POWERSHIFT TRANSMISSION

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

Removal and Installation ....................................................................... 5 3 Disassembly and Reassembly ............................................................. 5 4

Transmission Assembly .............................................................................. 5 4 Disassembly ............................................................................................. 5 4 Reassembly.............................................................................................. 5 10 Pump Assembly ..................................................................................... 5 10 Transmission Assembly .......................................................................... 5 14 Control Valve .............................................................................................. 5 17 Disassembly ............................................................................................ 5 17 Reassembly.............................................................................................. 5 18

Inspection and Adjustment ................................................................... 5 19

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

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

POWERSHIFT TRANSMISSION

Description

a (36)

b (31)

d (31)

c (35)

e (70)

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

207116

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

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

2 to 3.5 ton classes 66H8

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

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

Torque converter inlet pressure e Oil cooler c Accumulator valve Lube oil

Hydraulic Circuit

POWERSHIFT TRANSMISSION

Main regulator valve Clutch valve

F R Selector valve d b b a F

Torque converter outlet pressure

5-2 a c e

Unit: kPa (kgf/cm2) [psi] Main pressure b Clutch pressure Torque converter inlet pressure d Torque converter outlet pressure Lube oil pressure Engine speed: 1500 100 rpm
204869

Filter (100 mesh) with magnet

Oil pump Actual capacity : 36 liters (2197 cu. in.)/2400 rpm (Gasoline models) 33 liters (2014 cu. in.)/2200 rpm (Diesel models)

883 to 1079 (9 to 11) [128 to 156] 883 to 1079 (9 to 11) [128 to 156] 196 to 490 (2 to 5) [28 to 71] 147 to 294 (1.5 to 3) [21 to 43] 98 to 147 (1 to 1.5) [14 to 21]

POWERSHIFT TRANSMISSION

Control

R F N 1

4 2

6 5

207136

1 2 3 4

Transmission shift lever Clutch (inching) pedal Bracket (inching) Control valve assembly

5 6

Clutch valve plunger Solenoid valve assembly (for forward-reverse)

Removal and Installation

Removal
(1) Remove the engine and transmission as an assembly from the truck.

Installation
(1) Couple the torque converter and transmission to the engine. To do this, place the torque converter in the transmission housing so that the distance between the end face of the housing and the mating face of flexible plate is 50 to 52 mm (1.97 to 2.05 in.). The clearance between the flywheel and flexible plate should be 1 to 5 mm (0.04 to 0.20 in.) when the torque converter is coupled to the engine. If this clearance is zero, it is an indication that the torque converter is improperly coupled to the engine; recouple the converter to the engine properly. (2) Tighten the bolts securing the flexible plate to the flywheel through the access hole in the converter housing.

NOTE
For the removal and installation of the engine and transmission, refer to GROUP 4 POWER TRAIN.

(2) Unscrew the bolts securing the flexible plate through the access hole in the torque converter housing. (3) Separate the torque converter and transmission from the engine.

NOTE
Tighten the bolts in a criss-cross pattern.

5-3

POWERSHIFT TRANSMISSION

Disassembly and Reassembly Transmission Assembly

Disassembly

20 17 16 19 10

18 15 14 21 12

Bracket (inching) 2 8 4 5 23 24 2 11

22 Mount bracket 11 7 207119

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

5-4

POWERSHIFT TRANSMISSION

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

1. Remove two mount brackets from the transmission housing. 2. Remove the brackets (inching) and springs.

Suggestions for Disassembly

1. Removing torque converter assembly

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

204829

5-5

POWERSHIFT TRANSMISSION 2. Removing pump assembly

Lifting bolt holes (at locations marked )

Unscrew the pump mounting bolts and screw two bolts (special tool) into the M8 1.25 holes in the pump body to remove the pump assembly. Be sure to tighten the bolts equally, or the threads will suffer damage. Use M8 1.25 bolts having an effective thread length of 55 mm (2.2 in.) Special tools needed Bolt 91268 - 05100

209911

3. Removing transmission housing bolts

After removing the pump assembly, unscrew two transmission housing bolts (F1805 - 10025) from the torque converter housing side.

4. Removing transmission housing

Lay the transmission and torque converter assembly with transmission housing down. Unscrew the transmission housing bolts. Hang the transmission housing to a hoist, tap the transmission and clutch housing flanges near the dowel pins with a plastic hammer to separate the transmission housing from the torque converter housing.
204830

5. Removing input shaft ball bearing

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

Special tools needed Ref. No. 1 2 3 4 Tool name Puller Plate Bolt Gear puller T-24 (BANZAI make) Part No. 91268 - 13810 91268 - 13820 F1035 - 10020 Qty
4 2 3 207120

2 1 2 1

5-6

POWERSHIFT TRANSMISSION 6. Disassembling input shaft

Using a special tool or an arbor press, compress the clutch spring, and remove the snap ring.

Special tools needed Piston tool 91268 - 07100

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

Inspection after disassembly

1. Input shaft

(1) Check the splines for wear or damage. (2) Check the width of each seal ring groove for wear; also check the groove for damage. (3) Check to be sure that oil grooves and passages are open and clean, free from sign of clogging.
Oil passages 207121 Seal ring grooves

2. Gears

Check the gears and splines for wear or defects.

3. Clutch drums

(1) Check the sliding surfaces of mating and friction plates for wear or damage.

5-7

POWERSHIFT TRANSMISSION 4. Friction plates and mating plates

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

Thickness of mating plate

A B A B

207122

Thickness of friction plate

5. Clutch pistons

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

Seal ring Plug

NOTE
Do not disassemble the piston unless it is defective.

(2) Check the seal rings and their grooves for wear or damage.
Seal ring 207123

6. Transmission housing

Check the seal ring contact surfaces for wear or damage.

7. Magnet strainer

Check for clogging or breakage.

8. Idler shaft

Check the splines for wear or damage.

9. Output flange

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

5-8

POWERSHIFT TRANSMISSION 10. Oil pump

(1) Check top clearance A between the drive gear and pump body with feeler gauges. (2) Check side clearance B between the internal gear and drive gear and the pump body with a straight edge and feeler gauges. (3) Check the backlash between the drive gear and internal gear with feeler gauges. (4) Put the drive gear on the torque converter pump impeller, and check clearance C between the gear and pump boss. A: Standard value No. A Item Top clearance A A B Side clearance B Clearance C between pump boss and drive gear A B: Repair or service limit Unit: mm (in.) Dimension 0.30 to 0.33 (0.0118 to 0.0130) 0.040 to 0.083 (0.00157 to 0.00327) 0.150 (0.00591) 0.1 to 0.4 (0.004 to 0.016) 0.10 to 0.18 (0.0039 to 0.0071) 0.30 (0.0118)
Drive gear A C

204831

A Gear backlash B

5-9

POWERSHIFT TRANSMISSION

Reassembly Pump Assembly

2 3

3 204832

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

Suggestions for Reassembly

1. Installing oil seal

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

Oil seal

204833

5-10

POWERSHIFT TRANSMISSION 2. Installing pump

Internal gear Oil pump body

When installing the pump, coat automatic transmission fluid to the pump body interior, internal gear and drive gear.

3. Inspection after reassembly

Turn the drive gear by hand to make sure the pump gears rotate smoothly.
Drive gear 209927

7 1 3

2 4 5 8

207124

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

NOTE
Reassembly of the clutch spring and plates on the REVERSE gear side is the same as that on the FORWARD gear side.

5-11

POWERSHIFT TRANSMISSION

Suggestions for Reassembly

1. Installing piston assembly

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

2. Reassembling input shaft

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

207160

3. Installing plate

(1) Make sure that the combination and number of plates are correct. Number of plates 1 ton class Friction plate Mating plate 3 4 2, 3 ton classes 5 6

Mating plate (6) Friction plate (5) Belleville spring (1)

Drum

Pressure plate (1) 207125

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

207126

5-12

POWERSHIFT TRANSMISSION 4. Installing FORWARD gear and REVERSE gear

Make sure that the oil groove side of the thrust washer faces the gear when installed.

200213

5. Installing bearing

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

207127

6. Testing clutch piston

FORWARD side REVERSE side

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

REVERSE 207128

5-13

POWERSHIFT TRANSMISSION

Transmission Assembly

10 9

8 14

5 3 7

12

11

13 1

207129

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

5-14

POWERSHIFT TRANSMISSION

Suggestions for Reassembly

1. Reassembling sequence

To reassemble, follow the reverse of disassembly sequence.

2. Placing the torque converter housing

Lay the torque converter housing with its engine side down.

3. Applying grease

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

4. Applying oil on seal ring

Coat to the input shaft seal ring with automatic transmission fluid.

204839

5. Mounting the transmission housing

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

204830

6. Installing pump assembly

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

5-15

POWERSHIFT TRANSMISSION 7. Installing torque converter

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

50 to 52 mm (1.97 to 2.05 in.)

204840

8. Filling torque converter with AFT

Fill the torque converter after the transmission has been mounted on the truck and the engine is ready to be started. Run the engine at idle speed for a while. Stop the engine and, after 1 minute, check the oil level in the transmission with the oil level gauge in 15 minutes.

5-16

POWERSHIFT TRANSMISSION

Control Valve
Disassembly
3

10 4

9 2 5 1

8 6

8 6 7

206450

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

Inspection after disassembly

(1) Check oil ways and passages for clogging. (2) Check each spool for sign of wear, damage or seizure. (3) Check oil seals for damaged lips. (4) Check the orifice in the main regulator valve for cleanliness; also check the valve spring for fatigue or damage.
200220

5-17

POWERSHIFT TRANSMISSION

Reassembly

8 Section A-A

1 7 2 A 6 A 5 9

4 Section B-B C

4 3

C 10 Section C-C 11 206451A

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

Start by:

Thoroughly clean the oil ways and passages in the valve.

5-18

POWERSHIFT TRANSMISSION

Inspection and Adjustment Testing Hydraulic Pressure

1. Run the engine at idle speed for a while. Stop the engine and, after one minute check the oil level in the transmission with the oil level gauge in 15 minutes. 2. Warm up until the transmission oil temperature rises. 3. Check the no-load minimum and maximum speeds of the engine. If the speeds are not correct, make an adjustment by referring to SERVICE MANUAL for the engine. Unit: rpm Truck Model Item No-load minimum speed No-load maximum speed ( ); Diesel model 1.0 to 1.8 ton classes 650 (650) 2600 (2300) 2 to 3.5 ton classes 650 (650) 2600 (2300)

4. After checking the engine speeds, stop the engine. Raise the front wheels. To do this, jack the front axle housing, or place wood blocks under the outer mast and tilt the mast forward.

c Torque converter inlet pressure a Main pressure

CAUTION

The front wheels will rotate when the clutch pressure is tested.
e Lube oil pressure

5. Connect a pressure gauge to the tap for a pressure to be tested. The pressure taps are located as shown.
b Clutch pressure d Torque converter outlet pressure 207130

5-19

POWERSHIFT TRANSMISSION

6. Use the following tools when testing the oil pressure: Tool name/ Tool No. Connector 91268 - 04400 *Connector 64309 - 17733 Connector 91268 - 02300 *Gauge 64309 - 17714 *Gauge 64309 - 17713 *Hose 64309 - 17722 *Connector 64309 - 17331 For gauge Remarks M14 1.5 thread R(PT)1/8 thread M14 1.5 thread 600 kPa (6 kgf/cm2) [90 psi] 2000 kPa (20 kgf/cm2) [300 psi] Pressure taps a b c d,e

Remark: The asterisked tools are included in the gauge kit (64309 - 17701). 7. Start the engine. Move the transmission shift lever to the neutral position, and test the main pressure, torque converter inlet pressure, torque converter outlet pressure and lube oil pressure. 8. Move the transmission shift lever to the FORWARD and REVERSE position, and test the clutch pressure. A: Standard value Unit: kPa (kgf/cm2) [psi]

a Main pressure

883 to 1079 (9 to 11) [128 to 156] 883 to 1079 (9 to 11) [128 to 156] 196 to 490 (2 to 5) [28 to 71] 147 to 294 (1.5 to 3) [21 to 43] 98 to 147 (1 to 1.5) [14 to 21]

b Clutch pressure Torque converter inlet pressure Torque converter outlet pressure

e Lube oil pressure

Engine speed: 1500 100 rpm

5-20

POWERSHIFT TRANSMISSION

Adjusting Inching Pedal

ctu at ing

Free play

a ke ra ke B ro st

E Push rod length 207323

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

1. Adjusting the brake

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

(3) Adjust and confirm the brake drum-to-lining clearance. Do not adjust the clearance by setting the pushrod length. Unit: mm (in.) Truck Model Item Drum-to-lining clearance Stroke for brake application 1.0 to 1.8 ton classes 0.5 to 1.0 (0.02 to 0.04) 40 to 61 (1.57 to 2.4) 2 to 3.5 ton classes 0.2 to 0.7 (0.01 to 0.03) 49 to 95 (1.93 to 3.74) 5-21

POWERSHIFT TRANSMISSION

2. Adjusting the inching pedal

Start by:

Warm up the transmission oil, raise the front wheels, and block the rear wheels.

Adjusting

(1) Connect a pressure gauge to the clutch pressure tap. (2) Adjust the released height A of the inching pedal to 220 mm (8.7 in.) by the stopper bolt. Set the clearance B between the inching pedal and brake pedal connecting parts to 9 to 9.5 mm (0.354 to 0.374 in.) for the 1 ton class or 0.1 to 0.5 mm (0.004 to 0.020 in.) for the 2 to 3 ton classes. (3) Start the engine, and release the brake pedal. Depress the inching pedal until the brake starts to be applied (the pedal encounters resistance). Under this condition, make an adjustment by means of the push rod so that the clutch valve plunger stroke (D) is 16.5 mm (0.65 in.) at 0 kgf/cm2 hydraulic pressure. (4) Release the inching pedal, and make sure that clutch valve plunger stroke (C) is 9 to 9.5 mm (0.354 to 0.374 in.) for the 1 ton class or 6 to 9.5 mm (0.236 to 0.374 in.) for the 2 to 3 ton classes at 883 to 1079 kPa (9 to 11 kgf/cm 2) [128 to 156 psi] read on the pressure gauge. Make an adjustment by means of the inching cable. If the plunger stroke is out of specification, readjust the brake and brake pedal, and repeat the adjustment. If the plunger stroke is more than 9.6 mm (0.378 in.) , the drum-to-lining clearance is too small. If the plunger stroke is less than 8.9 mm (0.350 in.) for the 1 ton class or 5.9 mm (0.232 in.) for the 2 to 3 ton classes, the drum-to-lining clearance is too large.

207131A

981 (10) [142] 588 (6) 13.5 5 (0.531) (0.20) [85]

Clutch valve plunger stroke, mm (in.) 200244

Truck Model

Item Released height 220 A pedal (8.7) Clearance between inching 9 to 9.5 0.1 to 0.5 B pedal and brake (0.354 to 0.374) (0.004 to 0.020) pedal connecting parts Clutch valve 9 to 9.5 6 to 9.5 C plunger stroke (0.354 to 0.374) (0.236 to 0.374) Plunger D projection when brake is applied 5-22 16.5 (0.65)

1.0 to 1.8 ton classes

Clutch pressure, kPa (kgf/cm2) [psi]

2 to 3.5 ton classes

POWERSHIFT TRANSMISSION

Testing Clutch Valve

1. Connect a pressure gauge to the clutch pressure tap. 2. Start the engine, and move the transmission shift lever to the FORWARD position. 3. Depress the inching pedal. Gradually pull out the clutch valve plunger from its fully pushed position, and plot the hydraulic pressure curve relative to the clutch valve plunger stroke. Make sure that the plotted pressure curve is identical with the curve shown.
Clutch pressure, kPa (kgf/cm2) [psi] 981 (10) [142] 588 (6) [85]

5 (0.20)

10 (0.39) 206468

Clutch valve plunger stroke, mm (in.)

Testing Stall Speed

WARNING

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

1. Check to make sure that the transmission oil level is correct. (See the topic, 1. Testing hydraulic pressure.) 2. Warm up until the transmission oil temperature reaches 40 C to 60 C (104 F to 140 F). 3. Block the front and rear wheels, and apply the parking brake. 4. Check the no-load maximum speed of the engine. 5. Run the engine at idle speed. 6. Move the lever to the FORWARD position. Gradually depress the accelerator pedal all the way by the right foot. Under this condition, read the stall speed with an electric or stroboscopic tachometer.

CAUTION

Do not depress the inching pedal. Also, do not allow the engine to keep on running at the highest speed attained or the torque converter may suffer damage. Stall-speed running of the engine is limited to 30 seconds or less.

5-23

POWERSHIFT TRANSMISSION

7. Similarly read the stall speed for reverse drive. Unit: rpm Truck Model Item Stall speed (tolerance: 100) 1870 GP15K GP18K GP20K GP20K-HP GP25K GP25K-HP 1791 GP30K GP35K DP20K DP25K DP30K DP35K 2095

1971

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

10-m (33-ft) Start Acceleration Test

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

5-24

POWERSHIFT TRANSMISSION

Troubleshooting
Engine Engine lacks power Poor performance of engine Oil level too low Air being sucked in on suction side Faulty action of spool in main regulator valve Weakened spring in main regulator valve Worn gears in oil pump, resulting in reduced capacity Magnet strainer clogged Seal rings or O-rings worn Stator freewheel seized Impeller damaged or rubbing Air being sucked in on suction side Water in oil Oil level too low Pedal linkage maladjusted (brake shift and forward reverse) Main pressure too low, resulting in slipping clutches Seal rings or O-rings worn Clutch piston damaged Friction plate seized or dragging High mechanical resistance in road wheels Tune up engine. Tune up engine. Refill. Replace gasket and retighten. Repair or replace. Replace. Overhaul and check or replace defective parts. Clean or replace. Replace. Replace torque converter assembly. Replace torque converter assembly. Retighten or replace. Replace oil. Refill. Readjust. Readjust. Replace. Replace. Replace. Check and adjust brake system Replace. Refill. Replace. Replace. Check pump gears for wear or replace. Refill. Readjust. Replace. Replace. Repair. Replace. Replace. Replace. Replace. Clean or replace. Replace shafts. Repair or replace.

Torque converter

Not enough output power

Transmission

Road wheels

Torque converter

Flexible plate broken Not enough oil Oil pump drive defective Turbine shaft broken Main pressure too low Not enough oil Inching pedal link maladjusted Seal ring worn in servo case O-rings on input shaft worn Plug on input shaft loose or slipped off, resulting in oil leaks Clutch seized Shafts broken Clutch drum, particularly snap ring groove, defective Snap ring fitted to clutch drum broken Oil way for supplying oil pressure to clutch piston clogged Shaft splines worn Broken parts in reduction differential or front axle

No power flow Transmission

Power train

5-25

POWERSHIFT TRANSMISSION

Torque converter

Flexible plate broken Bearings damaged Rubbing blades of running member Bolts loose Splines worn Oil pump noisy Friction plates seized and dragging Bearings worn or seized Gears broken Bolts loose Splines worn Magnet strainer clogged Main regulator valve defective Restriction in oil pipe Oil too viscous in cold weather Instruments faulty Wrong kind of oil used Magnet strainer clogged Oil pump defective Excessive oil leaks (1) Main regulator valve spring broken or fatigued (2) Main regulator valve spool defective Air being sucked in Oil level too low Leaking oil seals Leaking joint of case Leaking pipe connection or joint

Replace. Replace. Replace.torque converter. Retighten or replace. Replace. Repair or replace. Replace friction plate. Replace. Replace. Retighten or replace. Replace. Clean or replace. Wash or replace. Replace. Replace oil. Replace. Replace oil. Clean or replace. Replace. Replace. Repair or replace. Retighten or replace packing. Refill. Check lips and sliding surfaces for wear. Replace seals. Retighten or replace packing. Repair or replace pipe, gasket and O-rings. Retighten and replace gasket. Replace. Replace oil. Replace packing and retighten. Repair. Lower oil level.

Transmission

Abnormal noise Loud noise

Low noise

Oil leaks

Leaking drain plug Cracks or blowholes in case Oil blowing out of transmission housing (1) Water in oil (2) Air being sucked in suction side (3) Oil leaks from air breather Oil level too high

5-26

POWERSHIFT TRANSMISSION

Oil level too high or too low Magnet strainer clogged Impeller rubbing Stator freewheel defective Torque converter Air being sucked in Water in oil Restriction in oil pipe (resulting in reduced circulation flow) Bearings worn or seized Instruments out of order Friction plates dragging Bearings worn or seized Control linkage defective Truck not operated properly Others (1) Cooling fan belt damaged (2) Oil cooler clogged (3) Brakes grabbing Main regulator valve defective Main pressure is too high Oil viscosity too high because of low temperature Wrong kind of oil used Magnet strainer clogged Oil pump failure Coil spring defective in main regulator valve Faulty movement of main regulator valve spool Air being sucked in Not enough oil Control linkage defective Clutch valve out of order Magnet strainer clogged Oil pump worn or otherwise defective Coil spring defective in main regulator valve Faulty movement of main regulator valve spool Air being sucked in Not enough oil Control linkage out of order Inching valve defective Seal ring broken in servo case Clutch piston seal rings broken

Oil temperature is too high

Refill or drain. Clean or replace. Replace torque converter assembly. Replace torque converter assembly. Retighten or replace O-ring. Replace oil. Repair or replace. Repair or replace. Replace. Replace friction plates. Repair or replace. Repair or replace. Urge user to operate properly. Replace. Clean or replace. Check and readjust. Repair or replace valve assembly. Replace oil. Replace oil. Clean or replace. Replace. Replace. Repair or replace. Retighten or replace packing. Refill. Repair or replace. Repair or replace. Clean or replace. Replace. Replace. Repair or replace. Retighten or replace packing. Refill. Repair or replace. Repair or replace. Replace. Replace.

Transmission

Others

Main pressure is too low

Clutch pressure is too low

5-27

POWERSHIFT TRANSMISSION

Stall speed out of specification

Lack of engine power if the speed is slightly low in both forward and reverse drive Stator and freewheel damaged if the speed is excessively low in both forward and reverse drive Inching pedal linkage defective, or friction plates slipping if the speed is too high

Tune up engine. Replace stator assembly. Repair or replace.

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POWERSHIFT TRANSMISSION

Service Data
A: Standard value Truck Model GP15K GP18K Item Stall speed (tolerance 100 rpm) rpm A 1870 GP20K GP20K-HP GP25K GP25K-HP B: Repair or service limit Unit: mm (in.) DP20K DP25K GP:1971 DP: 2095 GP/DP30K GP/DP35K

Main pressure

Clutch pressure

Engine at 1500 100 rpm A kPa (kgf/cm2) [psi] Engine at 800 50 rpm B kPa (kgf/cm2) [psi] Engine at 2500 100 rpm B kPa (kgf/cm2) [psi] Engine at 1500 100 rpm A kPa (kgf/cm2) [psi] Engine at 800 50 rpm B kPa (kgf/cm2) [psi] Engine at 2500 100 rpm B kPa (kgf/cm2) [psi] Engine at 1500 100 rpm A kPa (kgf/cm2) [psi]

883 to 1079 (9 to 11) [128 to 156] 785 (8) [144] 785 to 1177 (8 to 12) [114 to 171] 883 to 1079 (9 to 11) [128 to 156] 785 (8) [144] 785 to 1177 (8 to 12) [114 to 171] 196 to 490 (2 to 5) [28.4 to 71.1] 98 (1) [14] 98 to 588 (1 to 6) [14.2 to 85] 147 to 245 (1.5 to 3) [21.3 to 43] 49 (0.5) [7.1] 49 to 343 (0.5 to 3.5) [7.1 to 50] 98 to 147 (1 to 1.5) [14.2 to 21.3] Within 5 90 (3.54 0 0.00138) 89.90 (3.5394) 2.5 0.05 (0.098 0.0020) 2.0 (0.079) 2.5
+ 0.2 + 0.1 0 0.030

Torque converter inlet pressure

Engine at 800 50 rpm

B kPa (kgf/cm2) [psi] Engine at 2500 100 rpm B kPa (kgf/cm2) [psi] Engine at 1500 100 rpm A kPa (kgf/cm2) [psi]

Torque Engine at 800 50 rpm B converter kPa (kgf/cm2) [psi] outlet pressure Engine at 2500 100 rpm B kPa (kgf/cm2) [psi] Lubricating Engine at 1500 100 rpm A oil pressure kPa (kgf/cm2) [psi] 10-m (33 ft) starting acceleration (no load) sec. A A B A B Pump boss Width of seal ring groove 3 A B Outside diameter of sliding surface to oil seal 1 Width or seal ring 2

(0.098 + 0.008 ) + 0.004

3.0 (0.118)

2, 3

204984

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POWERSHIFT TRANSMISSION

A: Standard value Truck Model GP15K GP18K Item Diameter 1 A B GP20K GP20K-HP GP25K GP25K-HP

B: Repair or service limit Unit: mm (in.) DP20K DP25K GP/DP30K GP/DP35K

15 0.006 (0.59 0.00024 ) 0.024 0.00094 14.95 (0.5886)

Pilot boss
1

200411

Top clearance 1 Side clearance 2 Clearance between pump boss and drive gear 3 Gear backlash

A A B A A B A

0.3 to 0.33 (0.012 to 0.0130) 0.040 to 0.083 (0.00157 to 0.00327) 0.15 (0.0059) 0.1 to 0.4 (0.004 to 0.016) 0.1 to 0.18 (0.004 to 0.0071) 0.3 (0.012) DP: 33 [2014] at 2200 rpm GP: 36 [2197] at 2400 rpm DP: 23 [1404] at 2200 rpm GP: 26 [1587] at 2400 rpm

Oil pump

Capacity

liter (cu.in.)/min B
2

204831

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POWERSHIFT TRANSMISSION

A: Standard value Truck Model GP15K GP18K Item Face runout 1 (in free state) Clearance between engine flywheel and flexible plate mounting surface on torque converter 2 (to be measured before bolts are torqued) Flexible plate
1 2

B: Repair or service limit Unit: mm (in.) DP20K DP25K GP/DP30K GP/DP35K

GP20K GP20K-HP GP25K GP25K-HP

A B A

0.2 (0.008) 0.5 (0.020) 1 to 5 (0.04 to 0.20)

200412

Thickness of mating plate 1 Thickness of friction plate 2 Thickness of pressure plate 3 Backlash between friction plate and gear 4 Width of seal ring 5 Clutches Width of piston seal ring groove 6 Free length of clutch spring 7 Spring constant: k = N/mm (kgf/mm) [lbf/in]
4 3 7 2

A B A B A B A A B A B A B
1

1.6 0.1 (0.063 0.004) 1.3 (0.051) 2.6 0.1 (0.1023 0.004) 2.2 (0.087) 4.0 0.3 (0.157 0.012) 3.3 (0.13) 0.13 to 0.285 (0.0051 to 0.01122) 2 0.1 (0.08 0.004) 1.5 (0.060) 2.3 0.05 (0.091 0.0020) 2.5 (0.098) 75.5 (2.97) [k = 18.476 (1.884) [105.417]] 72.5 (2.85)

5 6

207132

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POWERSHIFT TRANSMISSION

A: Standard value Truck Model GP15K GP18K Item Width of stator shaft seal ring 1 Width of piston seal ring groove in stator shaft 2 Width of clutch piston seal ring 3 Width of clutch piston seal ring groove 4 Width of transmission housing seal ring 5 Input shaft and servo case Width of transmission housing seal ring groove 6 Inside diameter in transmission housing for seal ring 7 Thickness of input shaft thrust washer 8 Thickness of input shaft thrust washer 9 A B A B A B A B A B A B A B A B A B 2.5 GP20K GP20K-HP GP25K GP25K-HP

B: Repair or service limit Unit: mm (in.) DP20K DP25K GP/DP30K GP/DP35K

2.5 0.05 (0.098 0.0020) 2.0 (0.079)

+0.2 +0.1 +0.008

(0.098 +0.004 ) 3.0 (0.118)

2.5 0.05 (0.098 0.0020) 2.0 (0.079) 2.8 0.05 (0.110 0.0020) 3.0 (0.118) 2.5 0.05 (0.098 0.0020) 2.0 (0.079) 2.5 +0.2 (0.098 +0.008 ) +0.004 +0.1 3.0 (0.118) 30 +0.021 (1.18 +0 +0 30.2 (1.189) 2.5 (0.098) 2.2 (0.087) 3.0 (0.118) 2.7 (0.106)
1, 2
+0.00083

5, 6

3, 4

8 207133

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A: Standard value Truck Model GP15K GP18K Item Free movement of idler gear (looseness of mating splines) 1
Measuring point

B: Repair or service limit Unit: mm (in.) DP20K DP25K GP/DP30K GP/DP35K

GP20K GP20K-HP GP25K GP25K-HP

0.12 to 0.26 (0.0047 to 0.010)

Idler gear

shaft

204987

Free movement of output flange gear (looseness of mating splines) 1

Measuring point

0.054 to 0.14 (0.00213 to 0.0055)

Output shaft
1

204988

Gear backlash Free length of clutch spring 1 Spring constant: k = N/mm (kgf/mm) [lbf/in] Free length of clutch spring 2 Spring constant: k = N/mm (kgf/mm) [lbf/in] Free length of clutch spring 3 Spring constant: k = N/mm (kgf/mm) [lbf/in] Free length of clutch spring 4 Spring constant: k = N/mm (kgf/mm) [lbf/in]

A B A B A B A B A B

0.12 to 0.28 (0.0047 to 0.0110) 0.5 (0.020) 75 (2.95) [k = 2.112 (0.2154) [12.0525]] 72 (2.83) 50 (1.97) [k = 0.838 (0.0855) [4.784]] 48 (1.89) 36.8 (1.45) [k = 5.883 (0.6003) [33.59]] 35.5 (1.40) 28 (1.10) [k = 0.478 (0.0488) [2.730]] 26.5 (1.04)

Control valve

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A: Standard value Truck Model GP15K GP18K Item Free length of torque converter outlet and inlet regulator valve springs 5 Spring constant: k = N/mm (kgf/mm) [lbf/in] Free length of accumulator valve spring (inner) 6 Spring constant: k = N/mm (kgf/mm) [lbf/in] Free length of accumulator valve spring (outer) 7 Spring constant: k = N/mm (kgf/mm) [lbf/in]
6 7 2 1 3 4

B: Repair or service limit Unit: mm (in.) DP20K DP25K GP/DP30K GP/DP35K

GP20K GP20K-HP GP25K GP25K-HP

A B A B A B

25 (0.98) [k = 4.187 (0.427) [23.892]] 24 (0.94) 130 (5.12) [k = 0.597 (0.0609) [3.408]] 128 (5.04) 91 (3.58) [k = 7.303 (0.7447) [41.669]] 89 (3.50)

Control valve

206451

200418

Height of inching pedal 1 Clearance in pedal linkage 2 Plunger projection 3 Plunger projection when brake starts to apply 4 Push rod length 5 Inching pedal control

A 9 to 9.5 A (0.354 to 0.374) 9 to 9.5 A (0.354 to 0.374) A A

220 3 (8.7 0.12) 0.1 to 0.5 (0.004 to 0.020) 6 to 9.5 (0.236 to 0.374) 16.5 (0.650) 103.2 (4.06)

3 4 200419

2 5 207131A

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