 lb)
210340
(7) Transmission cooler hose

Disconnect the hose at the transmission side and leave
it lying along the frame.
4-13
POWER TRAIN
6. Engine Mounts, Thrust Rods and Associated Parts Removal
2
1
1
4
210341
Sequence
1. Thrust rod bracket 3. Transmission mounting bracket fitting nut
2. Engine mounting bracket fitting nut 4. Universal joint
(1) Thrust rod bracket

Remove the bolts attaching the bracket, then remove
the bracket with the thrust rod left attached to the
transmission mounting bracket.
(2) Universal joint

Remove the universal joint at the transmission side.
4-14
POWER TRAIN
7. Engine and Transmission Unit
210342
Fasten a hoist to the engine and transmission unit by

hitching slings to the eyes of the engine at two places and a
chain sling with lever block to the transmission at one place
as shown. Adjust the length of the chain sling with the
lever block so that the unit is horizontal. Slowly lift the
unit while moving it backward.
Weight of engine and

transmission unit 910 kg (2010 lb)
(3-speed transmission)
4-15
POWER TRAIN
Installation
To install, follow the reverse of removal sequence.
Suggestions for Installation

Output shaft
(1) Check the cushions of the engine and transmission
mounting brackets and replace them if damaged or
deteriorated.
(2) Mount the engine and transmission combination on the
mounting bracket while fitting the universal joint to the
transmission output flange.
Output flange
205457
(3) Tighten the mounting bolts to the specified torque. Engine mount (left shown, right opposite)
4 1
Ref. Item Tightening torque
No.
145 N·m
1 Rubber cushion bolts (14.8 kgf·m) 3
[107 lbf·ft]
60 N·m
2 Mounting bracket bolts (6.1 kgf·m) 206171
[44 lbf·ft]
Transmission mount (right side)
97 N·m 1
3 Rubber cushion bolts (9.9 kgf·m)
[72 lbf·ft] 2
60 N·m
3
4 Mounting bracket bolts (6.1 kgf·m)
[44 lbf·ft]
206172
Transmission mount (left side)

1
206173
4-16
POWER TRAIN
(4) Tighten the universal joint to the specified torque.
71±10 N·m
Tightening torque for
(7.2±1.0 kgf·m)
universal joint
[52±7 lbf·ft]
(5) Install the exhaust pipe with a new gasket.

(6) Install the harnesses, making sure their connectors and
terminals are tightened properly.
(7) Install the seat frame in position. When the self-
Seat frame
locking nuts contact the plain washers, tighten 2 turns
[3 mm (0.12 in.)] more.
Bolt
(8) Install the overhead guard or cab in position and tighten
the mounting bolts to the specified torque. Cushions
145 N·m
Tightening torque for
(14.8 kgf·m)
overhead guard or cab bolts Frame
[107 lbf·ft]
Nut 210337
(9) Install the parking brake wire with ball and nut. Then
test the operating effort of the lever.
245 to 294 N
Operating effort of parking
(25 to 30 kgf)
brake lever
[55 to 66 lbf]
(10) Install the brake pedal and inching pedal rods and
Unit: mm (in.)
cables, and check the height of the pedals and the
stroke of the inching valve plunger.
(7.48 in.)
190 mm
Unit: mm (in.)
Height of pedal 190 (7.48)
Stroke of inching valve plunger

9 (0.35)
with inching pedal released
9 mm
(0.35 in.)
(11) Connect the engine control cable to the injection pump 210343
lever, and make sure that the lever is in full throttle
position when the pedal is depressed all the way.
(12) Connect piping between the hydraulic pump and
steering control valve.
(13) Make sure that all wires have been connected properly,
and then connect the ground (negative) cables to the
batteries.
4-17
POWER TRAIN
(14) Refill the engine oil pan, radiator and transmission,

and check for leakage. For concentration of
antifreeze in coolant, consult your Cat lift truck
dealer.
(15) Fill the brake fluid reservoir, and bleed the brake
lines.
(16) Prime the fuel system.
(17) After having checked the various parts, start the
engine, and observe its running condition. If the
engine vibrates excessively, retighten the mounting
bolts to see if this retightening has any effect.
Operate the mast, forks and steering, and check the oil
level in the hydraulic tank, adding oil if necessary.
Recheck the engine oil, coolant and transmission oil
levels, and refill if necessary.
(18) Test the transmission as follows:
d
(a) Tilt the mast fully backward. Position wood
blocks under the mast and tilt the mast forward
to raise the front wheels until they clear the
ground. After raising the wheels, support the
frame with stands. Block the rear wheels.
(b) Start the engine and operate it at low idle. Move
the transmission shift lever to FORWARD
position to make sure the front wheels rotate in
the correct direction. Move the transmission
shift lever to REVERSE position and do the
201143A
same step.
(c) Move the travel speed select switch on the
console box to each position to make sure the
front wheels rotate at the correct speed in each
position.
CAUTION
During testing, the front wheels rotate. Set up a
fence around the truck to prevent anyone from
entering into the testing area.
4-18
POWER TRAIN
Refill Capacities (Approximate)

Unit: liter (U.S. gal.)
Truck Model
DP100 DP115 DP135 DP150
Item
Radiator 23 (6.1)
2-speed: 22 (5.8)
Transmission
3-speed: 23 (6.1)
Differential
Front axle 25 (7)
Final drive
Brake fluid reservoir 200 cc (12.2 cu in.)
Hydraulic tank 172 (45) 204 (54)
Fuel tank 230 (61) 280 (74)
Engine 12 (3.2)
Engine oil Oil filter 4 (1.0)
Total 16 (4.2)
NOTE: For recommended oil brands, etc., see the “GROUP 15 SERVICE DATA.”
4-19
POWER TRAIN
Service Data
A: Standard value
Truck Model
DP100 DP115 DP135 DP150
Item
Tightening torque for rubber cushion bolts 1

A 145 (14.8) [107]
N·m (kgf·m) [lbf·ft]
Tightening torque for mounting bracket bolts 2

A 60 (6.1) [44]
Tightening torque for rubber cushion bolts 3

A 97 (9.9) [72]
Tightening torque for mounting bracket bolts 4

A 60 (6.1) [44]
Engine mount (left side shown, right side opposite)
210344
Transmission mount (right side) Transmission mount (left side)
1 1
2
2
3
3
210345 210346
4-20
POWER TRAIN
A: Standard value
Truck Model
DP100 DP115 DP135 DP150
Item
Tightening torque for overhead guard or cab bolts 1

A 145 (14.8) [107]
Tightening torque for seat frame 2 When self-locking nuts contact plain washers,
A
N·m (kgf·m) [lbf·ft] tighten 2 turns [3 mm (0.12 in.)] more.
210347
Tightening torque for universal joint 1

A 70±10 (7.2±1.0) [52±7]
1 1
210348
4-21
2-SPEED POWERSHIFT TRANSMISSION
Specifications .......................................................................................... 5 – 1
Description ............................................................................................... 5 – 2
Torque Converter ...................................................................................... 5 – 2
Transmission ............................................................................................ 5 – 3
Power Flow ............................................................................................... 5 – 4
Control Valve ............................................................................................ 5 – 5
Main Regulator Valve ................................................................................ 5 – 5
Hydraulic Controls .................................................................................... 5 – 6
5
Speed Selector System ............................................................................ 5 – 8
Control System ......................................................................................... 5 – 9
Torque Converter .................................................................................... 5 – 12
Disassembly ............................................................................................. 5 – 12
Inspection ................................................................................................. 5 – 13
Reassembly .............................................................................................. 5 – 16
Transmission ............................................................................................ 5 – 18
Disassembly ............................................................................................. 5 – 18
Inspection ................................................................................................. 5 – 27
Reassembly .............................................................................................. 5 – 31
Control Valve ............................................................................................ 5 – 39
Disassembly ............................................................................................. 5 – 39
Inspection ................................................................................................. 5 – 40
Reassembly .............................................................................................. 5 – 41
Main Regulator Valve ............................................................................. 5 – 42
Disassembly ............................................................................................. 5 – 42
Inspection ................................................................................................. 5 – 42
Reassembly .............................................................................................. 5 – 42
Adjustment ............................................................................................... 5 – 43
Stall Speed Measurement ......................................................................... 5 – 47
10 m (33 ft) Start Acceleration Test ........................................................... 5 – 48
“Automatic 2-speed”/“Fixed 1st Speed” Test ............................................. 5 – 49
Service Data ............................................................................................. 5 – 55
Specifications
Truck Model
DP100 DP115 DP135 DP150
Item
Torque converter Model MI 16
Direction control: Electric, column shift

Control
Speed control: Automatic
1st: 1.556
Transmission Forward
2nd: 0.685
Gear ratio
1st: 1.556
Reverse
2nd: 0.685
5-1
Description
Torque Converter
7 5
2
From oil pump

4
1
8
To oil cooler
200550
1. Pilot boss 4. Turbine assembly 7. Pump (impeller)

2. Flexible plate 5. Stator 8. Stator shaft
3. Drive cover 6. Freewheel 9. Input shaft (transmission)
Oil for the operation of the torque converter is from the They allow the engine to turn fast while the truck
oil pump. It goes through outlet passage in the stator wheels are turning slowly. Thus, a high torque can be
shaft to the oil cooler, from which it goes to the applied, and the truck can accelerate. As the truck
transmission lubrication circuit. comes up to speed, the turbine begins to “catch up” the
The torque converter consists essentially of three pump (to cause the torque converter to act as a fluid
fundamental members: namely, the pump, turbine and coupling). When this happens, the oil leaving the
stator (reaction member). trailing edges of the turbine vanes is moving at about
the same speed as the pump. Now, the oil could pass
The pump is attached to the drive cover which in turn is
directly into the pump in a “helping” direction, without
driven by the engine through flexible plates. The
being given an assist by the stator. Under these
turbine is splined to the input shaft (of the
conditions, the stator vanes are in the way. The oil
transmission). The stator is attached to the stator shaft,
begins to hit the back sides of the stator vanes. To
with freewheel in between.
allow the stator vanes to move out of the way, the stator
The purpose of the stator is to cause the torque is mounted on a freewheeling mechanism (one-way
converter to multiply torque when the pump is turning clutch) that allows the stator to turn freely, or
faster than the turbine. This speed difference and “freewheel”, in only one direction.
increase in torque have the same effect as a low gear in
the manual transmission.
5-2
Transmission
9
8
7
2
R2 R1 6
3
F2 F1
207500
1. Flexible plate 4. Countershaft 7. Pump idler gear

2. Torque converter assembly 5. Output shaft 8. Pump drive gear
3. Input shaft 6. PTO drive gear 9. Pump case
The transmission is the powershift type and has two speeds

forward and two speeds reverse. It has four hydraulic
clutches of the disc type.
5-3
Power Flow

Forward 1st Reverse 1st
(39)
(60)
(52) (36)
(29)
(42)
(36)
(52)
(50) (56)
Forward 2nd Reverse 2nd
(54)
(52)
(54)
(52)
(37) (37)
205460B
Speed Gears engaged Gear ratio

52 56
1st x 1.556
52 36
Forward
52 37
2nd x 0.685
52 54
56
1st 1.556
36
Reverse
37
2nd 0.685
54
60 39
PTO gear x 0.929
42 60
5-4
Control Valve
2 5
A A
Section A – A
4
3
Section B – B
B B
C C
Section C – C
205461
1. Accumulator valve 3. Inching valve plunger 5. Travel speed (1st/2nd)

2. Direction valve 4. Inching valve valve
Main Regulator Valve
10 9 8
7 6 5 4 3 2 1
200554A
1. Bolts 5. Spool 9. Main pressure port

2. Cover 6. Body 10. Torque converter inlet
3. O-ring 7. Spring pressure port
4. Slug 8. Drain port
5-5
Orifice: Diam. 0.8 mm (0.031 in.) Solenoid valve
(direction selection) Orifice: Diam. 0.8 mm (0.031 in.)
Last chance filter 230 μ Last chance filter 230 μ
Torque converter
Hydraulic Controls
Solenoid valve
(speed selection)
Chassis area
Diam. 6 mm Solenoid valve

(0.24 in.) Orifice: Diam. 0.8 mm (direction selection)
Oil cooler (0.031 in.)
Last chance filter

230 μ
Oil filter
Torque converter bypass orifice:
Diam. 4.0 mm (0.157 in.) Oil filter for
forward/
reverse
5-6
Pc clutches
Torque converter inlet relief valve Pc (particle size 95 μ)
Setting: 0.05 to 0.49 MPa Response
(0.5 to 5.0 kgf/cm 2) Tap (plug) for (inching) valve
[7 to 71 psi] torque converter Setting: 0 to 0.22
inlet pressure MPa (0 to 2.2
(marked “T”) kgf/cm 2)
Pp [0 to 31.3 psi]
Lubrication relief valve Tap (plug) for
Setting: 0.02 to 0.15 MPa main pressure
(marked “M”) Main orifice: Diam. 2.0 mm
(0.2 to 1.5 kgf/cm 2) (0.079 in.) Accumulator valve
[3 to 21 psi] Pressure at start of
charging: 0.21 MPa
Main regulator valve (2.1 kgf/cm 2) [30 psi]
Lubrication
line Setting: 1.08 to 1.37 MPa
Pressure at end of
(11.0 to 14 kgf/cm 2)
Oil pump charging: 0.71 MPa
[156 to 199 psi]
Capacity: 70 liters (7.2 kgf/cm 2) [102 psi]
(18.5 U.S. gal.)/min
at 2300 rpm
Transmission oil reservoir

Suction strainer with magnet
100 mesh (particle size 220 μ)
205923
Oil Pressure Taps
PM
PT
PC
PP
210658
PM: Main pressure tap PP: Solenoid valve pilot pressure tap
PT: Torque converter inlet pressure tap PC: Clutch pressure tap
5-7
Speed Selector System
Travel speed select switch
1st speed clutch

Electronic Control Unit Travel speed
Output (solenoid) valve
(ECU)
gear 2st speed clutch
Electric signal
Travel speed sensor
0.5 mm Hydraulic pressure signal
(0.02 in.) Transmission case
Control system
Electronic Control Unit

(ECU)
Travel speed
select switch
Solenoid
valves
Travel speed sensor
210351
Location of components
The speed selector system is made up of an Electronic Unit: km/h (mph)

Control Unit (ECU), a travel speed sensor and a travel Travel speed
speed (solenoid) valve. Select switch
position (mode) DP100, DP135,
The selection of two modes “Automatic 2-speed” and DP115 DP150
“Fixed 1st speed” is done manually by means of the travel 0 to 10 0 to 9
speed select switch. 1st
Automatic (0 to 6.2) (0. to 5.6)
2-speed 10 to 26 9 to 27
2nd
(6.2 to 16.1) (5.6 to 16.8)
0 to 12 0 to 13
Fixed 1st speed
(0 to 7.5) (0 to 8.1)
5-8
Control System
R 8
N
F
1
2
10
7
4
5
6 3
210352
1. Transmission shift lever 6. Inching valve plunger

2. Inching bracket 7. Inching lever
3. Control valve 8. Inching cable
4. Travel speed (solenoid) valve 9. Electronic Control Unit (ECU)
5. Direction (solenoid) valve 10. Inching pedal
5-9

To remove the transmission assembly from the truck,
remove it together with the engine. Refer to “GROUP 4
POWER TRAIN.”
Transmission removal
(1) To separate the transmission from the engine, put the
engine on a stable stand, and support the transmission
with wood blocks.
(2) Remove the hydraulic pump from the transmission.
(3) Fasten a hoist to the transmission and lift the
transmission just enough to take the weight of the
transmission. To lift the transmission, tie a sling
around the torque converter housing and install an eye
bolt to the transmission cover, hitching a chain with
lever block to the eye bolt as shown.
(4) Remove the bolts that hold the flexible plates through
the access hole in the torque converter housing.
(5) Separate the transmission from the engine by lifting it
with a hoist.
205464
Torque converter removal

Remove the torque converter as an assembly from the
transmission by separating the stator shaft from the
transmission input shaft
NOTE
Remove the drain plug of the torque converter and
drain the oil.
5-10
Torque converter installation

(1) Couple the torque converter to the transmission. Make
25 mm (0.984 in.)
sure that the distance between the end face of the
torque converter housing and the mating face of the
flexible plate is 25 mm (0.984 in.). If this distance is
more than 25 mm (0.984 in.), it is an indication that
spline engagement between the torque converter stator
shaft and transmission input shaft is improper; re-
couple the torque converter to the transmission.
(2) Lift the transmission, and couple it to the engine.
(3) Make sure that the clearance between the flywheel and
flexible plates is 0 to 2 mm (0 to 0.08 in.) when the
transmission is coupled to the engine.
(4) Tighten the bolts that hold the flexible plates to the
flywheel through the access hole in the torque 200557
converter housing. The bolts should be tightened
evenly in a crisscross pattern. When tightening those
bolts, turn the torque converter with a heavy-duty
screwdriver put to the bolts.
(5) Install the hydraulic pump to the transmission.
(6) Mount the transmission harness.
Travel speed
Connect the travel speed sensor at the connector side, solenoid valve (S1)
and connect the thermounit at the terminal side.
Connect the F and R changeover solenoid valves
respectively to the terminals with F and R
identification marks at their roots.
Connect the travel speed solenoid valve to the terminal
which has no mark. The remaining terminal is for
grounding.
Solenoid Valve Harness Wire Color

Travel speed S1 RY R solenoid valve F solenoid valve
206064
F LgR
Transmission shift lever
R Br
PVC-R tape
NOTE
The transmission harness is common for the 2nd and
3rd speed transmissions. Travel speed Harness A
sensor side side
When the transmission harness is used for the 2nd
speed transmission, ensure that the terminal marked 2 Tie branch wire Cover the terminal
is not covered. (Refer to the illustration shown at onto truck cable. portions fully.
right.) 206250
(7) Pour in the torque converter oil.

5-11
Torque Converter
Disassembly
6
3
7
3
4
205626
Sequence
1. Bolts, Washers, Plate 5. Thrust washers, Thrust bearing
2. Flexible plates, Pilot boss, O-ring, Bolts, 6. Stator, Rollers, Hub, Springs, Spring caps,
Washers Thrust washers
3. Bolts, Drive cover, Ball bearing, Plug, Gasket, 7. Ball bearing, O-ring, Pump boss, Pump
Washers (impeller), Snap ring, Bolts, Washers
4. Spacer, Turbine
5-12
Suggestion for Disassembly

To remove the stator assembly, slightly force the stator just
like turning it counterclockwise to prevent the rollers from
falling and pull the stator together with the hub by sliding
the splines.
204530
Inspection
1. Pump (impeller)
(1) Check for cracks.
(2) Check for oil leaks due to looseness of the bolts holding
the boss to the pump, or defective O-ring.
(3) Check the face of the pump boss in contact with the oil
seal for wear.
(4) Check the face of the pump boss in contact with the
seal ring for wear.
Oil seal O-ring

Seal ring
200561
5-13
2. Stator
(1) Check the blades for cracks. Also check the fit of the
stator on the clutch cam.
(2) Check the clutch hub and cam for wear or flaws.
(3) Check the springs for damage. Also check the spring
caps for wear or distortion.
(4) Check the rollers for flaws, distortion or flat spots due
to wear.
(5) Check the clutch hub splines for defects.
(6) Check the thrust washers for wear or other defects.

Unit: mm (in.)
A 67.97 to 67.951
Outside diameter of (2.6760 to 2.67523)
clutch hub 1
B 67.8 (2.669)
10.185 to 10.2 3 4 1 2 5 6 7
Diameter of clutch A (0.40098 to 0.402)
rollers 2
B 10.1 (0.398)
A 4.95 to 5
Thickness of thrust (0.1949 to 0.197)
washer 3
B 4.8 (0.189) 200724
A 3.95 to 4
washer 4
B 3.8 (0.150)
A 2.9 to 3
washer 5
B 2.8 (0.11)
A 4.9 to 5
washer 6
B 4.8 (0.189)
A 4.95 to 5
washer 7
B 4.8 (0.189)
5-14
3. Turbine
(1) Check the vanes for cracks.
(2) Check the fit of the turbine boss in the turbine.
(3) Check the turbine boss splines for wear or other
defects.
4. Pilot boss
Check the surface in contact with the pilot bearing for wear
or other defects.
A: Standard value B: Repair or service limit 1
Unit: mm (in.)
− 0.007 − 0.00028
Diameter of portion in A 20 − 0.020 (0.79 − 0.00079 )
contact with engine
flywheel 1 B 19.85 (0.7815)
200411
5-15
Reassembly
1 10
13
11
4
2
9
3
7 12
13
5
205643
Sequence
1. Pump (impeller) 8. Thrust washer
2. Pump boss, O-ring, Bolts, Washers 9. Thrust bearing, Thrust washers
3. Ball bearing, Snap ring 10. Turbine
4. Stator assembly 11. Drive cover, O-ring, Bolts, Washers
5. Springs, Spring caps 12. Spacer, Ball bearing, Pilot boss, O-ring, Bolts,
6. Rollers Washers
7. Hub 13. Flexible plates, Plate, Bolts, Washers
5-16
Suggestions for Reassembly
1. Stator assembly 5 5
(1) Put hub 7 in the stator as shown. Put spring 5 and
spring cap 5 in each hole, and press in roller 6 while
pushing the spring cap.
6
(2) Install a total of ten rollers, and restore the hub to its
original position.
(3) After having assembled the stator, turn the hub by
hand, making sure that it rotates in only one direction.
7 202885A
2. Selection of spacer
Measure the dimensions A, B and C. Select a spacer equal
to the clearance (dimension D) and put it in position.
A
Part number Thickness of spacer
92322 - 14700 2.9 mm (0.114 in.)
92322 - 14800 3.0 mm (0.118 in.)
92322 - 14900 3.2 mm (0.126 in.) B
D C
92322 - 06600 3.4 mm (0.134 in.) 204534
92322 - 06700 3.5 mm (0.138 in.)
A 26.3 (1.035)
Standard dimensions B 19 (0.75)
mm (in.)
0 0
C 4 − 0.1 (0.16 − 0.004 )
3. Flexible plate
After having installed the flexible plate, measure the face
runout of the plates with a dial indicator. Replace the
plates if the runout has exceeded the service limit.
Unit: mm (in.)
A 0.2 (0.008)
Face runout of flexible
plate (in free state)
B 0.5 (0.020)
205922
5-17
Transmission
Disassembly
1. Control valve and external parts
6
10 4
9
2
5
12
3
13
11
18
14
17
15
8
16
210353
Sequence
1. Inching bracket, Spring, Bolts, Washers 11. Bracket, Bolts, Washers
2. Breather 12. Bracket, Bolts, Washers
3. Oil level gauge, Plug 13. Travel speed sensor cover,
4. Oil pipe, Eye bolt, Gaskets Travel speed sensor, Bolts, Washers
5. Oil pipe, Eye bolts, Gaskets 14. Thermounit
6. Oil pipe, O-rings, Bolts, Washers 15. Drain plug, Gasket
7. Oil pipe, O-rings, Bolts, Washers 16. Oil filter
8. Oil pipe, Eye bolt, Gaskets 17. Cover, O-ring, Bolts, Washers
9. Control valve, Gasket, Bolts, Washers 18. Magnet strainer assembly
10. Main regulator valve, Gasket, Bolts, Washers
5-18
2. Transmission cover and shafts
12
13
11
14
10
5
9
4
3
1
2
207501
Sequence
1. Transmission cover subassembly, Gasket, 8. Input shaft subassembly
O-rings, Bolts, Washers 9. Baffle plate, Bolts, Washers
2. Oil seals 10. Output shaft
3. Ball bearing 11. Travel speed sensor gear, Lock plate, Bolts
4. Output gear 12. Ball bearing
5. Snap ring 13. Output gear
6. Baffle plate, Bolts, Washers 14. Snap ring
7. Countershaft subassembly
5-19
Suggestions for Disassembly
1. Transmission cover subassembly 1 removal

Bolts (jack bolts)
Turn two Bolts (jack bolts) (special tool) in the M10 x 1.25
holes in the cover evenly until the cover is approximately
25 mm (1 in.) apart (the bearings get out of place). Then
remove the cover, taking care not to damage the seal rings
of the input shaft and countershaft. Do not attempt to
remove the lubrication line relief valve from the cover.
Special tool needed
Bolt 67284 - 15400

205479
2. Output gear (outside) 4 removal

Remove the output gear together with ball bearing 3 with a Output gear
gear puller.
Sliding hammer
3. Input shaft subassembly 8 and countershaft
subassembly 7 removal
Tap the rear end of the input shaft subassembly 8 to push it
forward. This will also cause the countershaft subassembly
to come off. Remove the countershaft subassembly by
turning it aside the input shaft subassembly. Then remove 205480
the input shaft subassembly.
4. Output shaft 10 removal

Turn a sliding hammer in the M10 x 1.25 hole in the end of
the output shaft, and remove the shaft together with the
output gear, ball bearing and travel speed sensor gear.
5-20
3. Stator shaft and oil pump
20
21
22
19
27
23
16 15 32
26
17
33
18
17
29
28
30
31
25
24
34
205679
Sequence
15. PTO cover, O-ring, Bolts, Washers 25. Oil seal
16. Snap ring 26. Idler gear shaft
17. Pump drive gear, Seal rings 27. Roller bearing
18. Ball bearing 28. PTO drive gear
19. Pump case, O-ring, Bolts, Washers 29. Ball bearing
20. Pump plate, O-ring, Gasket, Bolts, Washers 30. Ball bearing
21. Internal gear 31. Stator shaft, Seal ring, Bolts, Washers
22. Pump gear 32. Pump idler gear
23. Ball bearing 33. Roller bearing
24. Torque converter housing, Gasket, Bolts, 34. Transmission case, Dowels
Washers
5-21
1. Torque converter housing 24 removal

holes in the housing evenly until the housing is
approximately 18 mm (0.7 in.) apart (the PTO drive gear
ball bearing gets out of place). Fasten a hoist to the housing
and remove the housing.
Special tool needed
Bolt 67284 - 15400
2. Oil pump removal

Remove the oil pump as a subassembly including pump
case 19, pump plate 20, internal gear 21 and pump gear 22.
3. Idler gear shaft 26 removal

Turn the Shaft Puller (special tool) in the shaft hole. Install
the sliding hammer (used in removing output shaft 10) to
M20 × 1.5
this Puller and remove the shaft.
M10 × 1.25
Special tool needed
26
Shaft puller To be made by dealer
204852
4. PTO drive gear 28 removal

Grip ball bearing 29 with a gear puller. Put a protective
plate on the end of the stator shaft and remove the gear 28
together with two ball bearings
205483
5-22
5. Stator shaft 31 removal

holes in one end of the shaft evenly or hit the other end by
using a protective plate.
Special tool needed
Bolt 67284 - 15400
6. Roller bearing outer race removal

Do not remove the outer race of roller bearing 33 for idler
gear 32 unless it has a defect.
5-23
4. Input shaft subassembly
12
5
13
15
4
3
2 14
1
16
14
15
13
12
11
10
1
6
11 7
11
8
9
10
11
207502
Sequence
1. Seal rings 10. Snap rings, Pressure plates
2. Ball bearing 11. Friction plates, Mating plates
3. Thrust washer 12. Snap rings, Retainers
4. Gear (R2 drive), Needle roller bearing 13. Clutch springs
5. Thrust washer, Snap ring 14. Clutch pistons, Steel balls, Screws,
6. Ball bearing Piston seals
7. Thrust washer 15. Seal rings
8. Gear (R1 drive), Needle roller bearing 16. Input shaft
9. Thrust washer, Snap ring
NOTE
Do not attempt to remove the screws from the input
shaft. It is not necessary to disassemble clutch pistons
14 if the balls move freely in the pistons when the
pistons are shaken.
5-24
1. Input shaft ball bearing 6 removal

Use the special tools to remove ball bearing 6 from the
1
input shaft.
Special tools needed
Ref.
Tool name Part No. Q'ty
No.
Puller 91268 - 13810 2

4 2 3
Plate 91268 - 13820 1 207503
! Bolt F1035 - 10020 2

Unit: mm (in.)
Gear puller T-24 1
" — 1 4 ø11 (0. 2
[BANZAI make] (0.43)
47
)
87)
(7.
200
6
55 ) (0.24)
17
(2.
2 ) 2
(0.
08 60) (0. 5
( 12. ) 98
320 54 )
(3.
90 44)
2 (2.
6
6
(0.24)
21
(0.83)
1 2 M10 × 1.25
203541
2. Input shaft disassembling

A
Using the Piston Tool A (special tool) or an arbor press,
compress clutch spring 13 and retainer 12, and remove
snap ring 12.
Special tool needed
Piston tool A 92267 - 00300
207504
5-25
5. Countershaft subassembly
5 12
13
15
4
14
3 16
2
1
14
15
13
12
11
10
6
7
11
11 8
9
10
11
207505
Sequence
3. Thrust washer 12. Snap ring, Retainer
4. Gear (F2 drive), Needle roller bearing, Spacer 13. Clutch springs
5. Thrust washer, Snap ring 14. Clutch pistons, Steel balls, Screws,
6. Ball bearing Piston seals
8. Gear (F1 drive), Needle roller bearing 16. Countershaft
NOTE Suggestion for Disassembly
Do not attempt to remove the screws from the For disassembly, make reference to the disassembly of
countershaft. It is not necessary to disassemble the input shaft.
clutch pistons 14 if the balls move freely in the
pistons when the pistons are shaken.
5-26
Inspection
1. Oil pump
(1) Put the internal gear and pump gear in the pump case,
and measure top clearance 2.
(2) Using a dial indicator, measure side clearance 1
between the gears and pump case.
Unit: mm (in.)
0.040 to 0.078
A 2
(0.00157 to 0.00307)
Side clearance 1
B 0.09 (0.0035) 1
205486
0.3 to 0.345
A
(0.0118 to 0.0136)
Top clearance 2
B 0.35 (0.0138)
2. Stator shaft
(1) Check the splines for wear or damage.
(2) Check the oil passages for clogging.
3. Friction plates and mating plates

(1) Check for sign of seizure, uneven contact, warpage or
excessive wear.
4. Clutch drums
(1) Check the mating plate sliding surfaces for wear or
damage.
(2) Check the clutch piston sliding surfaces for wear or
damage.
5-27
5. Gears
7,8
(1) Check the gear and splines for wear or damage.
(2) Check the gear surface in contact with the needle roller
bearings for wear or damage.
Unit: mm (in.)
2.3±0.07
A
Thickness of mating (0.091±0.0028)
6 2 1 3
plate 1
B 2.1 (0.083)
4
2.6±0.1
A
Thickness of friction (0.102±0.004)
plate 2
B 2.2 (0.087) 5
Free movement of 0.10 to 0.30 207514

A
friction plate on gear 3 (0.0039 to 0.0118)
− 0.01 − 0.0004
A 4 − 0.03 (0.16 − 0.0012 )
Width of piston seal
ring 4
B 3.5 (0.138)
+ 0.2 + 0.008
A 4 + 0.1 (0.16 + 0.004 )
ring groove in piston 5
B 4.5 (0.177)
Free length of clutch 62.9 (2.48)

A
spring 6 k = 39.1 (3.992) [223.5]
Spring constant:
k = N/mm (kgf/mm)
B 60 (2.36)
[lbf/in.]
2.5±0.05
A
Width of clutch piston (0.098±0.0020)
seal ring 7
B 2.0 (0.079)
+ 0.2 + 0.008
A 2.5 + 0.1 (0.098 + 0.004 )
Width of clutch piston
seal ring groove 8
B 3.0 (0.118)
5-28
6. Input shaft and countershaft

(1) Check the seal rings, shaft and case for wear or damage.
Unit: mm (in.)
2.5±0.05
A
Width of piston seal ring (0.098±0.0020)
for input shaft 1
B 2.0 (0.079)
+ 0.2 + 0.008
A 2.5 + 0.1 (0.098 + 0.004 )
Width of piston seal ring
groove in input shaft 2
B 3.0 (0.118)
+ 0.025 + 0.00098
Inside diameter of stator A 35 0 (1.38 0 )
shaft in contact with seal
ring 3 B 35.2 (1.386)
2.5±0.05
Width of seal ring for A
(0.098±0.0020)
input shaft and
countershaft 4
B 2.0 (0.079)
+ 0.2 + 0.008
Width of seal ring groove A 2.5 + 0.1 (0.098 + 0.004 )
in input shaft and
countershaft 5 B 3.0 (0.118)
+ 0.025 + 0.00098
Inside diameter of A 35 0 (1.38 0 )
transmission cover in
contact with seal ring 6 B 35.2 (1.386)
4,5
1,2
6 3
207506
Remarks: The input shaft is shown. Items other than 1, 2 and 3 are common to the input shaft and countershaft.

(3) Check oil passages for clogging.
5-29
7. Gears
Check each gear for worn teeth or splines.
8. Magnet strainer assembly

Disassemble and clean the strainer. Replace the strainer if
defective.
9. Transmission cover and torque converter housing

oil seals
Replace the oil seals with new ones.
5-30
Reassembly
1. Input shaft subassembly (countershaft subassembly)
6 5 10 9 8 7 4 7 8 4 9 10 5
13
16 6
17 14
15
21
20 19
18 2 3 2 11 12 21 1
207507
Sequence
1. Input shaft or countershaft 12. Needle roller bearing
2. Sealing rings, Piston seals 13. Gear (R1 drive)
3. Pistons 14. Thrust washer
4. Springs 15. Ball bearing
5. Retainers 16. Thrust washer, Snap ring
6. Snap rings 17. Needle roller bearing
7. Mating plates 18. Gear (R2 drive)
8. Friction plates 19. Thrust washer
9. Pressure plates 20. Ball bearing
10. Snap rings 21. Seal rings
NOTE
The countershaft subassembly is similar in reassembly
sequence and suggestions to the input shaft, the only
difference being that the portion carrying the F2 drive
gear is long and has needle roller bearing and spacer
and that the torque converter side does not extend
beyond the ball bearing.
5-31
1. Piston installation
When putting pistons 3 in the clutch drum, apply ATF
(automatic transmission fluid) to their seal ring contact
surfaces.
2. Return spring installation A

compress springs 4 and retainers 5, and install snap rings 6.
Special tool needed
207504
3. Friction and mating plate installation Mating plate

(1) Make sure that the position and number of the plates are Friction plate
correct. Install the plates while applying ATF to them.
When replacing the friction plates, replace the mating
plates as a set.
207516
(2) Thrust washer installation

Install thrust washers 11, 14, 16 and 19 with the side
that has oil grooves toward the gear.
203800
4. Piston testing
After having assembled the clutch, apply air pressure of
approximately 690 kPa (7 kgf/cm2) [100 psi] to the oil hole
to make sure that the piston moves freely without any sign
of air leaks.
5-32
15 16
12
17
18
19 20
14 3
13 9
1
10
5 11 205680
Sequence
1. Transmission case, Dowels 8. Idler gear shaft 15. Pump plate, O-ring,
2. Roller bearing 9. Roller bearing Gasket, Bolts, Washers
3. Idler gear 10. Oil seal 16. Ball bearing
4. Stator shaft, Seal ring, 11. Torque converter housing, 17. Pump drive gear,
Bolts, Washers Gasket, Bolts, Washers Seal rings
5. Ball bearing 12. Pump case, O-ring, 18. Ball bearing
6. PTO drive gear Bolts, Washers 19. Snap ring
7. Ball bearing 13. Internal gear 20. PTO cover, O-ring,
14. Pump gear Bolts, Washers
NOTE
The dowels fitted into the transmission case have not
been removed. These dowels are for locating the pump
case, torque converter housing and transmission cover
subassembly for installation.
5-33
1. PTO drive gear 6 installation

Install ball bearings 5 and 7 to PTO drive gear 6. Install
the gear to stator shaft 4.
2. Oil seal 10 installation Unit: mm (in.)

Replace the oil seal with a new one. To install the new oil
seal, use the Installer (special tool).
ø98.5 (3.88)
ø140 (5.51)
Special tool needed
Oil seal installer To be made by dealer
ø40 (1.57)
13 (0.51) 8 (0.31)
150 (5.91)
205491
3. Oil pump assembling

Put internal gear 13, pump gear 14 and pump plate 15 in
pump case 12. Apply oil to the internal gear and pump
gear. Do not forget to install the O-ring.
4. Oil pump subassembly installation

Be sure to place the gasket and the O-ring for the oil hole
when installing the oil pump subassembly.
5. Pump drive gear 17 installation

Install ball bearing 16 on pump drive gear 17. Install two
seal rings in position and apply oil to these seal rings. Then
drive the gear assembly into the transmission case with the
splines in alignment with those of pump gear 14.
6. Ball bearing 18 installation

Unit: mm (in.)
2 − ø13 (0.51)
When installing ball bearing 18 in pump case 12, hold the
pump drive gear with the Pump Drive Gear Holder (special
15
tool), or have someone press the gear with a copper bar or

4(
6.0
the like, in order to prevent the gear from coming off.

6)
Special tool needed

ø4
ø1
0(
24
Pump drive gear )

ø1
To be made by dealer 39
1.5
.9
(0. 1)
80
holder
(4.
0
7)
1 (0. 3
(7.
8
17
09
9)
)
(0.3 28 0)
1
10 (1.
205492
5-34
3. Shafts and transmission cover
29
30
34
25
33 32 31 26 28 21 22 27 23 24
207508
Sequence
21. Output shaft 29. Input shaft subassembly
22. Snap ring 30. Countershaft subassembly
23. Output gear 31. Output gear
24. Ball bearing 32. Ball bearing
25. Travel speed sensor gear, Lock plate, Bolts 33. Oil seals
26. Snap ring 34. Transmission cover subassembly, Gasket,
27. Baffle plate, Bolts, Washers O-rings, Bolts, Washers
28. Baffle plate, Bolts, Washers
5-35
1. Output shaft 21 assembling and installation

Assemble output shaft 21, snap rings 22 and 26, output
gear 23, ball bearing 24 and travel speed sensor gear 25 in
a subassembly. Install the subassembly in the transmission
case. Use a new lock plate for the bolts that hold the travel
speed sensor gear.
2. Input shaft subassembly installation

Install a total of four seal rings, one on the front side and
three on the rear side. Apply oil to these rings when
installing them.
3. Oil seal 33 installation

Replace two oil seals with new ones. To install these seals, Transmission cover
apply grease to their lips and install them with the Oil Seal
Installer (special tool) with their main lips toward inside.
205494
Special tool needed

Unit: mm (in.)
1 (0.04) chamfer
ø68.5 (2.70)
ø94.5 (3.72)
ø108 (4.25)
(1.57)
ø40
10 (0.39) 28 (1.10)
170 (6.69)
1.5 (0.06)
205495
5-36
4. Transmission cover installation

Install hooks in the jack bolt holes in the transmission cover
and hitch slings to these hooks. Put the gasket on the
transmission case. Hoist the cover and install it in position.
Apply oil to the servo cases formed of the cover when
installing the cover. Do not forget to put the O-rings in the
oil holes
205496
5-37
18
13
9
15
10
17
14
7
16
12
1 5
2 4
11
3
210354
Sequence
1. Magnet strainer assembly 10. Control valve, Gasket, Bolts, Washers
2. Cover, O-ring, Bolts, Washers 11. Oil pipe, Eye bolt, Gaskets
3. Oil filter 12. Oil pipe, O-rings, Bolts, Washers
4. Plug, Gasket 13. Oil pipe, O-rings, Bolts, Washers
5. Thermounit 14. Oil pipe, Eye bolts, Gaskets
6. Travel speed sensor cover, 15. Oil pipe, Eye bolt, Gaskets
Travel speed sensor, Bolts, Washers 16. Plug, Oil level gauge
7. Bracket, Bolts, Washers 17. Breather
8. Bracket, Bolts, Washers 18. Inching bracket, Spring, Bolts, Washers
9. Main regulator valve, Gasket, Bolts, Washers
5-38
Control Valve
Disassembly
1
1
2 3
5
9
14 8
2
10
4
11
14
3 13
15
1 6
12
11
11
10 205473
Sequence
1. Solenoid valves, O-rings 8. Inching valve, Spring, Slug 12. Oil seal
2. Speed valve, Solenoid spring 9. Roller bearing, Plug, O-ring 13. Oil filter
3. Springs, Direction valve 10. Plate, O-ring, Bolts, Washers 14. Plugs, O-rings
4. Plug, O-ring, Roller bearing 11. Accumulator piston, 15. Valve body, Gasket
5. Oil filter, O-rings Spring guide,
6. Stopper pin, O-ring Springs (outer and inner)
7. Inching valve plunger, Spring
CAUTION
Slowly loosen each bolt and solenoid valve so that
the spring and plunger do not suddenly jump out.
5-39
Stopper pin 6 removal

Turn a screw in the M4 x 0.7 hole in the stopper pin 6 and
carefully remove the pin because removal of the stopper pin
will cause inching valve plunger 7 to fly out.
Inspection
(1) Check the oil holes in the valve body for restriction.
(2) Check each plunger for wear or damage. Make sure the
plunger moves freely.
(3) Check the orifice in the inching valve for restriction.
Also check the inching valve spring for damage.
Measure free length.
(4) Replace oil seal 12 with a new one.
200220
(5) Replace filter 13 with a new one.
(6) Wash filter 5, or replace it with a new one.
Unit: mm (in.)
Free length of speed valve 87.5 (3.44)
A 1
spring 1 k = 3.88 (0.396) [22.1]
Spring constant:
k = N/mm (kgf/mm) [lbf/in.] B 85 (3.35)
2
Free length of direction valve 32.5 (1.26)

A
springs 2 k = 8.61 (0.8786) [49.2]
Spring constant:
k = N/mm (kgf/mm) [lbf/in.] B 31.5 (1.24)
2
3
Free length of inching valve 39 (1.53)
A
spring 3 k = 2.12 (0.217) [12.1] 4
Spring constant:
6
28 (1.10)
Free length of return spring 4 A 5
k = 0.478 (0.0488) [2.73]
Spring constant:
k = N/mm (kgf/mm) [lbf/in.] 205699
B 26.5 (1.04)
Free length of accumulator 109.5 [4.31]

A
valve outer spring 5 k = 6.38 (0.651) [36.4]
Spring constant:
k = N/mm (kgf/mm) [lbf/in.] B 107.5 [4.23]
Free length of accumulator 154 (6.06)

A
valve inner spring 6 k = 6.86 (0.6998) [38.6]
Spring constant:
5-40
Reassembly
1 15
14
13 A A
Section A – A
13
12
11
10
3
8
7
Section B – B 9 B
B
16
C C
6 4
Section C – C 5
210192
Sequence
1. Valve body 9. Spring, Inching valve plunger
2. Oil filter 10. Stopper pin, O-ring
3. Oil seal 11. Oil filter, O-ring
4. Plate, O-ring 12. Spring, Direction valve
5. Accumulator piston, Springs (inner and outer), 13. Solenoid valves
Spring seat 14. Plug, O-ring, Roller bearing
6. Plate, O-ring 15. Spring, Travel speed valve, Solenoid valve
7. Plug, O-ring, Roller bearing 16. Plug, O-ring
8. Inching valve, Spring, Slug
Start by:
Clean the oil passages in the control valve thoroughly and
make sure they are not restricted.

(2) Apply ATF (automatic transmission fluid) to the valves
and plungers when installing them in the valve body.
5-41
Disassembly
5
2
6 4 3
210180
Sequence
1. Cover, O-ring, Bolts, Washers 4. Spring
2. Slug 5. Cover, O-ring, Bolts, Washers
3. Spool 6. Body
CAUTION
Slowly loosen bolts 1 so that the spring, spool
and slug do not suddenly jump out.
Inspection Reassembly
(1) Check the oil holes in the valve body for To reassemble, follow the reverse of disassembly
restriction. sequence.
(2) Check the valve spool for wear or damage. Make
sure the spool moves freely. Suggestion for Reassembly
(3) Check the spring for damage. Measure the free
Apply oil to the spool and slug when putting them in
length of the spring.
the body.
Unit: mm (in.)
Free length of main 112 (4.41)
A
regulator valve spring k = 4.99 (0.5087) [28.5]
Spring constant:
k = N/mm (kgf/mm)
B 109 (4.29)
[lbf/in.]
5-42
Adjustment
Brake pedal and inching pedal adjustment

Adjust the brake pedal before adjusting the inching pedal.
1. Brake pedal adjustment
190 mm (7.5 in.)

Bring the roller 1 of the brake pedal into contact with the 1
pedal 2 of the brake control valve 2 by means of the
adjusting bolt 4. Under this condition, the top height of the 4
3
pedal from the floor level will be approximately 190 mm
(7.5 in.).
NOTE: The set angle (39±1.5°) of the brake valve must be 2

kept unchanged. 210611
2. Inching pedal adjustment 6 mm

(0.24 in.) 4
(1) With the clutch valve plunger 1 pushed in all the way
3 1 2
[6 mm (0.24 in.) allowed for protrusion], attach the
transmission side return spring 2 to the inching lever 3
and inching bracket 4.
5
(2) Connect the inching cable 5 to the inching bracket 4,
then attach the clevis 6 to the inching lever 3.
6 210612
(3) Attach the pedal side turnbuckle 7 to the inching pedal

12
arm 8 and vehicle body side inching lever 9. Be sure
190 mm (7.5 in.)
11
that turnbuckle clevis pin holes are approximately 272
A
mm (10.7 in.) apart center to center.
(4) Attach the return spring 10 between the vehicle body 13
14
side inching lever 9 and seat frame. 8 7 10 9
(5) Tilting the inching pedal 11, adjust the clearance A
between cam follower 12 and brake pedal valve 13 to
14.5 mm (0.571 in.), then hold the inching pedal 11 in
that position with the adjusting bolt 14. Under this
condition, the top height of the inching pedal 11 from
the floor level will be approximately 190 mm (7.5 in.). 272 mm (10.7 in.)
210613
5-43
(6) Attach the inching cable 15 to the vehicle body side 9 mm

inching lever 9 and bracket 16. (0.35 in.)
12 1
(7) With the clearance A set at 14.5 mm (0.571 in.)
A
between cam follower 12 and brake valve pedal 13,
adjust the protrusion of clutch valve plunger 1 to 9 mm
(0.35 in.) with the turnbuckle 7. 13 7
9
16
15
210614
(8) Depress the inching pedal 11 and make sure that the
protrusion of clutch valve plunger 1 is 11.5±0.5 mm 11.5±0.5 mm
(0.453±0.020 in.) when the cam follower 12 touches (0.453±0.020 in.)
11 1
the brake valve pedal 13. If the 11.5±0.5 mm
(0.453±0.020 in.) cannot be obtained, adjust the length 12
of the turnbuckle 7.
13
210615
(9) Depress the inching pedal 11 all the way and make sure
that the protrusion of clutch valve plunger 1 is 19.5±1 19.5±1 mm
(0.768±0.039 in.)
mm (0.768±0.039 in.). Then, tighten the lock nut of
1
the turnbuckle 7 and adjusting bolt 14.
11
14
210616
5-44
Oil Pressure Measurement
NOTE
Front tires rotate during the measurement. Build a
fence around the vehicle to prevent access to it.
NOTE: Always perform pedal adjustments before oil

pressure measurement.
1. Main oil pressure measurement

(1) Connect a 2 MPa (20 kgf/cm2) [290 psi] oil pressure
Main pressure
gauge to the main oil pressure outlet of the regulator tap (M)
valve.
*Connector 64309 - 17733
*Hose 64309 - 17722
*Connector 64309 - 17731
*Gauge 64309 - 17713 210617
NOTE: Parts marked with an asterisk (*) are included

in the gauge kit 64309 - 17701.
(2) Idle the engine and check that the transmission oil is up
to the specified level.
(3) Warm up the engine to raise the transmission oil
temperature.
(4) Keep the engine idling (at between 1000 and 1500
rpm).
(5) Under the above condition, perform the oil pressure
measurement.
A: Standard value
Main oil pressure 1.08 to 1.37 MPa

(with engine idling at A (11 to 14 kgf/cm2)
1500±100 rpm) [157 to 199 psi]
NOTE: Monitor the idling speed through engine

tachometer during measurement.
5-45
2. Clutch Oil Pressure Measurement

Clutch pressure tap (Pc)
gauge to the clutch oil pressure outlet port of the
selector valve.
NOTE: Use the same special tools as used for main oil
(2) Lift the front tires off the floor by either of the
following methods.
210618
(a) The front axle housing is jacked up.
(b) The mast is tilted all the way backward first. With
a wooden block applied under the outer mast, the
mast is tilted forward to lift the front tires. Then,
an appropriate stand or square timber is placed
under the frame to keep the front tires lifted.
(3) Put scotch blocks under the rear tires.
(4) Implement the steps (2) through (4) of main oil pressure
measurement. End face of control valve body
(5) Place the transmission shift lever into the FORWARD

position, then release the parking brake.
(6) Depress the inching pedal gradually to pull out the
clutch (inching) valve plunger pushed all the way in.
Record pressure fluctuations with plunger stroke in the
meantime and make sure that the oil pressure change
patterns as shown at the left.
B
Reference data A
MPa (kgf/cm2) [psi]
Pedal height (from frame top surface 190 mm 1.23

Clutch pressure,
(12.5)
to uppermost end of pedal) (7.5 in.) [178]
0.22
(2.2)
Clearance between inching cam 14.5 mm 10.5 7 [31]
follower and brake valve (0.571 in.) (0.41) (0.28)
0
15 10 5 2
Plunger protrusion A when inching 9 mm (0.59) (0.39) (0.20) (0.08)
pedal is not depressed (0.35 in.) Clutch valve plunger stroke, mm (in.)
210619
Plunger protrusion B when brake 14 mm
begins to work (0.55 in.)
5-46
3. Torque converter inlet oil pressure measurement

Torque converter
(1) Connect a 0.6 MPa (6 kgf/cm2) [87 psi] oil pressure inlet pressure tap (T)
gauge to the torque converter inlet oil pressure inlet
port of the regulator valve.
*Connector 64309 - 17733
*Hose 64309 - 17722
*Connector 64309 - 17731

210620
*Gauge 64309 - 17713
NOTE: The parts marked with an asterisk (*) are

included in the gauge kit 64309 - 17701.
(2) Idle the engine and check that transmission oil is up to

the specified level.
temperature.
rpm), measure the torque converter inlet oil pressure.
A: Standard value
Torque converter inlet

oil pressure 0.05 to 0.49 MPa
A (0.5 to 5 kgf/cm2)
(with engine idling at
1500±100 rpm) [7 to 71 psi]

Stall Speed Measurement

(1) With the engine running at low idle, check to make sure
that the oil level is correct in the transmission case.
(2) Warm up transmission oil.
(3) Block the front and rear wheels, and apply the parking
brake.
(4) Run the engine at low idle.
5-47
(5) Move the transmission shift lever to the forward

position, and gradually depress the accelerator pedal all
the way. Under this condition, measure the stall speed
with an engine tachometer.
Stall speed
1760 rpm
(tolerance: ±100 rpm)
CAUTION
Do not attempt to depress the inching pedal. Do
not continue operation in stall condition for more
than 30 seconds. A failure to follow this
precaution would result in destruction of the
torque converter.
(6) Similarly measure the stall speed for reverse drive.
NOTE
(a) Any stall speed within ±100 rpm tolerance of the
specification is satisfactory.
(b) If the engine or torque converter is changed, the
stall speed will vary since the stall speed is
determined by the combination of engine and
torque converter.
10 m (33 ft) Start Acceleration Test

(1) Stand ready to start with the engine running at low idle,
the transmission shift lever in the neutral position and
the travel speed select switch in “Automatic 2-speed”
position.
(2) At the signal, move the transmission shift lever to the
forward position and, at the same time, depress the
accelerator pedal fully.
(3) Measure the time required for the truck to travel 10 m
(33 ft) with a stopwatch.
(4) Conduct the same test for reverse travel, too.
Travel time (no load) 5 seconds, maximum
5-48
“Automatic 2-speed”/“Fixed 1st Speed”

Test
Move the travel speed select switch mounted on the console
box to each position, and make sure that the speed selector
system functions properly. Move the switch when the truck
is at standstill.
DP100, DP115
(1) In the “Fixed 1st speed” position, the truck runs at a
maximum speed of 12 km/hr (7.5 mph) and a greater
torque is available.
(2) In the “Automatic 2-speed” position, the transmission
automatically shifts from the 1st to the 2nd speed when
the travel speed reaches 10 km/hr (6.2 mph) to allow 205698A
the truck to run at a maximum speed of 26 km/hr (16.1
mph).
DP135, DP150
the travel speed reaches 9 km/hr (5.6 mph) to allow the
truck to run at a maximum speed of 26 km/hr (16.1
mph).
5-49
Troubleshooting
Engine Poor performance Tune up engine.
Oil level too low Refill.

Air being sucked in on suction side Retighten or replace gasket.
Main regulator valve not operating Repair or replace.
properly
Main regulator valve spring fatigued Replace.
Oil pump gears worn, resulting in Overhaul and check or
Torque
converter reduced capacity replace defective parts.
Magnet strainer clogged Replace.
Seal rings or O-rings worn Replace after measuring oil
pressure.
Stator freewheel seized Replace stator assembly,
hub and roller.
Not enough Blades of running members damaged Repair or replace. Replace
output power or rubbing bearing.
Air being sucked in on suction side Retighten or replace.

Outlet pressure too low to suppress Readjust.
internal foaming
Water in oil Replace oil.
Transmission Main pressure too low, resulting in Readjust after measuring
slipping clutches oil pressure.
pressure.
Clutch piston damaged Replace.
Friction plate seized or dragging Replace.
Wheels High mechanical resistance Check and adjust brake

system.
5-50
Flexible plate broken Replace.

Torque
converter Oil pump drive defective Replace.
Turbine shaft broken Replace.
Main pressure too low Check pump gears for wear
or replace.

Inching pedal link maladjusted Readjust.
Seal rings worn in servo case Replace.
O-rings on input shaft worn Replace.
Plug on input shaft loose or slipped Repair.
No power
flow off, resulting in oil leaks
Clutch seized Replace.
Transmission
Shafts broken Replace.
Clutch drum, particularly snap ring Replace.
groove, defective
Snap ring fitted to clutch drum Replace.
broken
Oil line to clutch piston clogged Clean or replace.
Shaft splines worn Replace shafts.
Power train Broken parts in reduction and Refer to each section.

differential or front axle
Flexible plates broken Replace.

Bearings damaged Replace.
Torque Rubbing vanes of running members Replace.
converter Bolts loose Retighten or replace.
Splines worn Replace.
Oil pump worn Inspect or replace.
Abnormal
noise
Clutch seized and dragging Replace clutch plate.
Bearings worn or seized Replace.
Transmission Gears broken Replace.
Bolts loose Retighten or replace.
5-51
Oil strainer clogged Clean or replace.

Main regulator valve spool defective Wash or replace.
Restriction in oil pipe Replace.
Loud noise
Oil too viscous in cold weather Replace oil. *
Instruments out of order Replace.
Improper oil used Replace oil. *
Abnormal
noise Oil strainer clogged Clean or replace.
Oil pump defective Replace.
Excessive oil leaks
• Main regulator valve spring Replace.
defective
Low noise
• Main regulator valve spool Repair or replace.
defective
Air being sucked in Retighten or replace
packing.
Leaking oil seals Check lips and sliding surfaces for

wear. Replace seals.
Leaking joint of case Retighten or replace packing.
Leaking pipe connection or joint Repair or replace pipe, gasket and
O-rings.
Leaking drain plug Retighten or replace gasket.
Oil leaks Cracks or blowholes in case Replace.
Oil blowing out of transmission case
• Water in oil Replace oil.
• Air being sucked in on suction side Replace packing and retighten.
• Oil leaks from air breather Repair.
Oil level too high Lower oil level.
* (Refer to “Recommended Brands of Lubricants.”)
5-52
Oil level too high or too low Keep correct oil level.
Rubbing vanes of running members Repair or replace.
Stator freewheel defective Replace stator assembly.
Torque
converter O-ring.
Restriction in oil pipe (resulting in Repair or replace.
reduced circulation flow)
Bearings worn or seized Repair or replace.
Oil
temperature
is too high
Clutches dragging Replace clutch plates.
Transmission Bearings worn or seized Repair or replace.
Control linkage defective Repair or replace.
Truck not operated properly Advice user to drive truck

Others properly.
Others
• Cooling fan belt damaged Replace.
• Oil cooler clogged Clean or replace.
• Brakes grabbing Check and readjust.
Main regulator valve defective Repair or replace valve assembly.

Main pressure is too
high Oil viscosity too high in cold weather Replace oil. *
Magnet strainer clogged Clean or replace.

Coil spring defective in main regulator valve Replace.
Main pressure is too Main regulator valve spool defective Repair or replace.
low Air being sucked in Retighten or replace packing.
Inching valve out of order Repair or replace.
5-53

Oil pump worn or defective Replace.
Main regulator valve spool defective Repair or replace.
Clutch pressure is too packing.
low
Control linkage out of order Repair or replace.
Inching valve defective Repair or replace.
Seal ring broken in servo case Replace.
Clutch seal rings broken Replace.
Lack of engine power if the speed is slightly low in Tune up engine.

both forward and reverse drive
Stall speed out of
specification Stator and freewheel defective if the speed is Replace stator assembly.
excessively low in both forward and reverse drive
Inching pedal linkage defective, or clutch slipping Repair or replace.
if the speed is too high
Travel speed select switch in “Fixed 1st speed” Move switch to “Automatic
position 2-speed” position.
Solenoid valve defective Replace.
No automatic shifting
Solenoid valve inlet orifice clogged Clean or replace.
Solenoid valve spool or spring defective Repair or replace.
ECU control box internally defective Check or replace.
Transmission shifts up Harness open Repair.

when travel speed select
switch is in “Fixed 1st
speed” position Travel speed select switch defective Replace.
5-54
Service Data
Unit: mm (in.)
Truck Model
DP100 DP115 DP135 DP150
Item
Stall speed (tolerance: ±100 rpm) rpm A 1760
Main pressure (engine at 1500±100 rpm) MPa (kgf/cm2) [psi] A

1.08 to 1.37 (11 to 14) [156.4 to 199]
Clutch pressure (engine at 1500±100 rpm) MPa (kgf/cm2) [psi] A
Torque converter inlet pressure (engine at 1500±100 rpm)

A 0.05 to 0.49 (0.5 to 5.0) [7 to 71]
MPa (kgf/cm2) [psi]
Lubrication line pressure (engine at 1500±100 rpm)

A 0.02 to 0.15 (0.2 to 1.5) [3 to 21]
MPa (kgf/cm2) [psi]
10 m (33 ft) start acceleration (no load) A 5 seconds, maximum

0 0
A 100 − 0.035 (3.94 − 0.00138 )
Diameter of portion in contact with oil seal 1
B 99.85 (3.9311)
Pump boss
200721
− 0.007 − 0.00028
A 20 − 0.020 (0.79 − 0.00079 )
Diameter of portion in contact with engine flywheel 1
B 19.85 (0.7815)
Pilot boss
1
200411
5-55

Unit: mm (in.)
Truck Model
DP100 DP115 DP135 DP150
Item
A 0.040 to 0.078 (0.00157 to 0.00307)
Side clearance 1
B 0.09 (0.0035)
A 0.3 to 0.345 (0.0118 to 0.0136)
Top clearance 2
B 0.35 (0.0138)
Oil pump
1 205486
A 67.97 to 67.951 (2.6760 to 2.67523)

Outside diameter of clutch hub 1
B 67.8 (2.669)
A 10.185 to 10.2 (0.40098 to 0.402)
Diameter of clutch rollers 2
B 10.1 (0.398)
A 4.95 to 5 (0.1949 to 0.197)
Thickness of thrust washer 3
B 4.8 (0.189)
A 3.95 to 4 (0.1555 to 0.157)
B 3.8 (0.150)
A 2.9 to 3 (0.114 to 0.118)
B 2.8 (0.110)
A 4.9 to 5 (0.193 to 0.197)
B 4.8 (0.189)
Stator A 4.95 to 5 (0.1949 to 0.197)
B 4.8 (0.189)
3 4 1 2 5 6 7
200724
5-56

Unit: mm (in.)
Truck Model
DP100 DP115 DP135 DP150
Item
Face runout of flexible plates 1 A 0.2 (0.008)
(in free state) B 0.5 (0.020)
Distance between end face of torque converter
A 25 (0.984)
housing and mating face of flexible plate 2
Flexible 2
plates
1
200725
A 2.3±0.07 (0.091±0.0028)
Thickness of mating plate 1
B 2.1 (0.083)
A 2.6±0.1 (0.102±0.004)
Thickness of friction plate 2
B 2.2 (0.087)
Free movement of friction plate on gear 3 A 0.10 to 0.30 (0.0039 to 0.0118)
− 0.01 − 0.0004
A 4 − 0.03 (0.16 − 0.0012 )
Width of piston seal ring 4
B 3.5 (0.138)
+ 0.2 + 0.008
A 4 + 0.1 (0.16 + 0.004 )
Width of seal ring groove in piston 5
B 4.5 (0.177)
62.9 (2.48)
Free length of clutch spring 6 A
k = 39.1 (3.992) [223.5]
Clutches Spring constant: k = N/mm (kgf/mm) [lbf/in.]
B 60 (2.36)
6 2 1 3
5
210220
5-57

Unit: mm (in.)
Truck Model
DP100 DP115 DP135 DP150
Item
A 2.5±0.05 (0.098±0.0020)
Width of piston seal ring for input shaft 1
B 2.0 (0.079)
+ 0.2 + 0.008
A 2.5 + 0.1 (0.098 + 0.004 )
Width of piston seal ring groove in input shaft 2
B 3.0 (0.118)
+ 0.025 + 0.00098
Inside diameter of stator shaft in contact with seal A 35 0 (1.38 0 )
ring 3 B 35.2 (1.386)
A 2.5±0.05 (0.098±0.0020)
Width of seal ring for input shaft and countershaft 4
B 2.0 (0.079)
+ 0.2 + 0.008
Width of seal ring groove in input shaft and A 2.5 + 0.1 (0.098 + 0.004 )
countershaft 5 B 3.0 (0.118)
+ 0.025 + 0.00098
Inside diameter of transmission cover in contact A 35 0 (1.38 0 )
with seal ring 6 B 35.2 (1.386)
Width of clutch piston seal ring for input shaft and A 2.5±0.05 (0.098±0.0020)
Input shaft, countershaft 7 B 2.0 (0.079)
countershaft + 0.2 + 0.008
and Width of clutch piston seal ring groove in input A 2.5 + 0.1 (0.098 + 0.004 )
transmission shaft and countershaft 8 B 3.0 (0.118)
cover
4,5 1,2
6 7,8 3
210218
Remarks: The input shaft is shown. Items other than 1, 2 and 3 are common to the input shaft and
countershaft.
5-58
A: Standard value
Unit: mm (in.)
Truck Model
DP100 DP115 DP135 DP150
Item
Input gear and counter gear 1 A 0.12 to 0.28 (0.0047 to 0.0110)
Forward 1st speed gear and reverse 1st

A
speed gear 2
0.13 to 0.32 (0.0051 to 0.0126)
Forward 2nd speed gear and reverse 2nd
A
speed gear 3
Pump drive gear and idler gear 4 A

0.12 to 0.26 (0.0047 to 0.0102)
PTO drive gear and idler gear 5 A
4 5
3 2
Backlash of
gears R2 R1
F2 F1
2
210217
5-59

Unit: mm (in.)
Truck Model
DP100 DP115 DP135 DP150
Item
87.5 (3.44)
A
Free length of speed valve spring 1 k = 3.88 (0.396) [22.1]
Spring constant: k = N/mm (kgf/mm) [lbf/in.]
B 85 (3.35)
32.5 (1.28)
A
Free length of direction valve springs 2 k = 8.61 (0.8786) [49.2]
B 31.5 (1.24)
39 (1.53)
A
Free length of inching valve spring 3 k = 2.12 (0.217) [12.1]
B 38 (1.49)
28 (1.10)
A
Free length of return spring 4 k = 0.478 (0.0488) [2.73]
B 26.5 (1.04)
109.5 (4.31)
A
Free length of accumulator valve outer spring 5 k = 6.38 (0.651) [36.4]
B 107.5 (4.23)
154 (6.06)
A
Control Free length of accumulator valve inner spring 6 k = 6.86 (0.6998) [38.6]
valve Spring constant: k = N/mm (kgf/mm) [lbf/in.]
B 152 (5.98)
2
3
210208
5-60

Unit: mm (in.)
Truck Model
DP100 DP115 DP135 DP150
Item
112 (4.41)
A
Free length of main regulator valve spring 1 k = 4.99 (0.5087) [28.5]
B 109 (4.29)
Main
regulator
valve
1
210181
Inching pedal height (from frame to top end of

A 190 (7.48)
pedal) 1
Clearance between inching pedal cam follower and

A 14.5 (0.57)
brake control valve pedal 2
Protrusion of inching plunger with inching pedal

A 9 (0.35)
released 3
Protrusion of inching plunger when brake starts to

A 14 (0.55), minimum
be applied 4
Inching
pedal
control
2
3
4
210358
5-61
Specifications .......................................................................................... 6 – 1
Description ............................................................................................... 6 – 2
Torque Converter ...................................................................................... 6 – 2
Transmission ............................................................................................ 6 – 3
Power Flow ............................................................................................... 6 – 4
Control Valve ............................................................................................ 6 – 6
Main Regulator Valve ................................................................................ 6 – 6
Hydraulic Controls .................................................................................... 6 – 7
Speed Selector System ............................................................................ 6 – 8
Control System ......................................................................................... 6 – 9
6
Torque Converter .................................................................................... 6 – 12
Disassembly ............................................................................................. 6 – 12
Inspection ................................................................................................. 6 – 13
Reassembly .............................................................................................. 6 – 16
Transmission ............................................................................................ 6 – 18
Disassembly ............................................................................................. 6 – 18
Inspection ................................................................................................. 6 – 28
Reassembly .............................................................................................. 6 – 31
Control Valve ............................................................................................ 6 – 39
Disassembly ............................................................................................. 6 – 39
Inspection ................................................................................................. 6 – 40
Reassembly .............................................................................................. 6 – 41
Main Regulator Valve ............................................................................. 6 – 42
Disassembly ............................................................................................. 6 – 42
Inspection ................................................................................................. 6 – 42
Reassembly .............................................................................................. 6 – 42
Adjustment ............................................................................................... 6 – 43
Stall Speed Measurement ......................................................................... 6 – 47
10 m (33 ft) Start Acceleration Test ........................................................... 6 – 48
Travel Speed Select Switch ...................................................................... 6 – 49
Service Data ............................................................................................. 6 – 55
Specifications
Truck Model
DP100 DP115 DP135 DP150
Item
Torque converter Model MI 16
Direction control: Electric, column shift

Control
Speed control: Automatic
Transmission
Forward 1st: 2.402
Gear ratio 2nd: 1.010
Reverse 3rd: 0.532
6-1
Description
Torque Converter
7 5
2
From oil pump

4
1
8
To oil cooler
200550
1. Pilot boss 4. Turbine assembly 7. Pump (impeller)

2. Flexible plate 5. Stator 8. Stator shaft
3. Drive cover 6. Freewheel 9. Input shaft (transmission)
Oil for the operation of the torque converter is from the They allow the engine to turn fast while the truck
oil pump. It goes through outlet passage in the stator wheels are turning slowly. Thus, a high torque can be
shaft to the oil cooler, from which it goes to the applied, and the truck can accelerate. As the truck
transmission lubrication circuit. comes up to speed, the turbine begins to “catch up” the
The torque converter consists essentially of three pump (to cause the torque converter to act as a fluid
fundamental members: namely, the pump, turbine and coupling). When this happens, the oil leaving the
stator (reaction member). trailing edges of the turbine vanes is moving at about
the same speed as the pump. Now, the oil could pass
The pump is attached to the drive cover which in turn is
directly into the pump in a “helping” direction, without
driven by the engine through flexible plates. The
being given an assist by the stator. Under these
turbine is splined to the input shaft (of the
conditions, the stator vanes are in the way. The oil
transmission). The stator is attached to the stator shaft,
begins to hit the back sides of the stator vanes. To
with freewheel in between.
allow the stator vanes to move out of the way, the stator
The purpose of the stator is to cause the torque is mounted on a freewheeling mechanism (one-way
converter to multiply torque when the pump is turning clutch) that allows the stator to turn freely, or
faster than the turbine. This speed difference and “freewheel”, in only one direction.
increase in torque have the same effect as a low gear in
the manual transmission.
6-2
Transmission
11
10
9
F
2 2
R
5
3 1
6
207509
1. Flexible plate 5. Reverse clutch shaft 8. PTO drive gear

2. Torque converter assembly 6. 1st-speed/3rd-speed clutch 9. Pump idler gear
3. Input shaft shaft 10. Pump drive gear
4. Forward clutch shaft 7. Output shaft 11. Pump case
The transmission is the powershift type and has three

speeds forward and three speeds reverse. It has five
hydraulic clutches of the disc type.
6-3
Power Flow
Forward 1st Figures in ( ) indicate number of gear teeth.

(39)
(60)
(58)
(35)
(58) (34)
(42)
Forward 3rd
(24)
(58)
(58)
(35)
(56)
(34)
(58)
Forward 2nd
(60)
(58)
(54) (35) (31)
(34)
(53)
205618B

35 58 58 56
1st x x x 2.402
34 58 58 24
35 53
2nd x 1.010
34 54
35 58 58 31
3rd x x x 0.532
34 58 58 60
60 39
PTO gear x 0.929
42 60
6-4
Reverse 1st Figures in ( ) indicate number of gear teeth.

(39)
(60)
(34)
Reverse 3rd
(58)
(42)
(35)
(58)
(56) (34)
(58)
(60)
(35)
Reverse 2nd
(58)
(58)
(31)
(54)
(34)
(58)
(35)
(53)
205619B

35 58 56
1st x x 2.402
34 58 24
35 58 53
2nd x x 1.010
34 58 54
35 58 31
3rd x x 0.532
34 58 60
60 39
PTO gear x 0.929
42 60
6-5
Control Valve
Section A – A
3 4
A A B B
Section B – B 5
C C
6
Section C – C 1
205620
1. Accumulator valve 3. Inching valve plunger 5. Differential valve

2. Direction valve 4. 1st-speed valve 6. 2nd-speed/3rd-speed valve
10 9 8
7 6 5 4 3 2 1
200554A
1. Bolts 5. Spool 9. Main pressure port

2. Cover 6. Body 10. Torque converter inlet
3. O-ring 7. Spring pressure port
4. Slug 8. Drain port
6-6
Hydraulic Controls
Accumulator valve
Pressure at start of
Torque converter charging: 0.34 MPa
(3.5 kgf/cm2) [50 psi]
Last chance filter
Chassis area Pressure at end of
230 μ
Speed selector valve charging: 0.71 MPa
S2 (2nd/3rd speed) (7.2 kgf/cm2) [102 psi]
Orifice:Diam.0.8 mm Orifice: Diam. 0.8 mm Main orifice: Diam. 1.8 mm
Diam. 6 mm (0.031 in.) (0.031 in.) (0.071 in.)
Oil cooler (0.24 in.) Differential valve
Torque converter
bypass orifice: Speed selector valve Setting: 0.20 MPa
Diam. 4.0 mm (0.157 in.) S1 (1st speed) (2.0 kgf/cm2) [28 psi]
Last
chance Response (inching) valve
Torque converter inlet filter 230 μ Setting: 0 to 0.22 MPa
relief valve Oil filter (0 to 2.2 kgf/cm2)
Setting: 0.15 to 0.69 MPa [0 to 31.3 psi]
(1.5 to 7.0 kgf/cm2)
6-7
[21 to 100 psi] Tap (plug) for
torque
Lubrication relief valve converter inlet
Setting: 0.02 to 0.10 MPa pressure
(0.2 to 1.0 kgf/cm2) (marked “T”)
[3 to 14 psi] Oil filter for forward/ PS
Tap (plug) for reverse clutches (marked “S”)
main pressure (particle size 95 μ)
Oil pump (marked “M”)
Lubrication PD Solenoid valve
Capacity: 70 liters (18.5
line (marked “D”) (direction selection)
U.S. gal.)/min
Main regulator valve
at 2300 rpm
C2 CF R C3 C1 Setting: 1.08 to 1.27 MPa
(11.0 to 13.0 kgf/cm2)
Suction strainer [156 to 185 psi]
with magnet 100 mesh
(particle size 220 μ)
Transmission oil reservoir
Last chance filter 230 μ Last chance filter 230 μ

Solenoid valve
(direction selection) Orifice: Diam. 0.8 mm (0.031 in.) Orifice: Diam. 0.8 mm (0.031 in.)
205924
Speed Selector System
1st speed clutch

Electronic Control Unit Travel speed
Output (ECU) (solenoid) valve
2nd/3rd speed
gear clutch
Electric signal
Travel speed sensor
0.5 mm Hydraulic pressure signal
(0.02 in.) Transmission case
Control system
D Electronic Control Unit

(ECU)
Travel speed
select switch
Power
source
1
Solenoid
valves
Travel speed sensor
210360
Location of components
The speed selector system is made up of an Electronic Unit: km/h (mph)

Control Unit (ECU), a travel speed sensor and two speed Select switch Travel speed
selector valves, one for 2nd and 3rd speeds and the other position (mode) DP100, DP115 DP135, DP150
for 1st speed. 1st 0 to 6.5 0 to 6
(0 to 4.0) (0 to 3.7)
The selection of three modes “Fixed 1st speed”, Automatic 2nd 6.5 to 15 6 to 12.5
“Automatic 2-speed” and “Automatic 3-speed” is done 3-speed D (4.0 to 9.3) (3.7 to 7.8)
manually by means of the travel speed select switch. 15 to 31.5 12.5 to 33
3rd (9.3 to 20.5) (7.8 to 20.5)
1st 0 to 6.5 0 to 6
Automatic (0 to 4.0) (0 to 3.7)
2-speed 2 6.5 to 18.5 6 to 19
2nd (4.0 to 11.5) (3.7 to 11.8)
Fixed 1st speed 0 to 8 0 to 8.5
1 (0 to 5.0) (0 to 5.3)
6-8
Control System
N 2
F
7
5
10
5 6 3
206579
1. Transmission shift lever 6. Inching valve plunger

2. Inching bracket 7. Inching lever
3. Control valve 8. Inching cable
4. Travel speed (solenoid) valve 9. Electronic Control Unit (ECU)
5. Direction (solenoid) valve 10. Inching pedal
6-9

To remove the transmission assembly from the truck,
remove it together with the engine. Refer to “GROUP 4
POWER TRAIN.”
Transmission removal
(1) To separate the transmission from the engine, put the
engine on a stable stand, and support the transmission
with wood blocks.
(2) Remove the hydraulic pump from the transmission.
(3) The transmission has three lifting eyes, two eyes on the
differential side and one eye on the torque converter
side.
To lift the transmission, fasten two slings to the
differential side eyes and one sling (chain with lever
block) to the torque converter side eye. Balance the
transmission with the lever block and lift it at three
points just enough to take the weight of the
transmission.
(4) Remove the bolts that hold the flexible plates through
the access hole in the torque converter housing.
(5) Separate the transmission from the engine by lifting it
with a hoist.
210361
Torque converter removal

To remove the torque converter assembly from the
transmission, slide the splines of the stator shaft, PTO drive
gear and input shaft away from the mating splines.
NOTE
Remove the drain plug of the torque converter and
drain the oil.
6-10
Torque converter installation

(1) Couple the torque converter to the transmission. Make
sure that the distance between the end face of the 25 mm (0.984 in.)
torque converter housing and the mating face of the
flexible plates is 25 mm (0.984 in.). If this distance is
more than 25 mm (0.984 in.), it is an indication that
spline engagement between the torque converter stator
shaft and transmission input shaft is improper; re-
couple the torque converter to the transmission.
(2) Lift the transmission, and couple it to the engine.
(3) Make sure that the clearance between the flywheel and
flexible plates is 0 to 2 mm (0 to 0.08 in.) when the
transmission is coupled to the engine.
(4) Tighten the bolts that hold the flexible plates to the
flywheel through the access hole in the torque 200557
converter housing. The bolts should be tightened
evenly in a crisscross pattern. When tightening those
bolts, turn the torque converter with a heavy-duty
screwdriver put to the bolts.
(5) Mount the transmission harness.
Connect the travel speed sensor at the connector side,
and connect the torque converter thermounit at the F solenoid
terminal side.
Connect the F and R changeover solenoid valves
respectively to the terminals with F and R
identification marks at their roots.
There are two kinds of the travel speed solenoid valve,
S1 and S2. Connect the S2 solenoid to the terminal
marked 2, and the S1 solenoid to the terminal which
has no mark. The remaining terminal is for grounding.
Solenoid Valve Harness Wire Color

S1 RY R solenoid
Travel speed
S2 RB
F LgR
Transmission shift lever
R Br S2 solenoid S1 solenoid 206070
(6) Pour in the torque converter oil.
6-11
Torque Converter
Disassembly
6
3
7
3
4
205626
Sequence
1. Bolts, Washers, Plate 5. Thrust washers, Thrust bearing
2. Flexible plates, Pilot boss, O-ring, Bolts, 6. Stator, Rollers, Hub, Springs, Spring caps,
Washers Thrust washers
3. Bolts, Drive cover, Ball bearing, Plug, Gasket, 7. Ball bearing, O-ring, Pump boss, Pump
Washers (impeller), Snap ring, Bolts, Washers
4. Spacer, Turbine
6-12

To remove the stator assembly, slightly force the stator just
like turning it counterclockwise to prevent the rollers from
falling and pull the stator together with the hub by sliding
the splines.
204530
Inspection
1. Pump (impeller)
(1) Check for cracks.
(2) Check for oil leaks due to looseness of the bolts holding
the boss to the pump, or defective O-ring.
(3) Check the face of the pump boss in contact with the oil
seal for wear.
(4) Check the face of the pump boss in contact with the
seal ring.
Oil seal O-ring

Seal ring
200561
6-13
2. Stator
(1) Check the blades for cracks. Also check the fit of the
stator on the clutch cam.
(2) Check the clutch hub and cam for wear or flaws.
(3) Check the springs for damage. Also check the spring
caps for wear or distortion.
(4) Check the rollers for flaws, distortion or flat spots due
to wear.
(5) Check the clutch hub splines for defects.
(6) Check the thrust washers for wear or other defects.

Unit: mm (in.)
A 67.951 to 67.97
Outside diameter of (2.67523 to 2.6760)
clutch hub 1
B 67.8 (2.669)
A 10.185 to 10.2
Diameter of clutch (0.40098 to 0.402)
rollers 2
B 10.1 (0.398) 3 4 1 2 5 6 7
A 4.95 to 5
washer 3
B 4.8 (0.189)
A 3.95 to 4
Thickness of thrust (0.1555 to 0.157) 200724
washer 4
B 3.8 (0.150)
A 2.9 to 3
washer 5
B 2.8 (0.11)
A 4.9 to 5
washer 6
B 4.8 (0.189)
A 4.95 to 5
washer 7
B 4.8 (0.189)
6-14
3. Turbine
(1) Check the vanes for cracks.
(2) Check the fit of the turbine boss in the turbine.
(3) Check the turbine boss splines for wear or other
defects.
4. Pilot boss
Check the surface in contact with the pilot bearing for wear
or other defects.
A: Standard value B: Repair or service limit 1
Unit: mm (in.)
− 0.007 − 0.00028
Diameter of portion in A 20 − 0.020 (0.79 − 0.00079 )
contact with engine
flywheel 1 B 19.85 (0.7815)
200411
6-15
Reassembly
1 10
13
11
4
2
9
3
7 12
13
5
205643
Sequence
1. Pump (impeller) 8. Thrust washer
2. Pump boss, O-ring, Bolts, Washers 9. Thrust bearing, Thrust washers
3. Ball bearing, Snap ring 10. Turbine
4. Stator assembly 11. Drive cover, O-ring, Bolts, Washers
5. Springs, Spring caps 12. Spacer, Ball bearing, Pilot boss, O-ring, Bolts,
6. Rollers Washers
7. Hub 13. Flexible plates, Plate, Bolts, Washers
6-16
1. Stator assembly
5 5
(1) Put hub 7 in the stator as shown. Put spring 5 and
spring cap 5 in each hole, and press in roller 6 while
pushing the spring cap.
6
(2) Install a total of ten rollers, and restore the hub to its
original position.
(3) After having assembled the stator, turn the hub by
hand, making sure that it rotates in only one direction.
7 202885A
2. Selection of spacer
Measure the dimensions A, B and C. Select a spacer equal
to the clearance (dimension D) and put it in position.
A
Part number Thickness of spacer
92322 - 14700 2.9 mm (0.114 in.)
92322 - 14800 3.0 mm (0.118 in.)
92322 - 14900 3.2 mm (0.126 in.) B
D C
92322 - 06600 3.4 mm (0.134 in.) 204534
92322 - 06700 3.5 mm (0.138 in.)
A 26.3 (1.035)
Standard dimensions B 19 (0.75)
mm (in.)
0 0
C 4 − 0.1 (0.16 − 0.004 )
3. Flexible plate
After having installed the flexible plate, measure the face
runout of the plates with a dial indicator. Replace the
plates if the runout has exceeded the service limit.
Unit: mm (in.)
A 0.2 (0.008)
Face runout of flexible
plate (in free state)
B 0.5 (0.020)
205922
6-17
Transmission
Disassembly
4
8
5
6 3
8
7
2
1
14
17
11
10
16
18
15
9 12
9
13
210362
Sequence
1. Air breather 10. Oil filter
2. Oil level gauge, Plug, Gasket 11. Travel speed sensor cover,
3. Oil pipe, Eye bolt, Gaskets Travel speed sensor, Bolts, Washers
4. Inching bracket, Spring 12. Thermounit
5. Main regulator valve, Gasket, Bolts, Washers 13. Drain plug, Gasket
6. Oil pipe, O-rings, Bolts, Washers 14. Suction pipe, O-rings, Bolts, Washers
7. Control valve, Gasket, O-rings, Bolts, 15. Cover, O-ring, Bolts, Washers
Washers 16. Magnet strainer assembly
8. Oil pipes, Eye bolts, Gaskets 17. Bracket, Bolts, Washers
9. Oil pipes, Eye bolts, Gaskets 18. Bracket, Bolts, Washers
6-18
2. Transmission cover and shafts
12
13
23
24
22
21
20
11
4
16 19
17
14
15
18 9
8
6
10
4
3
5 1,2
207510
Sequence
1. Servo case, O-ring, Bolts, 7. Output gear (53 teeth) 15. Output shaft
Washers 8. Output gear (31 teeth) 16. Travel speed sensor gear,
2. Servo case, O-ring, Bolts, 9. Snap ring Lock plate, Bolts
Washers 10. Baffle plate, Bolts, Washers 17. Ball bearing
3. Servo case, O-ring, Bolts, 11. 1st-speed/3rd-speed clutch 18. Output gear (56 teeth)
Washers shaft assembly 19. Snap ring
4. Transmission cover 12. Forward clutch shaft 20. Nut
subassembly, Gasket, assembly 21. Input gear
O-rings, Bolts, Washers 13. Reverse clutch shaft 22. Snap ring
5. Oil seals assembly 23. Input shaft
6. Ball bearing 14. Baffle plate, Bolts, Washers 24. Ball bearing
6-19
1. Transmission cover subassembly 4 removal

holes in the cover evenly until the cover is approximately
25 mm (1 in.) apart (the bearings get out of place). Then
remove the cover. Do not attempt to remove the lubrication
line relief valve from the cover.
Special tool needed
Bolt 67284 - 15400
205629
2. Output gear (outside) 7 removal

Remove the output gear together with ball bearing 6 with a Output gear
gear puller. Sliding hammer
3. Output shaft 15 removal

Turn a sliding hammer in the M10 x 1.25 hole in the end of
the output shaft, and remove the shaft together with the
output gear, ball bearing and travel speed sensor gear.
205480
4. Ball bearing 17 removal

Remove the output shaft with a press and a tooling as
shown, or remove the gear with a puller, to remove the
bearing.
Tooling
205630
5. Nut 20 removal
Straighten the locking tab of the nut away from the flat of
the input shaft and remove the nut with a socket wrench and
an impact wrench. When removing the nut, hold the
splined end of the input shaft with a pipe wrench, or put a
bar to the input gear in such a manner as to prevent the shaft
from turning counterclockwise.
6-20
30
31
32
29
33 37
26 25
42
27 36
43
28
27
39
38
40
41
35
44
47
45
34
46
205631
Sequence
25. PTO cover, O-ring, Bolts, Washers 36. Idler gear shaft
26. Snap ring 37. Roller bearing
27. Pump drive gear, Seal rings 38. PTO drive gear
28. Ball bearing 39. Ball bearing
29. Pump case, O-ring, Bolts, Washers 40. Ball bearing
30. Pump plate, O-ring, Gasket, Bolts, Washers 41. Stator shaft, Seal ring, Bolts, Washers
31. Internal gear 42. Pump idler gear
32. Pump gear 43. Roller bearing
33. Ball bearing 44. Roller bearing (outer race)
34. Torque converter housing, Gasket, Bolts, 45. Roller bearing (outer race)
Washers 46. Roller bearing (outer race)
35. Oil seal 47. Transmission case, Dowels
6-21
1. Torque converter housing 34 removal

holes in the housing evenly until the housing is
approximately 18 mm (0.7 in.) apart (the PTO drive gear
ball bearing gets out of place). Fasten a hoist to the housing
and remove the housing.
Special tool needed
Bolt 67284 - 15400
2. Oil pump removal

Remove the oil pump as a subassembly including pump
case 29, pump plate 30, internal gear 31 and pump gear 32.
3. Idler gear shaft 36 removal

Turn the Shaft Puller (special tool) in the shaft hole. Install M20 × 1.5
the sliding hammer (used in removing output shaft 15) to
M10 × 1.25
this Puller and remove the shaft.
Special tool needed 36
Shaft puller To be made by dealer
210188
4. PTO drive gear 38 removal

Grip ball bearing 39 with a gear puller. Put a protective
plate on the end of the stator shaft and remove the gear
38
together with two ball bearings.
210193
6-22
5. Stator shaft 41 removal

holes in one end of the shaft evenly, or hit the other end by
using a protective plate.
Special tool needed
Bolt 67284 - 15400
6. Roller bearing outer race removal

Do not remove the outer races 44, 45 and 46 of the roller
bearings installed in the transmission case and the outer
race of roller bearing 43 installed on idler gear shaft 36
unless they are defective.
6-23
4. Forward clutch shaft subassembly
5 12
13
15
4
14
3
2 16
1
14
15
13
12
11
10
6
7
11 11
8
9
10
11
207511
Sequence
4. Gear (2nd-speed drive), Needle roller bearings 13. Clutch springs
5. Thrust washer 14. Clutch pistons, Steel balls, Screws,
6. Roller bearing Piston seals
8. Gear (forward drive), Needle roller bearings 16. Forward clutch shaft
NOTE
Do not attempt to remove the screws from the forward
clutch shaft. It is not necessary to disassemble clutch
pistons 14 if the balls move freely in the pistons when
the pistons are shaken.
6-24
1. Ball bearing 2 removal

Grip 2nd-speed drive gear 4 with a gear puller and remove
the bearing together with the gear and thrust washer 3.
2. Roller bearing 6 removal

Grip forward drive gear 8 with a gear puller and remove the
bearing together with the gear and thrust washer 7.
3. Input shaft disassembling

A
compress clutch spring 13 and retainer 12, and remove
snap ring 12.
Special tool needed
207504
6-25
5. 1st-speed/3rd-speed clutch shaft subassembly
5 12
13
4 15
14
3
2 16
1
14
15
13
12
11
10
6
11 7
11 8
9
10
11
207512
Sequence
4. Gear (3rd-speed drive), Needle roller bearings 13. Clutch springs
5. Thrust washer 14. Clutch pistons, Steel balls, Screws,
6. Roller bearing Piston seals
8. Gear (1st-speed drive), Needle roller bearings 16. 1st-speed/3rd-speed clutch shaft

NOTE
Do not attempt to remove the screws from the 1st- For disassembly, make reference to the disassembly of
speed/3rd-speed clutch shaft. It is not necessary to the forward clutch shaft.
disassemble clutch pistons 14 if the balls move
freely in the pistons when the pistons are shaken.
6-26
6. Reverse clutch shaft subassembly
9
10
12
11
13
2
1
3
4
8
5
6
7
207513
Sequence
1. Seal rings 8. Friction plates, Mating plates
2. Ball bearing 9. Snap ring, Retainer
3. Roller bearing 10. Clutch spring
4. Thrust washer 11. Clutch piston, Steel balls, Screws, Piston seal
5. Gear (reverse drive), Needle roller bearings 12. Seal ring
6. Thrust washer 13. Reverse clutch shaft
7. Snap ring, Pressure plate

NOTE
Do not attempt to remove the screws from the For disassembly, make reference to the disassembly of
reverse clutch shaft. It is not necessary to the forward clutch shaft.
disassemble clutch piston 11 if the balls move freely
in the piston when the piston is shaken.
6-27
Inspection
1. Oil pump
(1) Put the internal gear and pump gear in the pump case,
and measure top clearance 2.
(2) Using a dial indicator, measure side clearance 1
between the gears and pump case.
Unit: mm (in.)
0.040 to 0.078
A 2
(0.00157 to 0.00307)
Side clearance 1
B 0.09 (0.0035) 1
205486
0.3 to 0.345
A
(0.0118 to 0.0136)
Top clearance 2
B 0.35 (0.0138)
2. Stator shaft
(2) Check the oil passages for clogging.
3. Friction plates and mating plates

(1) Check for sign of seizure, uneven contact, warpage or
excessive wear.
4. Clutch drums
(1) Check the mating plate sliding surfaces for wear or
damage.
(2) Check the clutch piston sliding surfaces for wear or
damage.
6-28
5. Gears
7,8
(1) Check the gear and splines for wear or damage.
(2) Check the gear surface in contact with the needle roller
bearings for wear or damage.
Unit: mm (in.)
2.3±0.07
A
Thickness of mating (0.091±0.0028)
plate 1 6 2 1 3
B 2.1 (0.083)
4
2.6±0.1
A
Thickness of friction (0.102±0.004)
plate 2
B 2.2 (0.087)
5
Free movement of 0.10 to 0.30 207514
A
friction plate on gear 3 (0.0039 to 0.0118)
− 0.01 − 0.0004
A 4 − 0.03 (0.16 − 0.0012 )
ring 4
B 3.5 (0.138)
+ 0.2 + 0.008
A 4 + 0.1 (0.16 + 0.004 )
ring groove in piston 5
B 4.5 (0.177)
Free length of clutch 62.9 (2.48)

A
spring 6 k = 39.1 (3.992) [223.5]
Spring constant:
k = N/mm (kgf/mm)
B 60 (2.36)
[lbf/in.]
2.5±0.05
A
Width of clutch piston (0.098±0.0020)
seal ring 7
B 2.0 (0.079)
+ 0.2 + 0.008
A 2.5 + 0.1 (0.098 + 0.004 )
Width of clutch piston
seal ring groove 8
B 3.0 (0.118)
6-29
6. Forward clutch shaft, reverse clutch shaft and 1st-

speed/3rd-speed clutch shaft
(1) Check the seal rings and seal ring contact surfaces of
the shaft and servo cases for wear or damage.
Unit: mm (in.)
1,2
2.5±0.05
A
Width of piston seal ring (0.098±0.0020)
for each clutch shaft 1
B 2.0 (0.079) 3
+ 0.2 + 0.008
Width of piston seal ring A 2.5 + 0.1 (0.098 + 0.004 )
groove in each clutch
shaft 2 B 3.0 (0.118)
+ 0.025 + 0.00098
Inside diameter of each A 35 0 (1.38 0 )
servo case in contact with
seal ring 3 B 35.2 (1.386) 205635

(3) Check oil passages for clogging.
7. Gears
Check each gear for worn teeth or splines.
8. Magnet strainer assembly

Disassemble and clean the strainer. Replace the strainer if
defective.
9. Transmission cover and torque converter housing

oil seals
Replace the oil seals with new ones.
6-30
Reassembly
1. Forward clutch shaft subassembly
(1st-speed/3rd-speed clutch shaft subassembly/reverse clutch shaft subassembly)
16 5 10 9 78 4 7 8 4 9 10 5 11
6
6
14 15
21
20 13
19 18 17 2 3 2 12
207515
Sequence
1. Forward clutch shaft (1st-speed/3rd-speed 11. Thrust washer, Snap ring
clutch shaft or reverse clutch shaft) 12. Needle roller bearings
2. Sealing rings, Piston seals 13. Gear (forward drive)
3. Pistons 14. Thrust washer
4. Springs 15. Roller bearing
5. Retainers 16. Thrust washer
6. Snap rings 17. Needle roller bearings
7. Mating plates 18. Gear (2nd-speed drive)
8. Friction plates 19. Thrust washer
9. Pressure plates 20. Ball bearing
10. Snap rings 21. Seal rings
NOTE
The reassembly sequence and suggestions for the
reverse clutch shaft subassembly are similar to the
forward clutch shaft subassembly as far as the clutch is
concerned.
6-31
1. Piston installation
When putting pistons 3 in the clutch drum, apply ATF
(automatic transmission fluid) to their seal ring contact
surfaces.
2. Return spring installation

A
compress springs 4 and retainers 5, and install snap rings 6.
Special tool needed
207504
3. Friction and mating plate installation

Mating plate
(1) Make sure that the position and number of the plates are Friction plate
correct. Install the plates while applying ATF to them.
When replacing the friction plates, replace the mating
plates, too.
207516
(2) Thrust washer installation

Install thrust washers 11, 14, 16 and 19 with the side
that has oil grooves toward the gear.
203800
4. Piston testing
After having assembled the clutch, apply air pressure of
approximately 690 kPa (7 kgf/cm2) [100 psi] to the oil hole
to make sure that the piston moves freely without any sign
of air leaks.
6-32
15 16
12
18
19 17
14 20
1 13
3
9
10
4
6
5 11
205638
Sequence
1. Transmission case, Dowels 8. Idler gear shaft 15. Pump plate, O-ring,
2. Roller bearing 9. Roller bearing Gasket, Bolts, Washers
3. Idler gear 10. Oil seal 16. Ball bearing
4. Stator shaft, Seal ring, 11. Torque converter housing, 17. Pump drive gear,
Bolts, Washers Gasket, Bolts, Washers Seal rings
5. Ball bearing 12. Pump case, O-ring, Bolts, 18. Ball bearing
6. PTO drive gear Washers 19. Snap ring
7. Ball bearing 13. Internal gear 20. PTO cover, O-ring,
14. Pump gear Bolts, Washers
NOTE
The dowels fitted into the transmission case should not
been removed. These dowels are for locating the pump
case, torque converter housing and transmission cover
subassembly for installation.
6-33
1. PTO drive gear 6 installation

Install ball bearings 5 and 7 to PTO drive gear 6. Install
the gear to stator shaft 4.

Unit: mm (in.)
Replace the oil seal with a new one. To install the new oil
seal, use the Installer (special tool).
ø98.5 (3.88)
ø140 (5.51)
Special tool needed
ø40 (1.57)
13 (0.51) 8 (0.31)
150 (5.91)
205491
3. Oil pump assembling

Put internal gear 13, pump gear 14 and pump plate 15 in
pump case 12. Apply oil to the internal gear and pump
gear. Do not forget to install the O-ring.
4. Oil pump subassembly installation

Do not forget to put the gasket and the O-ring for the oil
hole when installing the oil pump subassembly.
5. Pump drive gear 17 installation

Install ball bearing 16 on pump drive gear 17. Install two
seal rings in position and apply oil to these seal rings. Then
drive the gear assembly into the transmission case with the
splines in alignment with those of pump gear 14.
6. Ball bearing 18 installation

Unit: mm (in.)
2 − ø13 (0.51)
When installing ball bearing 18 in pump case 12, hold the
pump drive gear with the Pump Drive Gear Holder (special
15
tool), or have someone press the gear with a copper bar or

4(
the like, in order to prevent the gear from coming off.

6.0
6
)
Special tool needed

ø4
ø1
0(
24
Pump drive gear )

ø1
To be made by dealer 39
1.5
.9
holder (0. 1)
80
(4.
0
7)
1 (0.3
(7.
8
17
09
9)
)
(0.3 28 0)
1
10 (1.
205492
6-34
3. Shafts and transmission cover
45 21
37
26
25
28
39 24
46
27
47 22
38
23
44
43 42 41 40 34 36 29 35 30 31 32 33
207517
6-35
Sequence
21. Roller bearing (outer race) 35. Baffle plate, Bolts, Washers
22. Roller bearing (outer race) 36. Baffle plate, Bolts, Washers
23. Roller bearing (outer race) 37. Forward clutch shaft subassembly
24. Ball bearing 38. 1st-speed/3rd-speed clutch shaft subassembly
25. Input shaft 39. Reverse clutch shaft subassembly
26. Snap ring 40. Output gear (31 teeth)
27. Input gear 41. Output gear (53 teeth)
28. Nut 42. Ball bearing
29. Output shaft 43. Oil seals
30. Snap ring 44. Transmission cover subassembly, Gasket,
31. Output gear (56 teeth) Bolts, Washers, O-rings
32. Ball bearing 45. Servo case, O-ring, Bolts, Washers
33. Travel speed sensor gear, Lock plate, Bolts 46. Servo case, O-ring, Bolts, Washers
34. Snap ring 47. Servo case, O-ring, Bolts, Washers
1. Input shaft 25 assembling and installation

(1) Install ball bearing 24 on the input shaft, then install
the shaft in the transmission case.
(2) Tighten nut 28 to the specified torque and bend it
against the flat of the input shaft for locking. When
tightening the nut, hold the torque converter side of the
shaft with a pipe wrench, or put a bar to input gear 27
in such a manner as to prevent the shaft from turning
clockwise.
294 to 392 N·m

Tightening torque for nut (30 to 40 kgf·m)
[217 to 289 lbf·ft]
2. Output shaft 29 assembling and installation

Assemble output shaft 29, snap rings 30 and 34, output
gear 31, ball bearing 32 and travel speed sensor gear 33 in
a subassembly. Install the subassembly in the transmission
case. Use a new lock plate for the bolts that hold the travel
speed sensor gear.
6-36

Replace two oil seals with new ones. Apply grease to the Transmission cover
lips of the oil seals and, using the Oil Seal Installer (special
tool), install the seals in position with the lips toward inside.
205494
Special tool needed Unit: mm (in.)

1 (0.04) chamfer
ø68.5 (2.70)
ø94.5 (3.72)
ø108 (4.25)
(1.57)
ø40
10 (0.39) 28 (1.10)
170 (6.69)
1.5 (0.06) 205495
4. Transmission cover installation

Install hooks in the jack bolt holes in the transmission cover
and hitch slings to these hooks. Put the gasket on the
transmission case. Hoist the cover and install it in position.
Do not forget to put the O-rings in the oil holes.
205640
5. Servo cases 45, 46 and 47 installation

When installing the servo cases, apply oil to the inside
surfaces of the cases and the seal rings of the shafts. Do not
forget to install the O-rings to the cases.
6-37
13
8
12
11 14
8 10
15
16
18
1
17
2
7 4
7
3
210363
Sequence
1. Magnet strainer assembly 10. Control valve, Gasket, O-rings, Bolts, Washers
2. Cover, O-ring, Bolts, Washers 11. Oil pipe, O-rings, Bolts, Washers
3. Plug, Gasket 12. Main regulator valve, Gasket, Bolts, Washers
4. Thermounit 13. Inching bracket, Spring
5. Travel speed sensor cover, 14. Oil pipe, Eye bolt, Gaskets
Travel speed sensor, Bolts, Washers 15. Oil level gauge, Plug, Gasket
6. Suction pipe, O-rings, Bolts, Washers 16. Air breather
7. Oil pipe, Eye bolt, Gaskets 17. Bracket, Bolts, Washers
8. Oil pipe, Eye bolt, Gaskets 18. Bracket, Bolts, Washers
9. Oil filter
6-38
Control Valve
Disassembly
1
3
4
5
19 18
21 9 4
A
18 6
21
2 A
1
16
14
15 7
20 17
14
11
10
13
12 205641
Sequence
1. Solenoid valves, O-rings 7. Stopper pin, O-ring 14. Pin, Seat, O-ring
(two) 8. Inching valve plunger, Spring 15. Oil filter, O-rings
2. Springs, Spring seats 9. Inching valve, Slug, Spring 16. Last chance filters (four)
3. Direction valve 10. Roller bearing, Plug, O-ring 17. Roller bearing, Plug
4. Solenoid valves, O-rings 11. Spring, Differential valve 18. Roller bearing, Plug
(two) 12. Plate, O-ring, Bolts, Washers 19. Plug, O-ring
5. 2nd-speed/3rd-speed valve, 13. Accumulator valve piston, 20. Oil seal
Spring Springs (inner and outer) 21. Valve body, Gasket
6. 1st-speed valve, Spring
CAUTION
Slowly loosen each bolt and solenoid valve so that
the spring and plunger do not suddenly jump out.
6-39
Stopper pin 7 removal

Turn a screw in the M4 x 0.7 hole in the stopper pin and
carefully remove the pin because removal of the stopper pin
will cause inching valve plunger 8 to fly out.
Inspection
(1) Check the oil holes in the valve body for restriction.
(2) Replace all oil seals with new ones.
(3) Check the orifices in the inching valve for restriction.
Also check the inching valve springs for fatigue or
damage.
(4) Replace oil filter 16 with a new one.
(5) Wash oil filter 15, or replace it with a new one.
200220
Unit: mm (in.)
Free length of selector valve 36.5 (1.44)
A
springs 1 k = 5.658 (0.577) [32.3]
7 7
Spring constant:
28 (1.10)
Free length of return spring 2 A
k = 0.478 (0.0488) [2.73] 1
Spring constant:
k = N/mm (kgf/mm) [lbf/in.] 4
B 26.5 (1.04)
Free length of differential valve 59.5 (2.34)

A
spring 3 k = 2.311 (0.2357) [13.2] 2
Spring constant:
3 1
Free length of inching valve 39 (1.53)
A
spring 4 k = 2.128 (0.217) [12.1]
Spring constant: 6 5
205707
Free length of accumulator 125.5 (4.94)
A
valve outer spring 5 k = 5.363 (0.5469) [30.6]
Spring constant:
Free length of accumulator 170.5 (6.71)

A
valve inner spring 6 k = 4.128 (0.4210) [23.5]
Spring constant:
Free length of direction valve 32.5 (1.28)

A
springs 7 k = 8.616 (0.8786) [49.2]
Spring constant:
6-40
Reassembly
19 12 4 18 19
20
14 20
15
6
Section A – A
A A B B
5 17
Section B – B
13
21 11 17
10 C
C
9 16
7
Section C – C
8 3 1
210196
Sequence
1. Valve body 12. Spring, Inching valve, Slug
2. Oil seal 13. Spring, inching valve plunger
3. Plug, Roller bearing 14. Stopper pin, O-ring
4. Plug, Roller bearing 15. 1st-speed valve, Spring
5. Last chance filters (four) 16. 2nd-speed/3rd-speed valve, Spring
6. Oil filter, O-ring 17 Solenoid valves, O-rings (two)
7. Seat, O-ring, Pin 18. Direction valve
8. Springs (inner and outer), Accumulator piston 19. Spring seats, Springs
9. Plate, O-ring, Bolts, Washers 20. Solenoid valves, O-rings (two)
10. Differential valve, Spring 21. Plug, O-ring
11. Plug, O-ring, Roller bearing
Start by:
Wash the oil passages in the control valve thoroughly and
make sure they are not restricted.

(2) Apply ATF (automatic transmission fluid) to the valves
and plungers when installing them in the valve body.
6-41
Disassembly
5
2
6 4 3
210180
Sequence
1. Cover, O-ring, Bolts, Washers 4. Spring
2. Slug 5. Cover, O-ring, Bolts, Washers
3. Spool 6. Body
CAUTION
Slowly loosen bolts 1 so that the spring, spool
and slug do not suddenly jump out.
Inspection Reassembly
(1) Check the oil holes in the valve body for To reassemble, follow the reverse of disassembly
restriction. sequence.
(2) Check the valve spool for wear or damage. Make
sure the spool moves freely. Suggestion for Reassembly
(3) Check the spring for damage. Measure the free
Apply oil to the spool and slug when putting them in
length of the spring.
the body.
Unit: mm (in.)
Free length of main 112 (4.41)
A
regulator valve spring k = 4.99 (0.5087) [28.5]
Spring constant:
k = N/mm (kgf/mm)
B 109 (4.29)
[lbf/in.]
6-42
Adjustment
Brake pedal and inching pedal adjustment
Adjust the brake pedal before adjusting the inching pedal.
1. Brake pedal adjustment
190 mm (7.5 in.)

Bring the roller 1 of the brake pedal into contact with the
1
pedal 2 of the brake control valve 2 by means of the
adjusting bolt 4. Under this condition, the top height of the
4
pedal from the floor level will be approximately 190 mm 3
(7.5 in.).
NOTE: The set angle (39±1.5°) of the brake valve must be

2
kept unchanged.
210611
6 mm
2. Inching pedal adjustment (0.24 in.) 4
(1) With the clutch valve plunger 1 pushed in all the way 3 1 2
[6 mm (0.24 in.) allowed for protrusion], attach the
transmission side return spring 2 to the inching lever 3
and inching bracket 4. 5
(2) Connect the inching cable 5 to the inching bracket 4,

then attach the clevis 6 to the inching lever 3.
6 210612
(3) Attach the pedal side turnbuckle 7 to the inching pedal 12

190 mm (7.5 in.)
11
arm 8 and vehicle body side inching lever 9. Be sure
A
that turnbuckle clevis pin holes are approximately 272
mm (10.7 in.) apart center to center. 14
13
(4) Attach the return spring 10 between the vehicle body 8 7 10 9
side inching lever 9 and seat frame.
(5) Tilting the inching pedal 11, adjust the clearance A
between cam follower 12 and brake pedal valve 13 to
14.5 mm (0.571 in.), then hold the inching pedal 11 in
that position with the adjusting bolt 14. Under this
condition, the top height of the inching pedal 11 from 272 mm (10.7 in.)
the floor level will be approximately 190 mm (7.5 in.).
210613
6-43
(6) Attach the inching cable 15 to the vehicle body side 9 mm

inching lever 9 and bracket 16. (0.35 in.)
12 1
(7) With the clearance A set at 14.5 mm (0.571 in.)
A
between cam follower 12 and brake valve pedal 13,
adjust the protrusion of clutch valve plunger 1 to 9 mm
(0.35 in.) with the turnbuckle 7. 13 7
9
16
15
210614
(8) Depress the inching pedal 11 and make sure that the
protrusion of clutch valve plunger 1 is 11.5±0.5 mm 11.5±0.5 mm
(0.453±0.020 in.)
(0.453±0.02 in.) when the cam follower 12 touches the
11 1
brake valve pedal 13. If the 11.5±0.5 mm (0.453±0.02
in.) cannot be obtained, adjust the length of the 12
turnbuckle 7.
13
210615
(9) Depress the inching pedal 11 all the way and make sure 19.5±1 mm
(0.768±0.039 in.)
that the protrusion of clutch valve plunger 1 is 19.5±1 1
mm (0.768±0.039 in.). Then, tighten the lock nut of
11
the turnbuckle 7 and adjusting bolt 14.
14
210616
6-44
Oil Pressure Measurement
NOTE
Front tires rotate during the measurement. Build a
fence around the vehicle to prevent access to it.
NOTE: Always perform pedal adjustments before oil

1. Main oil pressure measurement

Main pressure tap (M)
gauge to the main oil pressure outlet of the regulator
valve.
*Connector 64309 - 17733
*Hose 64309 - 17722
*Connector 64309 - 17731
*Gauge 64309 - 17713 210621
NOTE: Parts marked with an asterisk (*) are included

in the gauge kit 64309 - 17701.
(2) Idle the engine and check that the transmission oil is up
to the specified level.
temperature.
rpm).
(5) Under the above condition, perform the oil pressure
measurement.
A: Standard value
Main oil pressure 1.08 to 1.27 MPa

(with engine idling at A (11 to 13 kgf/cm2)
1500±100 rpm) [157 to 184 psi]

6-45
2. Direction clutch oil pressure measurement

gauge to the direction clutch oil pressure outlet port of Direction clutch pressure tap (PD)
the selector valve.
NOTE: Use the same special tools as used for main oil
(2) Lift the front tires off the floor by either of the
following methods.
(a) The front axle housing is jacked up.
210622
(b) The mast is tilted all the way backward first. With
a wooden block applied under the outer mast, the
mast is tilted forward to lift the front tires. Then,
an appropriate stand or square timber is placed
under the frame to keep the front tires lifted.
(3) Put scotch blocks under the rear tires.
(4) Implement the steps (2) through (4) of main oil End face of control valve body
(5) Place the transmission shift lever into the FORWARD
position, then release the parking brake.
(6) Depress the inching pedal gradually to pull out the
clutch (inching) valve plunger pushed all the way in.
Record pressure fluctuations with plunger stroke in the
meantime and make sure that the oil pressure change
patterns as shown at the left.
B
A
Reference data
MPa (kgf/cm2) [psi]
0.98
Clutch pressure,
(10)
Pedal height (from frame top surface 190 mm [142]
to uppermost end of pedal) (7.5 in.) 0.22

(2.2)
10.5 7 [31]
Clearance between inching cam 14.5 mm (0.41) (0.28)
follower and brake valve (0.571 in.) 15 10 5 2

0
(0.59) (0.39) (0.20) (0.08)
Plunger protrusion A when inching 9 mm Clutch valve plunger stroke, mm (in.)

pedal is not depressed (0.35 in.) 210623
Plunger protrusion B when brake 14 mm

begins to work (0.55 in.)
6-46
3. Torque converter inlet oil pressure measurement

Torque converter
(1) Connect a 0.6 MPa (6 kgf/cm2) [87 psi] oil pressure inlet pressure tap (T)
gauge to the torque converter inlet oil pressure inlet
port of the regulator valve.
*Connector 64309 - 17733
*Hose 64309 - 17722
*Connector 64309 - 17731
*Gauge 64309 - 17713 210624
NOTE: The parts marked with an asterisk (*) are

included in the gauge kit 64309 - 17701.
(2) Idle the engine and check that transmission oil is up to

the specified level.
temperature.
rpm), measure the torque converter inlet oil pressure.
A: Standard value
Torque converter inlet

oil pressure 0.15 to 0.69 MPa
A (1.5 to 7.0 kgf/cm2)
(with engine idling at
1500±100 rpm) [22 to 100 psi]

Stall Speed Measurement

(1) With the engine running at low idle, check to make sure
that the oil level is correct in the transmission case.
(2) Warm up transmission oil.
(3) Block the front and rear wheels, and apply the parking
brake.
(4) Run the engine at low idle.
6-47
(5) Move the transmission shift lever to the forward

position, and gradually depress the accelerator pedal
fully. Under this condition, measure the stall speed
with an engine tachometer.
Stall speed
1760 rpm
(tolerance: ±100 rpm)
CAUTION
Do not attempt to depress the inching pedal. Do
not continue operation in stall condition for more
than 30 seconds. A failure to follow this
precaution would result in destruction of the
torque converter.
(6) Similarly measure the stall speed for reverse drive.
NOTE
(a) Any stall speed within ±100 rpm tolerance of the
specification is satisfactory.
(b) If the engine or torque converter is changed, the
stall speed will vary since the stall speed is
determined by the combination of engine and
torque converter.
10 m (33 ft) Start Acceleration Test

(1) Stand ready to start with the engine running at low idle,
the transmission shift lever in the neutral position and
the travel speed select switch in D (automatic 3-speed)
position.
(2) At the signal, move the transmission shift lever to the
forward position and, at the same time, depress the
accelerator pedal all the way.
(3) Measure the time required for the truck to travel 10 m
(33 ft) with a stopwatch.
(4) Conduct the same test for reverse travel, too.
Travel time (no load) 5 seconds, maximum
6-48
Travel Speed Select Switch

Move the travel speed select switch mounted on the console
box to each position, and make sure that the speed selector
system functions properly. Move the switch when the truck
is at standstill.
DP100, DP115
the travel speed reaches 6.5 km/hr (4.0 mph) to allow 207499
the truck to run at a maximum speed of 18.5 km/hr
(11.5 mph).
the travel speed reaches 6.5 km/h (4.0 mph). It
automatically shifts from the 2nd to the 3rd speed when
the travel speed reaches 15 km/h (9.3 mph) to allow the
truck to run at a maximum speed of 27 km/h (16.5
mph).
DP135, DP150
maximum speed of 8.5 km/hr (5.3 mph) and a greater
the travel speed reaches 6.5 km/hr (4.0 mph) to allow
the truck to run at a maximum speed of 19 km/hr (11.8
mph).
the travel speed reaches 6 km/h (3.7 mph). It
automatically shifts from the 2nd to the 3rd speed when
the travel speed reaches 12.5 km/h (7.8 mph) to allow
the truck to run at a maximum speed of 32 km/h (19.6
mph).
6-49
Troubleshooting
Engine Poor performance Tune up engine.

Air being sucked in on suction side Retighten or replace gasket.
Main regulator valve not operating Repair or replace.
properly
Main regulator valve spring fatigued Replace.
Oil pump gears worn, resulting in Overhaul and check or
Torque
converter reduced capacity replace defective parts.
Magnet strainer clogged Replace.
pressure.
Stator freewheel seized Replace stator assembly,
hub and roller.
Not enough Blades of running members damaged Repair or replace. Replace
output power or rubbing bearing.
Air being sucked in on suction side Retighten or replace.

Outlet pressure too low to suppress Readjust.
internal foaming
Transmission Main pressure too low, resulting in Readjust after measuring
slipping clutches oil pressure.
pressure.
Clutch piston damaged Replace.
Friction plate seized or dragging Replace.
Wheels High mechanical resistance Check and adjust brake

system.
6-50

Torque
converter Oil pump drive defective Replace.
Turbine shaft broken Replace.
Main pressure too low Check pump gears for wear
or replace.

Inching pedal link maladjusted Readjust.
Seal rings worn in servo case Replace.
O-rings on input shaft worn Replace.
Plug on input shaft loose or slipped Repair.
No power
flow off, resulting in oil leaks
Clutch seized Replace.
Transmission
Shafts broken Replace.
Clutch drum, particularly snap ring Replace.
groove, defective
Snap ring fitted to clutch drum Replace.
broken
Oil line to clutch piston clogged Clean or replace.
Shaft splines worn Replace shafts.
Power train Broken parts in reduction and Refer to each section.

differential or front axle

Bearings damaged Replace.
Torque Rubbing vanes of running members Replace.
converter Bolts loose Retighten or replace.
Oil pump worn Inspection or replace.
Abnormal
noise
Clutch seized and dragging Replace clutch plate.
Bearings worn or seized Replace.
Transmission Gears broken Replace.
Bolts loose Retighten or replace.
6-51

Main regulator valve spool defective Wash or replace.
Restriction in oil pipe Replace.
Loud noise
Oil too viscous in cold weather Replace oil. *
Abnormal
noise Oil strainer clogged Clean or replace.
Excessive oil leaks
• Main regulator valve spring Replace.
defective
Low noise
• Main regulator valve spool Repair or replace.
defective
packing.
Leaking oil seals Check lips and sliding surfaces for

wear. Replace seals.
Leaking joint of case Retighten or replace packing.
Leaking pipe connection or joint Repair or replace pipe, gasket and
O-rings.
Leaking drain plug Retighten or replace gasket.
Oil leaks Cracks or blowholes in case Replace.
Oil blowing out of transmission case
• Water in oil Replace oil.
• Air being sucked in on suction side Replace packing and retighten.
• Oil leaks from air breather Repair.
Oil level too high Lower oil level.
6-52
Oil level too high or too low Keep correct oil level.
Rubbing vanes of running members Repair or replace.
Stator freewheel defective Replace stator assembly.
Torque
converter O-ring.
Restriction in oil pipe (resulting in Repair or replace.
reduced circulation flow)
Bearings worn or seized Repair or replace.
Oil
temperature
is too high
Clutches dragging Replace clutch plates.
Transmission Bearings worn or seized Repair or replace.
Truck not operated properly Advice user to drive truck

Others properly.
Others
• Cooling fan belt damaged Replace.
• Oil cooler clogged Clean or replace.
• Brakes grabbing Check and readjust.
Main regulator valve defective Repair or replace valve assembly.

Main pressure is too
high Oil viscosity too high in cold weather Replace oil. *

Main pressure is too Main regulator valve spool defective Repair or replace.
low Air being sucked in Retighten or replace packing.
Inching valve out of order Repair or replace.
6-53

Oil pump worn or defective Replace.
Main regulator valve spool defective Repair or replace.
Clutch pressure is too packing.
low
Control linkage out of order Repair or replace.
Inching valve defective Repair or replace.
Seal ring broken in servo case Replace.
Clutch seal rings broken Replace.
Lack of engine power if the speed is slightly low in Tune up engine.

both forward and reverse drive
Stall speed out of
specification Stator and freewheel defective if the speed is Replace stator assembly.
excessively low in both forward and reverse drive
Inching pedal linkage defective, or clutch slipping if Repair or replace.
the speed is too high
Travel speed select switch in “Fixed 1st speed” Move switch to “Automatic”
position position.
Solenoid valve defective Replace.
No automatic shifting
Solenoid valve inlet orifice clogged Clean or replace.
Solenoid valve spool or spring defective Repair or replace.
ECU control box internally defective Check or replace.
Transmission shifts up Harness open Repair.

when travel speed select
switch is in “Fixed 1st
speed” position Travel speed select switch defective Replace.
6-54
Service Data
Unit: mm (in.)
Truck Model
DP100 DP115 DP135 DP150
Item
Stall speed (tolerance: ±100 rpm) rpm A 1760
Main pressure (engine at 1500±100 rpm) MPa (kgf/cm2) [psi] A
Speed clutch pressure (engine at 1500±100 rpm)
A 1.08 to 1.27 (11 to 13) [156 to 185]
MPa (kgf/cm2) [psi]
Direction clutch pressure (engine at 1500±100 rpm)
A
MPa (kgf/cm2) [psi]
Torque converter inlet pressure (engine at 1500±100 rpm)
A 0.15 to 0.69 (1.5 to 7.0) [21 to 100]
MPa (kgf/cm2) [psi]
Lubrication line pressure (engine at 1500±100 rpm)
A 0.02 to 0.10 (0.2 to 1.0) [3 to 14]
MPa (kgf/cm2) [psi]
10 m (33 ft) start acceleration (no load) A 5 seconds, maximum
0 0
A 100 − 0.035 (3.94 − 0.00138 )
Diameter of portion in contact with oil seal 1
B 99.85 (3.9311)
Pump boss
1
200721
− 0.007 − 0.00028
A 20 − 0.020 (0.79 − 0.00079 )
Diameter of portion in contact with engine flywheel 1
B 19.85 (0.7815)
Pilot boss
1
200411
6-55

Unit: mm (in.)
Truck Model
DP100 DP115 DP135 DP150
Item
A 0.040 to 0.078 (0.00157 to 0.00307)
Side clearance 1
B 0.09 (0.0035)
A 0.3 to 0.345 (0.0118 to 0.0136)
Top clearance 2
B 0.35 (0.0138)
Oil pump
1 205486
A 67.951 to 67.97 (2.67523 to 2.6760)

Outside diameter of clutch hub 1
B 67.8 (2.669)
A 10.185 to 10.2 (0.40098 to 0.402)
Diameter of clutch rollers 2
B 10.1 (0.398)
A 4.95 to 5 (0.1949 to 0.197)
B 4.8 (0.189)
A 3.95 to 4 (0.1555 to 0.157)
B 3.8 (0.150)
A 2.9 to 3 (0.114 to 0.118)
B 2.8 (0.110)
A 4.9 to 5 (0.193 to 0.197)
B 4.8 (0.189)
Stator A 4.95 to 5 (0.1949 to 0.197)
B 4.8 (0.189)
3 4 1 2 5 6 7
200724
6-56

Unit: mm (in.)
Truck Model
DP100 DP115 DP135 DP150
Item
Face runout of flexible plates 1 A 0.2 (0.008)
(in free state) B 0.5 (0.020)
Distance between end face of torque converter
A 25 (0.984)
housing and mating face of flexible plates 2
Flexible 2
plates
1
200725
A 2.3±0.07 (0.091±0.0028)
Thickness of mating plate 1
B 2.1 (0.083)
A 2.6±0.1 (0.102±0.004)
Thickness of friction plate 2
B 2.2 (0.087)
Free movement of friction plate on gear 3
(looseness of mating splines) A 0.10 to 0.30 (0.0039 to 0.0118)
− 0.01 − 0.0004
A 4 − 0.03 (0.16 − 0.0012 )
Width of piston seal ring 4
B 3.5 (0.138)
+ 0.2 + 0.008
A 4 + 0.1 (0.16 + 0.004 )
Width of seal ring groove in piston 5
B 4.5 (0.177)
62.9 (2.48)
Free length of clutch spring 6 A
Clutches k = 39.1 (3.992) [223.5]
B 60 (2.36)
6 2 1 3
5
210220
6-57

Unit: mm (in.)
Truck Model
DP100 DP115 DP135 DP150
Item
A 2.5±0.05 (0.098±0.0020)
Width of piston seal ring for each shaft 1
B 2.0 (0.079)
+ 0.2 + 0.008
A 2.5 + 0.1 (0.098 + 0.004 )
Width of piston seal ring groove in each shaft 2
B 3.0 (0.118)
+ 0.025 + 0.00098
Inside diameter of servo case and clutch shaft in A 35 0 (1.38 0 )
contact with seal ring 3 B 35.2 (1.386)
+ 0.025 + 0.00098
Inside diameter of stator shaft in contact with seal A 35 0 (1.38 0 )
ring 4 B 35.2 (1.386)
A 2.5±0.05 (0.098±0.0020)
Width of clutch piston seal ring for each shaft 5
B 2.0 (0.079)
+ 0.2 + 0.008
Width of clutch piston seal ring groove in each shaft A 2.5 + 0.1 (0.098 + 0.004 )
6 B 3.0 (0.118)
Forward
clutch shaft,
reverse
clutch shaft,
1st-speed/
3rd-speed
clutch shaft
and
servo cases
1,2 3 5,6
207518
1,2
4
207519
6-58
A: Standard value
Unit: mm (in.)
Truck Model
DP100 DP115 DP135 DP150
Item
Input gear and forward and reverse gears 1 A 0.12 to 0.28 (0.0047 to 0.0118)
Forward gear and reverse and 1st-speed/3rd-speed A 0.14 to 0.32 (0.0055 to 0.0126)
gears 2
2nd-speed gear and output gear 3 A 0.12 to 0.28 (0.0047 to 0.0110)
1st-speed gear and output gear 4 A
0.13 to 0.30 (0.0051 to 0.0118)
3rd-speed gear and output gear 5 A
Pump drive gear and idler gear 6 A
0.12 to 0.26 (0.0047 to 0.0102)
PTO drive gear and idler gear 7 A
1 6
2 7
Backlash of
gears 3
2 F
2
1
5
4
3 1
210219
6-59

Unit: mm (in.)
Truck Model
DP100 DP115 DP135 DP150
Item
A 36.5 (1.44)
Free length of selector valve spring 1 k = 5.658 (0.577) [32.3]
B 35.5 (1.40)
A 28 (1.10)
Free length of return spring 2 k = 0.478 (0.0488) [2.73]
B 26.5 (1.04)
A 59.5 (2.34)
Free length of differential valve spring 3 k = 2.311 (0.2357) [13.2]
B 57.5 (2.26)
A 39 (1.53)
Free length of inching valve spring 4 k = 2.128 (0.217) [12.1]
B 38 (1.49)
A 125.5 (4.94)
Free length of accumulator valve outer spring 5 k = 5.363 (0.5469) [30.6]
B 123 (4.84)
A 170.5 (6.71)
Free length of accumulator valve inner spring 6 k = 4.128 (0.4210) [23.5]
Control B 168 (6.61)
valve 32.5 (1.28)
Free length of direction valve springs 7 A k = 8.616 (0.8786) [49.2]
B 31.5 (1.24)
7
7
1
4
3
1
6 5 210209
6-60

Unit: mm (in.)
Truck Model
DP100 DP115 DP135 DP150
Item
A 112 (4.41)
Free length of main regulator valve spring 1 k = 4.99 (0.5087) [28.5]
B 109 (4.29)
Main
regulator
valve
1
210181
Inching pedal height (from frame to top end of

A 190 (7.48)
pedal) 1
Clearance between inching pedal cam follower and

A 14.5 (0.571)
brake control valve pedal 2
Protrusion of inching plunger with inching pedal

A 9 (0.35)
released 3
Protrusion of inching plunger when brake starts to

A 14 (0.55), minimum
be applied 4
Inching
pedal
control
3
4
210358
6-61
FRONT AXLE AND REDUCTION DIFFERENTIAL
Specifications .......................................................................................... 7 – 1
Description ............................................................................................... 7 – 2
Front Wheels (Tires) .................................................................................. 7 – 3
Front Axle and Reduction Differential Assembly ........................................ 7 – 5
Reduction Differential Assembly ................................................................ 7 – 7
Front Axle ................................................................................................. 7 – 9
Disassembly .............................................................................................. 7 – 9
Inspection .................................................................................................. 7 – 12
Reassembly ............................................................................................... 7 – 14
Reduction Differential ........................................................................... 7 – 17
Disassembly .............................................................................................. 7 – 17
7
Inspection .................................................................................................. 7 – 19
Reassembly ............................................................................................... 7 – 21
Service Data ............................................................................................ 7 – 29

Cat DP150 Forklift Service Manual 1

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Service Manual

Chassis & Mast

,QFOXGHV0LWVXELVKL 'DQG6D16TL Engine Service Manual%HJLQVRQ3DJH

6D16 '7/Diesel Engine Service Manual (Pub. No. 99709-68130)%HJLQVRQSDJH

Safety Related Signs

The following safety related signs are used in this service

Indicates a specific potential hazard

Indicates a specific potential hazard

NOTE Indicates a condition that can cause

Pub. No. 99799-80120

5. Use steps and grab handles (if applicable) when

1. Service data in the text

GROUP INDEX Items

COOLING SYSTEM Removal and Installation, Fan Belt Adjustment 2

Console Box, Major Components, Lamp Bulb Specifications,

2-speed Transmission, 3-speed Transmission, Gear Ratios, Removal

REAR AXLE Rear Axle, Power Cylinder, Minimum Turning Radius 8

STEERING SYSTEM Steering Control Valve, Tilt Steering Assembly 10

MASTS AND FORKS Simplex Mast 12

HYDRAULIC SIDE SHIFTERS Side Shifter Assembly, Hydraulic Cylinder 14

Truck Models Covered

This Service Manual furnishes servicing and maintenance

Truck model Transmission Designation – Serial number Engine mounted

DP100 Powershift 3DP – 10011- up Mitsubishi 6D16TL diesel engine

DP115 Powershift 4DP – 10011- up Mitsubishi 6D16TL diesel engine

DP135 Powershift 5DP – 10011- up Mitsubishi 6D16TL diesel engine

DP150 Powershift 6DP – 10011- up Mitsubishi 6D16TL diesel engine

Serial Number Locations

Name plate Chassis serial number

Ref. Truck Model

A Lift 3300 (130)

B Fork length 1220 (48)

C Fork width 180 (7.1)

D Fork thickness 70 (2.8) 90 (3.5)

E Tilt angle (forward – backward) 15° – 12°

G Overall width (outside of tires) 2514 (99) 2599 (102)

I Tread (front) 1900 (75) 1906 (75)

J Tread (rear) 1930 (76) 1890 (74)

K Wheelbase 2800 (110) 3100 (122)

M Ground clearance (at frame) 340 (13.4) 380 (15.0)

Type Forced circulation

Corrugated fin with pressure cap

Oil cooler type Plate fin type

Capacity (complete system)

Detail of transmission oil cooler

1. Intercooler 6. Drain cock

The radiator with a tube-and-fin type core comes standard. &DW)RUNOLIW0LWVXELVKL'LHVHO(QJLQH3DUWV

Removal and Installation

Radiator and Intercooler

Make sure the coolant temperature is cool before

Suggestions for Removal

Weight of intercooler 9 kg (20 lb)

Weight of radiator 30 kg (66 lb)

(2) Replace the radiator if the fins are damaged beyond

3. Antifreeze and Coolant

Radiator corroded Repair or replace.

Hose clamps loose Retighten or replace.

Drain cock defective Replace.

Cracks in coolant passage in engine Check and repair.

Debris in radiator fin Clean.

Radiator fins distorted Repair or replace.

Thermostat defective Repair or replace.

Hose clamps loose Retighten or replace.

Transmission shift lever Electric

,QFOXGHV0LWVXELVKL 'DQG6D16TL Engine Service Manual%HJLQVRQ3DJH

6D16 '7/Diesel Engine Service Manual (Pub. No. 99709-68130)%HJLQVRQSDJH