1. Specifications... 5-3 2. Structure... 5-4 2.1 Torque converter... 5-4 2.2 Transmission... 5-5 2.3 Power Train Line... 5-6 2.4 Control Valve... 5-7 2.5 Main Regulator Valve... 5-7 2.6 Torque Converter Drive Transmission Hydraulic System Schematic... 5-8 2.7 Automatic 2-speed Shifting Mechanism... 5-9 2.8 Torque Converter Drive Control System... 5-10 3. Suggestions for Removal and Installation... 5-11 3.1 Removal... 5-11 3.1.1 Transmission Removal... 5-11 3.1.2 Torque Converter Removal... 5-11 3.2 Installation... 5-12 4. Disassembly and Reassembly... 5-13 4.1 Torque converter... 5-13 4.1.1 Disassembly... 5-13 4.1.2 Inspection and Repair... 5-14 4.1.3 Reassembly... 5-16 4.2 Transmission (2nd)... 5-18 4.2.1 Disassembly... 5-18 4.2.2 Inspection and Repair... 5-26 4.2.3 Reassembly... 5-30 4.3 Control Valve... 5-37 4.3.1 Disassembly... 5-37 4.3.2 Inspection and Repair... 5-39 4.3.3 Reassembly... 5-40 4.4 Main Regulator Valve... 5-41 4.4.1 Disassembly... 5-41 4.4.2 Inspection and Repair... 5-41 4.4.3 Reassembly... 5-41 5. Readjust... 5-42 5.1 Oil Pressure Measurement... 5-42 5.1.1 Preparation... 5-42 1 2 3 4 5 6 7 8 9 10 11 12 13 14 5-1
5.2 Clutch Valve Test... 5-43 5.2.1 Preparation... 5-43 5.2.2 Testing procedure... 5-43 5.3 Stall Speed Measurement... 5-44 5.3.1 Measurement procedure... 5-44 5.4 10m (33 ft) Start Acceleration Test... 5-45 5.4.1 Testing procedure... 5-45 5.5 Confirming the function of Automatic 2-speed transmission... 5-45 5.6 Inching Pedal Adjustment... 5-46 5.6.1 Preparation... 5-46 5.6.2 Readjust... 5-47 6. Troubleshooting... 5-48 7. Service Data... 5-53 7.1 Stall Speed... 5-53 7.2 Pump boss... 5-53 7.3 Pilot boss... 5-54 7.4 Oil Pump... 5-54 7.5 Stator... 5-55 7.6 Flexible plate... 5-55 7.7 Clutches... 5-56 7.8 Input shaft, Counter shaft and Transmission Cover... 5-57 7.9 Backlash of Gears... 5-58 7.10 Control Valve... 5-59 7.11 Main Regulator Valve... 5-60 7.12 Inching Pedal Control... 5-61 5-2
1. Specifications Torque converter Transmission Truck model DP60 DP70 Type Maker model 3-element, 1-stage, 2-phase ML15 Stall torque ratio 2.9 Operation method Reduction ratio Forward/ Reverse Reverse Forward Reverse Forward/reverse switching electrical column shift H/L automatic drive 1st: 2.138 2nd: 0.685 1st: 2.138 2nd: 0.685 5-3
2. Structure 2.1 Torque converter 205458 1 Turbine runner 7 Hub 13 Thrust bearing 2 Stator assembly 8 Roller 14 Spacer 3 Pump impeller 9 Spring 15 Ball bearing 4 Drive cover 10 Spring cap 16 Pilot boss 5 Pump boss 11 Thrust washer 17 Flexible plate 6 Ball bearing 12 Thrust washer 5-4
2.2 Transmission 205459 1 Flexible plates 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. The gear shifting is a power-shift type implemented by the hydraulic multi-disc type clutch. 5-5
2.3 Power Train Line Figures in ( ) indicate number of gear teeth. Forward 1st Reverse 1st Forward 2nd Reverse 2nd 205460B Speed Gears engaged Gear ratio Forward 1st 52/52 62/29 2.138 2nd 52/52 37/54 0.685 Reverse 1st 62/29 2.138 2nd 37/54 0.685 PTO gear 60/42 39/60 0.929 5-6
2.4 Control Valve Section A A Section B B Section C C 205461 1 Accumulator valve 3 Clutch valve plunger 5 Speed (H/L) valve 2 Directional valve 4 Clutch valve 2.5 Main Regulator Valve 10 9 8 7 6 5 4 3 2 1 200554A 1 Bolt 5 Spool 8 Drain port 2 Cover 6 Body 9 Main pressure port 3 O-ring 7 Spring 10 Torque converter inlet pressure port 4 Slug 5-7
2.6 Torque Converter Drive Transmission Hydraulic System Schematic Chassis area Torque converter bypass orifice: Diam. 4.0 mm (0.157 in.) Torque converter Diam. 6 mm (0.24 in.) Oil filter Transmission oil reservoir Orifice: Diam. 0.8 mm (0.031 in.) Orifice: Diam. 0.8 mm (0.031 in.) Last chance filter 230 m Last chance filter 230 m Solenoid valve (speed selection) Orifice: Diam. 0.8 mm (0.031 in.) Solenoid valve (direction selection) Last chance filter 230 m Tap (plug) for torque converter inlet pressure (marked T ) Tap (plug) for main pressure (marked M ) Pc Oil cooler Torque converter inlet relief valve Setting: 49 to 490 kpa (0.5 to 5.0 kgf/cm 2 ) [7 to 71 psi] 98 to 981 kpa (1.0 to 10.0 kgf/cm 2 ) [14 to 142 psi] Lubrication relief valve Setting: 20 to 147 kpa (0.2 to 1.5 kgf/cm 2 ) [3 to 21 psi] Oil pump Capacity: 70 liters (18.5 U.S. gal)/min at 2300 rpm Lubrication line Solenoid valve (direction selection) Main regulator valve Setting: 1079 to 1373 kpa (11.0 to 14 kgf/cm 2 ) [156 to 199 psi] k k k Pc Pp Main orifice: Diam. 2.0 mm (0.079 in.) k Oil filter for forward/ reverse clutches (particle size 95 m) Response (inching) valve Setting: 0 to 216 kpa (0 to 2.2 kgf/cm 2 ) [0 to 31.3 psi] Accumulator valve Pressure at start of charging: 206 kpa (2.1 kgf/cm 2 ) [30 psi] Pressure at end of charging: 706 kpa (7.2 kgf/cm 2 ) [102 psi] Suction strainer with magnet 100 mesh (particle size 220 m) 205923 5-8
2.7 Automatic 2-speed Shifting Mechanism Control System Travel speed selector switch Output gear Electronic Control Unit (ECU) Travel speed (solenoid) valve 1st speed clutch 2nd speed clutch Pulse generator Electric signal 0.5 mm (0.02 in.) Transmission case Hydraulic pressure signal Electronic Control Unit (ECU) Power source Speed selector switch Solenoid valves Pulse generator 205646 The automatic 2-speed transmission is made up of a combination of the torque converter drive transmission enabling 2 speeds for each of the forward and reverse directions with the dedicated control system, which consists of the pulse generator, ECU, and solenoid valves. With the speed selection switch, it is possible to shift the travel speed manually between the Automatic 2-speed and Fixed 1st speed modes whichever is more suitable for the current operational situation. Selector switch position (mode) Automatic 2-speed Fixed 1st speed Travel speed 1st 0 to 6 km/h (0 to 6.2 mph) 2nd 6 to 27.5 km/h (6.2 to 17.1 mph) 0 to 10 km/h (0 to 6.2 mph) NOTE ECU is an acronym of Electronic Control Unit. 5-9
2.8 Torque Converter Drive Control System 211312 1 Direction lever 6 Clutch valve plunger 2 Inching bracket 7 Inching lever 3 Control Valve 8 Cable 4 Solenoid valve (for 1st and 2nd) 9 ECU 5 Solenoid valve (for forward/reverse) 10 Inching pedal 5-10
3. Suggestions for Removal and Installation When installing and removing the transmission assembly to/from the truck, handle it as an unit of the engine. For the actual operation practices refer to 4. POWER TRAIN. 3.1 Removal 3.1.1 Transmission Removal (1) Place the engine on a stable stand, since it will be left as an single unit after the transmission is separated from it. Make the whole unit stable by additionally supporting the transmission part with the placed wooden blocks. (2) Remove the hydraulic gear pump from the transmission. (3) Hoist the transmission with wire ropes and lift it just enough to take the weight of the transmission. To lift the transmission, tie a wire rope around the torque converter case. To lift the transmission, screw a washer-based eye bolt into the transmission cover, and hitch a chain with the eye bolt. Use this 2-point lifting method with the leveling block inserted under the transmission to ensure its level. (4) Remove the flexible plate fastening bolts through the access hole in the transmission case. (5) Separate the transmission from the engine by lifting the transmission with the hoist. 3.1.2 Torque Converter Removal (1) The torque converter can be removed easily, since it is merely inserted into the stator shift, PTO drive gear, and input shaft of the transmission, which is just removed as an assembly. 205464 NOTE Because the torque converter does boot have a drain plug, it is not possible to completely drain the remaining oil. The oil must be drained by facing the pump boss side down during removal. 5-11