Powershift Transmission PDF

POWERSHIFT TRANSMISSION
Structure and Function ........................................................................ 6 – 1

Transmission ............................................................................................. 6 – 1
Torque Converter ....................................................................................... 6 – 2
Control Valve ............................................................................................. 6 – 3
Hydraulic System Schematic of Powershift Transmission .......................... 6 – 4
Removal and Installation ..................................................................... 6 – 7
Removal .................................................................................................... 6 – 7
Installation ................................................................................................. 6 – 7
Control Valve ........................................................................................... 6 – 8
Disassembly .............................................................................................. 6 – 8
Reassembly ............................................................................................... 6 – 9 6
Input Shaft Assembly ........................................................................... 6 – 11
Disassembly .............................................................................................. 6 – 11
Oil Pump Assembly ............................................................................... 6 – 14
Disassembly .............................................................................................. 6 – 14
Reassembly ............................................................................................... 6 – 16
Inspection and Adjustment ................................................................ 6 – 17
Oil Pressure Measurement ........................................................................ 6 – 17
Clutch (Inching) Pedal Adjustment ............................................................ 6 – 20
Inching Cable Adjustment .......................................................................... 6 – 22
Troubleshooting ..................................................................................... 6 – 23
Tightening Torque .................................................................................. 6 – 27
Service Data ............................................................................................. 6 – 28
Structure and Function
Transmission
11 10 9 8 7 6 5 4 3 2 1
15 14 13 11 12
16
18
17
210280
1 Torque converter 7 Clutch piston 13 Drive pinion shaft

2 Oil pump housing 8 Clutch drum 14 Pinion shaft spacer
3 Oil pump cover 9 Return spring 15 Reduction gear
4 Main shaft 10 Forward gear 16 Idler gear
5 Reverse gear 11 Needle bearing 17 Control valve
6 Orifice 12 Oil pump gear 18 Solenoid valve
6-1
Torque Converter
1
7
4 3
2
6
8
210281
1 Turbine runner 6 Clutch hub

2 Stator assembly 7 Drive cover
3 Flexible plate 8 Turbine boss
4 Pump impeller 9 Pilot boss
5 Pump boss
6-2
Control Valve
12
11
10
7
6
8
5
3
4
210282
1 Accumulator piston 7 Regulator valve spring

2 Accumulator piston spring 8 Side plate
3 Accumulator piston stopper 9 Side plate gasket
4 Converter relief valve 10 Inching valve
5 Converter relief valve spring 11 Inching valve spring
6 Regulator valve 12 Solenoid valve
6-3
Hydraulic System Schematic of Powershift Transmission
Hydraulic circuit (at neutral)

Control valve ASSY
Forward Forward solenoid valve

clutch
hydraulic T port
Forward clutch Reverse clutch pressure
W port P port
Reverse solenoid
Reverse valve
clutch
hydraulic T port
pressure
W port
P port
Multiple disc clutch ASSY
Inching valve
Accumulator
Choke
Main hydraulic
pressure
Oil cooler
Choke Choke
Regulator valve
Oil pump
Torque converter
inlet hydraulic Oil filter
Relief valve pressure
Torque converter
210283
6-4
Hydraulic circuit (at forward)

Control valve assembly
Forward solenoid valve

Forward
clutch T port
hydraulic
W port
P port
Reverse solenoid
Reverse valve
clutch
hydraulic T port
pressure
W port
P port
Multiple disc clutch
Inching valve
Accumulator
Choke
Main hydraulic
pressure
Oil cooler
Choke Choke
Regulator valve
Oil pump
Torque converter
Relief valve pressure
Torque converter
210284
6-5
Hydraulic circuit (at reverse)

Control valve assembly
Forward solenoid valve

Forward
clutch T port
hydraulic
W port P port
Reverse solenoid
valve
Reverse
clutch T port
hydraulic
pressure
W port P port
Multiple disc clutch assembly
Inching valve
Accumulator
Choke
Main hydraulic
pressure
Oil cooler
Choke Choke
Regulator valve
Oil pump
Torque converter
Relief valve
pressure
Torque converter
210285
6-6
Removal and Installation
Removal
(1) Remove the power train assembly.
(2) Drain the oil from the front axle.
(3) Remove the bolts holding the flexible plate to the
engine flywheel through the hole in the converter case.
(4) Separate the torque converter and transmission
combination from the engine.
(5) Separate the torque converter and transmission
combination from the differential carrier.
Installation
(1) Install the torque converter and transmission assembly
to the differential carrier.
NOTE
Wash the flange faces of the transmission case and the
differential carrier with solvent and apply a coat of
sealant to these faces.
(2) Couple the torque converter and transmission

combination to the engine. Put the torque converter in
the transmission case so that the mating face of the
flexible plate protrudes approx.13 mm (0.51 in.) from
the end face of the transmission housing (See also the
“GROUP 5 POWER TRAIN.”). 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 not coupled to
the engine properly. Re-couple it to the engine.
(3) Tighten the bolts that hold the flexible plate to the
flywheel through the hole in the converter case.
NOTE
Tighten the bolts in a diagonal sequence.
(4) Refill the front axle housing with the recommended

gear oil.
6-7
Control Valve
Disassembly
10
15
11
12
14 13
2
5
4
9
6
1
210286
Sequence
1 Side plate 9 Accumulator piston
2 Inching valve spring 10 Regulator valve plug, O-ring
3 Inching valve 11 Relief valve plug, O-ring
4 Regulator valve spring 12 Relief valve spring
5 Regulator valve 13 Relief valve
6 Accumulator stopper 14 Solenoid valve, Bolt
7 Accumulator outer spring 15 Solenoid valve, Bolt
8 Accumulator inner spring
Inspection after Disassembly
1. Vavle housing
Check all oil holes for clogging.
2. Valves
(1) Check for wear or damage. Make sure the sliding
surfaces are smooth.
(2) Check the small holes for clogging.
3. Springs
Check for fatigue and damage.
6-8
Reassembly
2 1
14
13
15
12
11
4
5
10
3
8
9
7
211120
Sequence
1 Solenoid valve, Bolt 9 Accumulator outer spring
2 Solenoid valve, Bolt 10 Accumulator stopper
3 Relief valve 11 Regulator valve
4 Relief valve spring 12 Regulator valve spring
5 Relief valve plug, O-ring 13 Inching valve
6 Regulator valve plug, O-ring 14 Inching valve spring
7 Accumulator piston 15 Side plate, Side plate gascket, Bolt
8 Accumulator inner spring
6-9
Suggestions for Reassembly
1. Cleaning oil passages

The oil passages in the valve housing must be cleaned
thoroughly. Make sure there is no clogging in any passage
before reassembling the control valve.
2. Tightening torques
Tighten the following parts to the specified torques.
2.94 to 3.82 N·m

Bolt 1 (0.3 to 0.39 kgf·m)
[2.17 to 2.82 lbf·ft]
19.6 to 29.4 N·m
Relief valve plug 5,
(2 to 3 kgf·m)
Regulator valve plug 6
[14.5 to 21.7 lbf·ft]
15.7 to 20.6 N·m
Bolt 15
(1.6 to 2.1 kgf·m)
(for side plate)
[11.6 to 15.2 lbf·ft]
6-10
Input Shaft Assembly
Disassembly
2
3
5
4
6 A
15
14
A 15
13 B
11
12
16
10
B 9
210287
6-11
Sequence
1 Ball bearing, Spacer, Snap ring, Thrust washer 9 Forward gear
2 Reverse gear 10 Needle bearing, Thrust washer
3 Needle bearing, Thrust washer 11 Snap ring, Pressure plate, Friction plate,
4 Snap ring, Pressure plate, Friction plate, Mating plate, Belleville spring (coned disc
Mating plate, Belleville spring (coned disc spring)
spring) 12 Clutch spring, Snap ring, Spring retainer
5 Clutch spring, Snap ring, Spring retainer 13 Clutch piston, Piston ring
6 Clutch piston, Piston ring 14 Input shaft assembly
7 Sealing ring (3 pieces) 15 Seal ring
8 Ball bearing, Spacer, Snap ring, Thrust washer 16 Set screw
Suggestions for Disassembly
Disassembling input shaft

With the clutch spring compressed using the special tool or
a press, remove the snap ring.
1. Input shaft
(1) Check splines for wear or other damage.
(2) Check the seal rings A and their grooves for wear or B B
B
damage, and measure the width of each groove.
(3) Check the oil passages B for clogging.
(4) Check the clutch drum and input shaft for looseness.
B A B B
A
209915
2. Gear
Check gear and splines for wear or damage.
3. Drum
(1) Check the plate sliding surfaces for wear or other
damage.
(2) Check the clutch piston sliding surfaces for wear or
other damage.
6-12
4. Friction plates and mating plates

(1) Check for burns, traces of uneven contact, deformation
and wear.
(2) Check splines for wear or other damage.
5. Piston ring
Check piston ring for wear or damage.
A: Standard value B: Repair or service limit

2.5 to 2.65 mm 209916
A
Thickness of friction plate (0.098 to 0.104 in.)
B 2.2 mm (0.087 in.)
1.53 to 1.67 mm
A
Thickness of mating plate (0.060 to 0.066 in.)
B 1.4 mm (0.055 in.)
6-13
Oil Pump Assembly
Disassembly
210288
Sequence
1 Pump bolt 4 Oil pump housing
2 Pump cover bolt 5 Oil pump drive gear
3 Oil pump cover 6 Internal gear
Suggestion for Disassembly

NOTICE: Inspect the oil seal in the oil pump body. Do not
remove the oil seal unless defects are spotted
during inspection.
6-14
1. Gear
(1) Check the gear teeth for wear, chipping or other
defects.
(2) Measure the clearances between the drive gear 1,
internal gear 2 and the oil pump housing 3. If the
clearances are over the limit, replace the appropriate
parts.
0.02 to 0.04 mm
Standard value
(0.00079 to 0.0016 in.)
Repair or service limit 0.08 mm (0.0032 in.) 1
2
3 210289
(3) Measure the gap between the internal gear tooth tips
and the crescent. Replace the parts that have values
over the limits.
0.2 to 0.34 mm
Standard value
(0.0079 to 0.013 in.)
Repair or service limit 0.38 mm (0.015 in.)
210290
(4) Measure the gap between the external circumference of

the outer gear and the oil pump housing.
0.09 to 0.18 mm
Standard value
(0.0035 to 0.0071 in.)
210291
6-15
(5) Measure the oil pump sleeve bushing internal diameter

of the oil pump housing.
42 to 42.039 mm
Standard value
(1.654 to 1.655 in.)
210292
Reassembly
To reassemble, follow the reverse of disassembly sequence,
and do the following steps:
Operation check
Turn the drive gear of the reassembled oil pump assembly
with your fingers to check that it turns smoothly.
6-16
Inspection and Adjustment
Oil Pressure Measurement

1. Transmission oil level check
(1) Check the transmission fluid level with the level gauge.
(2) Start and run the engine at an idling speed for about 3
minutes, and then stop the engine.
(3) Wait for about 30 seconds after stopping the engine,
and check the level.
(4) The checking procedure must be completed within 5
minutes after the engine has stopped.
2. Engine warm-up
Warm up the engine to raise the temperature of the
transmission oil.
3. Engine speed measurement

After the engine is warmed up, measure the idling speed
and maximum no-load speed according to the engine
service manual. Make the necessary adjustments if either or
both of the speeds do not meet the specifications.
4. Preparation for oil pressure measurement

(1) Stop the engine after checking and adjusting the engine
speeds.
(2) Raise the front wheels to clear the ground either by
jacking up the front axle housing or placing a wood
block under the outer mast and tilting the mast forward.
(3) Block the rear wheels.
! WARNING
The front wheels turn during the clutch pressure
measurement. Be careful and stay away from the
wheels.
b
(4) Connect the oil pressure gauge to each of the oil a
c d
pressure taps indicated in the illustration. 210727
a: Main pressure
b: Forward clutch pressure
c: Reverse clutch pressure
d: Torque converter inlet pressure
NOTICE: When loosening the plugs a through d, tap

the plug head once or twice to make the
work easier.
6-17
(5) Use the following tools for the oil pressure measurements.
Oil pressure measurement tools
Special tool/ Forward clutch Reverse clutch Torque converter

Remarks Main pressure
part number pressure pressure inlet pressure
Connector G (PF) 1/8 and
65628 - 00400 Rc (PT) 1/8 thread
Connector R (PT) 1/8 and
64309 - 17733 G (PF) 3/8 thread
600 kpa
Gauge G (PF) 3/8 (6 kgf/cm2) — — —
64309 - 17714 thread [87 psi]
2000 kPa
Gauge G (PF) 3/8 (20 kgf/cm2) —
64309 - 17713 thread [290 psi]
Both side
Hose G (PF) 3/8
64309 - 17722 thread
Both side
Connector G (PF) 3/8 For gauge
64309 - 17731 thread connection
NOTICE: Tools listed above are included in the gauge kit 64309 - 17701.
6-18
5. Oil pressure measurement procedure

(1) Start the engine, shift the direction lever into the neutral position and measure the main pressure and torque
converter inlet pressure.
(2) Measure the forward clutch pressure and reverse clutch pressure with the lever shifted into the forward position,
then measure it again with the lever in the reverse position.
A: Standard value
Unit: MPa (kgf/cm2) [psi]
Engine rpm Shift Oil pressure
0.88 to 1.08
700 min−1 (rpm) N A (9 to 11)
[128 to 157]
a Main pressure
0.98 o 1.27
2000 min−1 (rpm) N A (10 to 13)
[142 to 184]
0.88 to 1.08
700 min−1 (rpm) Forward A (9 to 11)
[128 to 157]
b Forward clutch pressure
0.98 o 1.27
2000 min−1 (rpm) Forward A (10 to 13)
[142 to 184]
0.88 to 1.08
700 min−1 (rpm) Reverse A (9 to 11)
[128 to 157]
c Reverse clutch pressure
0.98 o 1.27
2000 min−1 (rpm) Reverse A (10 to 13)
[142 to 184]
0.05 to 0.3
700 min−1 (rpm) N A (0.5 to 3)
[7 to 44]
d Torque converter inlet pressure
0.2 to 0.54
2000 min−1 (rpm) N A (2 to 5.5)
[29 to 78.3]
6-19
Clutch (Inching) Pedal Adjustment
Brake
ineffective Play
stroke 3
Top of floor plate

C B Detail C Detail B
b
2
210728
The clutch (inching) mechanism is linked to the brake

pedal. Depressing the brake pedal cuts the pressure acting
on the transmission before the brakes take effect, bringing
the transmission to a neutral condition.
A faulty inching mechanism may create such problems as
failure in clutch disengagement and partial clutch
engagement. This in turn may cause an abnormal increase
in the transmission temperature, as well as braking
malfunctions and clutch plate seizures. Be sure to make all
the following adjustments carefully so that these problems
may be avoided.
1. Adjusting brake pedal

(1) Adjust the brake pedal height A (from the floor plate
top surface to the brake pedal top surface) to the
following standard value by turning the stopper bolt 1
and then lock it with the lock nut.
Brake pedal height A 191 mm (7.52 in.)
(2) Remove the clearance between the push rod pin of the
brake master cylinder 2 and the piston (zero clearance).
6-20
(3) Turn the push rod of the brake master cylinder until the
clearance b in the detail B is adjusted to the range
indicated below.
Truck Model 1 ton 2, 3 ton

Item class classes
0.5 to 1.0 mm
Clearance b (0.020 to 0.039 in.)
(4) Lock the clevis firmly with the lock nut.

(5) If the pedal has been properly adjusted, the brake pedal
free play becomes the range indicated below.

Item class classes
7 mm
Brake pedal free play
(0.276 in.)
2. Adjusting inching pedal

(1) Adjust the height A of the inching pedal (from the floor
plate top surface to the inching pedal top surface) to the
following standard value with the stopper bolt 3.
Inching pedal height A 191 mm (7.52 in.)
(2) Adjust the clearance c between the bolt and linkage in

the portion C to the following value and lock it firmly
with the nut.

Item class classes
Clearance c between 7 mm
bolt and linkage (0.276 in.)
6-21
Inching Cable Adjustment

(1) Block the rear wheels, then raising the front wheels
following the procedure described in the preceding oil Inching lever pin
pressure measurement section.
(2) Connect an oil pressure gauge to the oil pressure tap
Outer
(position b in the illustration). tightening nut
(3) Make sure that the inching rod extension amount A is
within the following range.
Inching
cable
Inching rod extension 82.3±1 mm
amount A (3.24±0.04 in.)
(4) Connect the inching cable to the inching lever pin. Inching cable
play B
(5) Adjust play B on the pedal end of the inching cable to a
value within the following range by turning the outer
tightening nut.
Inching rod
0.5 to 1.5 mm
Play B of inching cable extension amount A
(0.02 to 0.06 in.)
210729
(6) Check that the play of the inching pedal is within the
following range.
1.5 to 6.5 mm
Play of inching pedal
(0.06 to 0.26 in.)
(7) Start the engine, then place the direction lever in the
FWD position.
(8) Depress the inching pedal. Make sure that inching rod
extension amount A does not exceed the following
value and the forward clutch oil pressure is zero.
Inching rod extension

71.7 mm (2.82 in.)
amount A
6-22
Troubleshooting
Engine Engine lacks power Tune up engine.

Poor performance of engine Tune up engine.
Oil level too low Refill.

Air being sucked in on suction side Replace gasket and
retighten.
Faulty action of spool in main regulator valve Repair or replace.
Weakened spring in main regulator valve Replace.
Torque Worn gears in oil pump, resulting in Overhaul and check or
converter reduced capacity replace defective parts.
Magnet strainer clogged Clean or replace.
Seal rings or O-rings worn Replace.
Stator freewheel seized Replace torque converter
assembly.
Not enough
Impeller damaged or rubbing Replace torque converter
output power assembly.
Air being sucked in on suction side Retighten or replace.
Water in oil Replace oil.
Pedal linkage maladjusted Readjust.
Transmission Main pressure too low, resulting in slipping Readjust.
clutches
Seal rings or O-rings worn Replace.
Clutch piston damaged Replace.
Friction plate seized or dragging Replace.
Road wheels High mechanical resistance in road wheels Check and adjust brake
system
Flexible plate broken Replace.

Not enough oil Refill.
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 ring worn in servo case Replace.
O-rings on input shaft worn Replace.
Plug on input shaft loose or slipped off, Repair.
No power flow resulting in oil leaks
Transmission Clutch seized Replace.
Shafts broken Replace.
Clutch drum, particularly snap ring groove, Replace.
defective
Snap ring fitted to clutch drum broken Replace.
Oil way for supplying oil pressure to clutch Clean or replace.
piston clogged
Shaft splines worn Replace shafts.
Power train Broken parts in reduction differential or Repair or replace.
front axle
6-23
Flexible plate broken Replace.

Bearings damaged Replace.
Rubbing blades of running member Replace.torque
Torque converter.
converter Bolts loose Retighten or replace.
Splines worn Replace.
Oil pump noisy Repair or replace.
Friction plates seized and dragging Replace friction plate.

Bearings worn or seized Replace.
Transmission Gears broken Replace.
Bolts loose Retighten or replace.
Splines worn Replace.
Abnormal
noise
Main regulator valve defective Wash or replace.
Loud noise Restriction in oil pipe Replace.
Oil too viscous in cold weather Replace oil.
Instruments faulty Replace.
Wrong kind of oil used Replace oil.

Oil pump defective Replace.
Excessive oil leaks
(1) Main regulator valve spring broken or Replace.
Low noise fatigued
(2) Main regulator valve spool defective Repair or replace.
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 and replace
Oil leaks gasket.
Cracks or blowholes in case Replace.
Oil blowing out of transmission housing
(1) Water in oil Replace oil.
(2) Air being sucked in suction side Replace packing and
retighten.
(3) Oil leaks from air breather Repair.
Oil level too high Lower oil level.
6-24
Oil level too high or too low Refill or drain.

Impeller rubbing Replace torque converter
assembly.
Stator freewheel defective Replace torque converter
assembly.
Torque
converter Air being sucked in Retighten or replace
O-ring.
Water in oil Replace oil.
Restriction in oil pipe (resulting in reduced Repair or replace.
Oil temperature circulation flow)
is too high Bearings worn or seized Repair or replace.
Instruments out of order Replace.
Friction plates dragging Replace friction plates.
Transmission Bearings worn or seized Repair or replace.
Control linkage defective Repair or replace.
Truck not operated properly Urge user to operate
Others properly.
Others
(1) Cooling fan belt damaged Replace.
(2) Oil cooler clogged Clean or replace.
(3) Brakes grabbing Check and readjust.
Main regulator valve defective Repair or replace valve

assembly.
Main pressure is too
high Oil viscosity too high because of low temperature Replace oil.
Wrong kind of oil used Replace oil.

Oil pump failure Replace.
Coil spring defective in main regulator valve Replace.
Main pressure is too Faulty movement of main regulator valve spool Repair or replace.
low Air being sucked in Retighten or replace packing.
Control linkage defective Repair or replace.
Clutch valve out of order Repair or replace.

Oil pump worn or otherwise defective Replace.
Coil spring defective in main regulator valve Replace.
Fautly movement of main regulator valve spool Repair or replace.
Clutch pressure is too Air being sucked in Retighten or replace packing.
low Not enough oil Refill.
Control linkage out of order Repair or replace.
Inching valve defective Repair or replace.
Seal ring broken in servo case Replace.
Clutch piston seal rings broken Replace.
6-25
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 damaged if the speed is Replace stator assembly.
excessively low in both forward and reverse drive
Inching pedal linkage defective, or friction plates Repair or replace.
slipping if the speed is too high
6-26
Tightening Torque
Unit: N·m (kgf·m) [lbf·ft]

Truck Models
1 ton class 2 ton class 3 ton class
Item
Clutch housing cover fixing bolts 15.7 to 20.6 (1.6 to 2.1) [11.6 to 15.2]
Torque converter housing Torque converter housing, transmission
30.4 to 40.2 (3.1 to 4.1) [22.4 to 29.7]
case joining bolts
Oil pump cover, oil pump housing bolts 3.73 to 5.00 (0.38 to 0.51) [2.75 to 3.69]
Oil pump
Oil pump assembly mounting bolt 15.7 to 20.6 (1.6 to 2.1) [11.6 to 15.2]
Transmission case, differential-carrier
44.1 to 51.9 (4.5 to 5.3) [32.5 to 38.3]
fixing bolts
Suction filter spacer fixing bolts 15.7 to 20.6 (1.6 to 2.1) [11.6 to 15.2]
Air breather 4.4 to 5.9 (0.45 to 0.60) [3.25 to 4.35]
Transmission Draining plug 24.5 to 34.3 (2.5 to 3.5) [18.1 to 25.3]

Oil temperature sensor 31.4 to 47.1 (3.2 to 4.8) [23.2 to 34.7]
Orifice plug 4.4 to 5.9 (0.45 to 0.60) [3.25 to 4.35]
Oil pipe fixing bolts 15.7 to 20.6 (1.6 to 2.1) [11.6 to 15.2]
Drive pinion locking nut 245 to 294 (25 to 30) [181 to 217]
Control valve mounting bolt 15.7 to 20.6 (1.6 to 2.1) [11.6 to 15.2]
Orifice plug 4.4 to 5.9 (0.45 to 0.60) [3.25 to 4.35]
Solenoid valve fixing bolts 2.94 to 3.82 (0.30 to 0.39) [2.17 to 2.82]
Side plate fixing bolt 15.7 to 20.6 (1.6 to 2.1) [11.6 to 15.2]
Control valve Inching valve stoppr bolt 15.7 to 17.6 (1.6 to 1.8) [11.6 to 13.0]
Regulator, torque converter relief valve
19.6 to 29.4 (2.0 to 3.0) [14.5 to 21.7]
plug
Hydraulic pressure inspecting port plug 4.4 to 5.9 (0.45 to 0.60) [3.25 to 4.35]
Inching control lever fixing nut 15.7 to 20.6 (1.6 to 2.1) [11.6 to 15.2]
6-27
Service Data
A: Standard value
Unit: mm (in.)
Truck Models
Items
engine at
A 0.88 to 1.08 MPa (9 to 11 kgf/cm2) [128 to 157 psi]
Main pressure 700 min−1 (rpm)
(shift at Neutral position) engine at
2000 min−1 (rpm)
engine at
Forward clutch pressure 700 min−1 (rpm)
(shift at Forward position) engine at
2000 min−1 (rpm)
engine at
Reverse clutch pressure 700 min−1 (rpm)
(shift at Reverse position) engine at
2000 min−1 (rpm)
engine at
A 0.05 to 0.3 MPa (0.5 to 3 kgf/cm2) [7 to 44 psi]
Torque converter inlet pressure 700 min−1 (rpm)
(shift at Neutral position) engine at
A 0.2 to 0.54 MPa (2 to 5.5 kgf/cm2) [29 to 78.3 psi]
2000 min−1 (rpm)
Free length A 102 (4.02)
Accumlator piston
spring (inner) 1 Load at height
A 40.2 N (4.1 kgf) [9.04 lbf]
86.1 mm (3.39 in.)
Accumlator piston
spring (outer) 2 Load at height
A 107 N (10.9 kgf) [24 lbf]
86.1 mm (3.39 in.)
Free length A 87.2 (3.43)
Control Regulator valve
valve spring 3 Load at height
A 49 N (5 kgf) [11 lbf]
75.8 mm (2.98 in.)
Free length A 27.9 (1.1)
Converter relief
valve spring 4 Load at height
A 22.1 N (2.25 kgf) [4.97 lbf]
23 mm (0.91 in.)
Inching valve
spring 5 Load at height
A 32 N (3.26 kgf) [7.19 lbf]
56.5 mm (2.22 in.)
6-28
Truck Models
Items
Control
valve
211121
6-29

Powershift Transmission PDF

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POWERSHIFT TRANSMISSION

Structure and Function ........................................................................ 6 – 1

Structure and Function

1 Torque converter 7 Clutch piston 13 Drive pinion shaft

1 Turbine runner 6 Clutch hub

1 Accumulator piston 7 Regulator valve spring

Hydraulic System Schematic of Powershift Transmission

Hydraulic circuit (at neutral)

Forward Forward solenoid valve

Hydraulic circuit (at forward)

Forward solenoid valve

Hydraulic circuit (at reverse)

Forward solenoid valve

Removal and Installation

(2) Couple the torque converter and transmission

(4) Refill the front axle housing with the recommended

Inspection after Disassembly

Suggestions for Reassembly

1. Cleaning oil passages

2.94 to 3.82 N·m

Input Shaft Assembly

Suggestions for Disassembly

Disassembling input shaft

Inspection after Disassembly

4. Friction plates and mating plates

A: Standard value B: Repair or service limit

Oil Pump Assembly

Suggestion for Disassembly

Inspection after Disassembly

(4) Measure the gap between the external circumference of

(5) Measure the oil pump sleeve bushing internal diameter

Inspection and Adjustment

Oil Pressure Measurement

3. Engine speed measurement

4. Preparation for oil pressure measurement

NOTICE: When loosening the plugs a through d, tap

Oil pressure measurement tools

Special tool/ Forward clutch Reverse clutch Torque converter

5. Oil pressure measurement procedure

Clutch (Inching) Pedal Adjustment

Top of floor plate

The clutch (inching) mechanism is linked to the brake

1. Adjusting brake pedal

Brake pedal height A 191 mm (7.52 in.)

Truck Model 1 ton 2, 3 ton

(4) Lock the clevis firmly with the lock nut.

Truck Model 1 ton 2, 3 ton

2. Adjusting inching pedal

Inching pedal height A 191 mm (7.52 in.)

(2) Adjust the clearance c between the bolt and linkage in

Truck Model 1 ton 2, 3 ton

Inching Cable Adjustment

Inching rod extension

Engine Engine lacks power Tune up engine.

Oil level too low Refill.

Flexible plate broken Replace.

Flexible plate broken Replace.

Friction plates seized and dragging Replace friction plate.

Magnet strainer clogged Clean or replace.

Leaking oil seals Check lips and sliding

Oil level too high or too low Refill or drain.

Main regulator valve defective Repair or replace valve

Wrong kind of oil used Replace oil.