hyster-897949-11-03-srm0635

FOUR-SPEEDPOWERSHIFTTRANSMISSION

REPAIR(HR 36000)

H36.00-48.00E (H800-1050E) [D117];RS45-30CH, RS46-35CH, RS45-25IH, RS46-30IH,

RS45-46TP, RS45-46TBP [A222];HR45-25, HR45-27, HR45-31, HR45-40S, HR45-36L, HR45-40LS,

HR45-45LSX, HR45H [A227, B227]

PART NO. 897949 1300 SRM 635

SAFETY PRECAUTIONSMAINTENANCE AND REPAIR

When lifting parts or assemblies, make sure all slings, chains, or cables are correctlyfastened, and that the load being lifted is balanced. Make sure the crane, cables, andchains have the capacity to support the weight of the load.

Do not lift heavy parts by hand, use a lifting mechanism.

Wear safety glasses.

DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repairon electric lift trucks.

Disconnect the battery ground cable on internal combustion lift trucks.

Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUTTHE LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Mainte-nance section.

Keep the unit clean and the working area clean and orderly.

Use the correct tools for the job.

Keep the tools clean and in good condition.

Always use HYSTER APPROVED parts when making repairs. Replacement partsmust meet or exceed the specifications of the original equipment manufacturer.

Make sure all nuts, bolts, snap rings, and other fastening devices are removed beforeusing force to remove parts.

Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs,or if the unit needs repairs.

Be sure to follow the WARNING and CAUTION notes in the instructions.

Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuelare flammable. Be sure to follow the necessary safety precautions when handling thesefuels and when working on these fuel systems.

Batteries generate flammable gas when they are being charged. Keep fire and sparksaway from the area. Make sure the area is well ventilated.

NOTE: The following symbols and words indicate safety information in thismanual:

WARNINGIndicates a condition that can cause immediate death or injury!

CAUTIONIndicates a condition that can cause property damage!

Four-Speed Powershift Transmission Table of Contents

TABLE OF CONTENTS

General ............................................................................................................................................................... 1Torque Converter Repair ................................................................................................................................... 2

Torque Converter, Remove ............................................................................................................................ 2Torque Converter, Disassemble .................................................................................................................... 2Clean and Inspect .......................................................................................................................................... 2Torque Converter, Assemble ......................................................................................................................... 2Torque Converter (Turbine) Housing, Disassemble..................................................................................... 5Relief Valve for Lube Pressure, Disassemble and Assemble....................................................................... 5Oil Sealing Rings Sleeve, Replace ................................................................................................................ 5Torque Converter Housing, Assemble .......................................................................................................... 6Torque Converter, Install .............................................................................................................................. 6

Transmission Repair .......................................................................................................................................... 6Remove, Transmission Only.......................................................................................................................... 6Remove, Transmission and Engine Assembly.............................................................................................. 7Transmission, Disassemble ........................................................................................................................... 8

Output Shaft, Disassemble and Assemble............................................................................................... 9Fourth-Speed Shaft, Disassemble and Assemble .................................................................................... 10Third-Speed Shaft, Disassemble and Assemble ...................................................................................... 11Forward Shaft and Clutch, Disassemble and Assemble ......................................................................... 14Reverse and Second-Speed Shaft and Clutch, Disassemble and Assemble ........................................... 16First-Speed Shaft and Clutch, Disassemble and Assemble .................................................................... 18Input Shaft, Disassemble and Assemble.................................................................................................. 20

Speed Sensor, Install ..................................................................................................................................... 20Transmission, Clean and Inspect.................................................................................................................. 22Transmission, Assemble................................................................................................................................ 22Control Valve.................................................................................................................................................. 24

Clean and Inspect...................................................................................................................................... 24Assemble and Install................................................................................................................................. 24

Install, Transmission .................................................................................................................................... 25Install, Transmission and Engine Assembly................................................................................................ 25Clean Oil System of Transmission after Major Repair................................................................................ 26

Automatic Powershift Control (APC 100)......................................................................................................... 26Functional Description .................................................................................................................................. 26Fuses .............................................................................................................................................................. 29Transmission Control Lever.......................................................................................................................... 29

First-Speed Shaft Bearings Adjustment........................................................................................................... 32Torque Converter Stall Speed Check ................................................................................................................ 35Transmission Oil Pressures Check ................................................................................................................... 35

Clutch Pressures Check ................................................................................................................................ 35Torque Converter (Torque Converter Regulator) Oil Pressure Check........................................................ 35

Troubleshooting.................................................................................................................................................. 37Diagrams, Schematics, or Arrangements ......................................................................................................... 39

Figure 31. Transmission Hydraulic Diagram.......................................................................................... 40

This section is for the following models:

H36.00-48.00E (H800-1050E) [D117];RS45-30CH, RS46-35CH, RS45-25IH, RS46-30IH,

RS45-46TP, RS45-46TBP [A222];HR45-25, HR45-27, HR45-31, HR45-40S, HR45-36L, HR45-40LS,

HR45-45LSX, HR45H [A227, B227]

2003 HYSTER COMPANY i

"THEQUALITYKEEPERS"

HYSTERAPPROVEDPARTS

1300 SRM 635 General

GeneralThis four-speed powershift transmission is anHR-36000 series transmission manufactured bySpicer-Clark.

This section has the repair procedures for thetorque converter, transmission, control valve, andthe oil pump for the transmission. See the sectionFour-Speed Powershift Transmission Descrip-tion and Operation 1300 SRM 634 for informationon the operation of this transmission. The transmis-sion assembly is shown in Figure 1.

ALWAYS replace all seals, O-rings, metal seal rings,gaskets, and snap rings with new ones. Lubricate allseals with clean transmission oil before installation.Lubricate metal seal rings with multipurpose grease#2 before installation. Use care with seals especiallyduring installation to prevent damage.

If possible, use magnaflux to check all gears andshafts. Check gear teeth for wear, pitting, chipping,nicks, cracks, or scoring. If gears show spots wherehardened surface has worn through, replace gear.Make sure shafts are not bent or the splines twisted.

1. TRANSMISSION OIL PUMP2. FORWARD CLUTCH3. THIRD CLUTCH4. REAR COVER5. FIRST CLUTCH6. OUTPUT YOKE7. OUTPUT GEAR

8. TRANSMISSION HOUSING9. OIL SUMP AND PAN10. FOURTH CLUTCH11. SECOND CLUTCH12. REVERSE CLUTCH13. IMPELLER HUB GEAR

14. TORQUE CONVERTERHOUSING

15. TURBINE OF TORQUECONVERTER

16. INPUT SHAFT AND GEAR17. PUMP DRIVE GEAR

Figure 1. Transmission (HR-36000)

1

Torque Converter Repair 1300 SRM 635

Torque Converter RepairTORQUE CONVERTER, REMOVEThe torque converter is removed during removal ofthe transmission. See Remove, Transmission Onlyprocedures for the transmission.

TORQUE CONVERTER, DISASSEMBLEIf it is necessary to disassemble the torque converter,do so as follows and as shown in Figure 2:

1. Remove capscrews and lockwashers that fastendrive plates and bearing cover to impeller cover.Remove backing ring, drive plates, bearing cover,and O-ring.

2. Remove two rings and washer spacer that fas-tens the turbine hub. One ring is thicker thanthe hub locating ring.

NOTE: Use a drain pan for the oil in the convertersection that did not drain during initial drain of oil.

3. Remove screws and washers that fasten impellercover. Use a screwdriver at the slots to removeimpeller cover, turbine, and turbine hub. Re-move large O-ring for the cover.

4. Remove locating snap ring from under turbinehub. This ring is thinner than the retainer ringof Step 2. Remove snap ring that fastens statorto stator support. The stator support is fastenedto the stator with a dowel. Do not remove spacerif stator or spacer will not be replaced.

5. Remove retainer for oil baffle (Figure 3). Use aspecial removal tool to remove impeller and oilbaffle. The special removal tool is very similar toa gear puller, but is for larger diameter parts.

6. Remove screws and washers that fasten statorsupport to converter housing. Rotate stator sup-port so there is clearance between stator supportand pump drive gear. The "cutout" in the statorsupport allows this clearance.

7. Remove snap ring for the impeller hub gear (Fig-ure 3). Remove hub gear from impeller hub. Re-move oil baffle, oil seal, and baffle seal ring.

8. Remove screws and washers that fasten hub toimpeller. Remove backing ring. Remove impellerfrom hub. Remove O-ring between hub and im-peller.

9. Straighten locking tabs for hub bolts. Removeturbine-to-hub bolts and washers. Remove tur-bine hub.

If necessary, disassemble turbine and impeller cover.Install blocks under the edges of the impeller cover tosuspend the turbine and hub. Remove bearing snapring and spacer. Use a drift and hammer to removeturbine and hub from impeller cover bearing.

CLEAN AND INSPECT

WARNINGCleaning solvents can be flammable and toxicand can cause skin irritation. When usingcleaning solvents, always follow the solventmanufacturers recommended safety precau-tions.

Clean the parts of the torque converter in solvent.Dry parts with compressed air. Inspect splines andgear teeth for damage. Inspect shafts, bearings,and bearing surfaces for scratches, wear, or damage.Clean holes that have threads and capscrews wherea thread-locking compound is used.

TORQUE CONVERTER, ASSEMBLEIf the turbine and impeller cover were not disassem-bled, go to Step 3.

If disassembled, assemble turbine and impeller coveras follows (see Figure 2):

1. Align holes in turbine and turbine hub and in-stall lock tabs, hub bolts, and washers. Tightenhub bolts to 122 to 134 Nm (90 to 99 lbf ft). Benda corner of lock tab over bolt heads.

2. Align impeller cover over turbine and hub. In-stall bearing for impeller cover in cover and overturbine hub. Install new O-ring. Install spaceron turbine hub. Install bearing rings.

2

1300 SRM 635 Torque Converter Repair

Figure 2. Torque Converter and Flywheel

3

Torque Converter Repair 1300 SRM 635

Legend for Figure 2

1. TURBINE HUB2. SNAP RING3. REACTION MEMBER4. SPACER5. BEARING6. IMPELLER HUB7. O-RING8. IMPELLER

9. BACKING RING10. BEARING COVER11. RING12. IMPELLER COVER13. LOCK TAB14. TURBINE15. FLYWHEEL16. DRIVE PLATES

1. SNAP RING2. BEARING3. BEARING SUPPORT4. HYDRAULIC PUMP GEAR5. TURBINE HOUSING6. SPRING7. PISTON RING8. SLEEVE9. STATOR SUPPORT

10. TUBE11. WASHER12. INPUT SHAFT13. RETAINER14. BAFFLE15. SEAL RING16. OIL SEAL17. IMPELLER GEAR

Figure 3. Input Shaft and Pump Drive Gears

4

1300 SRM 635 Torque Converter Repair

3. Make sure the surface of impeller hub and holesfor screws are clean and dry. Put new O-ring onimpeller hub. If removed, use a drift or press thesame size as the bearing and install hub bearingand snap ring in hub.

4. Align holes in impeller with hub holes. Do NOTdamage O-ring. The two dimples that are 180degrees apart on backing ring must be installedtoward engine flywheel. Install backing ringand install new special self-locking screws andwashers. Tighten screws to 79 to 87 Nm (58 to64 lbf ft).

CAUTIONMake sure the total time to install and tightenthe special screws is less than 15 minutes. Ifany screw is removed for any reason, it mustbe replaced. The epoxy left in the hub holemust be removed with a tap and cleaned withsolvent. Make sure the hole is dry before in-stalling a new screw.

5. Put a thin coat of Loctite 638 on the outer di-ameter of the oil seal of the oil baffle (Figure 3).Press oil seal in oil baffle with lip of seal down.

6. Carefully install oil baffle on impeller withoutdamaging oil seal. Install a new sealing ring foroil baffle. Install hub gear on impeller hub andinstall snap ring.

TORQUE CONVERTER (TURBINE)HOUSING, DISASSEMBLEIf necessary, disassemble converter housing assem-bly as follows:

1. Remove snap ring for front bearing of input shaft.Use a hammer with a soft face to lightly hit inputshaft to remove it and bearing from housing.

2. Put a mark on each pump gear for correct loca-tion during installation. Remove bearing sup-port screws and lockwashers for the drive (cen-ter) gear. Remove drive gear and bearing assem-bly. Remove other two pump gear and bearingassemblies using the same procedure.

RELIEF VALVE FOR LUBE PRESSURE,DISASSEMBLE AND ASSEMBLEIf the unit has this relief valve, disassemble, clean, orreplace and assemble the valve as shown in Figure 4.

1. HOUSING2. WASHER3. SPRING4. SEAT

5. PLUNGER6. VALVE SEAT

RETAINER7. RETAINING RING

Figure 4. Relief Valve Assembly

OIL SEALING RINGS SLEEVE, REPLACEThere is a sleeve at the front end of the forward,reverse, and fourth-gear clutch shafts. Remove thesleeves ONLY if they are to be replaced.

1. Remove locating ring for front bearing of clutchshaft.

2. Remove retainer plate screw, washer, and plate.

3. Remove sleeve using a puller.

4. Use a press or a driver to prevent damage to thesleeve during installation. Make sure the notchin the new sleeve is aligned with the sleeve locknotch.

5. Put sleeve lock in position. Install capscrew andwasher. Tighten capscrew.

6. Install locating ring for front bearing of clutchshaft in ring groove.

5

Transmission Repair 1300 SRM 635

TORQUE CONVERTER HOUSING,ASSEMBLEAssemble converter housing assembly as follows andas shown in Figure 3:

1. Install two pump drive gears as marked duringdisassembly. Install transmission pump gear atcenter location. Tighten all mount capscrews.

2. Install input shaft and gear. Use a hammer witha soft face to tap shaft so bearing snap ring canbe installed. Install snap ring and continue to tapshaft so snap ring is against shoulder in housing.

3. Open locating ring for the front bearing of thereverse clutch. See Figure 15. Use a hammer

with a soft face to tap shaft of the reverse andsecond clutch until locating ring is completely ingroove of converter housing.

4. Open locating ring for the front bearing of thefourth-speed clutch. See Figure 7. Use a hammerwith a soft face to tap shaft of the fourth-speedclutch until locating ring is completely in grooveof converter housing.

5. Install the front bearing of the forward clutch.

TORQUE CONVERTER, INSTALLThe torque converter is assembled in the torque con-verter housing and is installed with the transmis-sion. See Install, Transmission .

Transmission RepairREMOVE, TRANSMISSION ONLYNOTE: The transmission can be removed from underthe lift truck or as a complete assembly with the en-gine. If an inspection pit is not available, the truckmust be raised 500 mm (19.7 in.) from the ground toprovide easier access and removal.

1. Place truck on level surface.

2. Shut down engine.

3. Apply parking brake.

4. Operate all hydraulics to release pressure in thesystem.

NOTE: When removing battery cables, removeground cable first.

5. Disconnect the cables at the battery.

6. Remove floor plates and covers to provide accessto the hydraulic pump and transmission.

7. Close shut-off valves on hydraulic tank.

8. Disconnect the drive shaft at the differential.

9. Remove the drive shaft between the transmis-sion and the differential.

10. Disconnect the wiring harness on top of thetransmission.

11. Disconnect the wires at the solenoids on thetransmission control valve.

12. Disconnect the wires at the pressure and temper-ature sending unit on the transmission.

13. Place tags on lines for identification.

14. Remove the drain plug from the transmissionsump.

15. Drain the oil.

16. Put plugs and caps on open fittings.

17. Disconnect the hoses at the hydraulic pumps.


NOTE: The hydraulic pumps are fastened to thetransmission with 4 capscrew each.

The drive shaft of the hydraulic pump is engaged insplines in the drive gear.

The drive shaft of the hydraulic pump will slide fromthe drive gear when the hydraulic pump is removed.

19. Remove the hydraulic pumps.

20. Disconnect and remove the dipstick assembly.

21. Install blocks and a jack under the flywheel endof the engine as a support.

22. Disconnect exhaust system to avoid possibledamage.

6

1300 SRM 635 Transmission Repair

WARNINGVerify the lifting device has the minimum ca-pacity of 725 kg (1600 lb).

23. Connect a lifting device to the transmission.

24. Remove the transmission mounts to the frame.See Figure 5.

NOTE: RS45-30CH, RS46-35CH, RS45-25IH, RS46-30IH (A222) SHOWN.1. TRANSMISSION

HOUSING2. TRANSMISSION

MOUNT

3. FRAME MOUNT4. FRAME BRACKET5. ISOLATOR

Figure 5. Transmission Mount

25. Remove the 8 bolts securing the drive plates tothe torque converter.

26. Remove all fasteners between engine flywheelhousing and torque convertor housing.

27. Verify all the connections have been removed.

28. Carefully slide back the transmission from theframe approximately 40 mm (1.60 in.) to permitthe transmission to be lowered.

WARNINGThe transmission is heavy, verify that the lift-ing devices are securely positioned.

29. Carefully, to avoid damage to the flex plate, lowerthe transmission assembly past the cross mem-ber support.

REMOVE, TRANSMISSION AND ENGINEASSEMBLYNOTE: The transmission can be removed from underthe lift truck or as a complete assembly with the en-gine. If an inspection pit is not available, the truckmust be raised 500 mm (19.7 in.) from the ground toprovide easier access and removal.

1. Place truck on level surface.

2. Shut down engine.

3. Apply parking brake.

4. Operate all hydraulics to release pressure in thesystem.

NOTE: When removing battery cables, removeground cable first.

5. Disconnect the cables at the battery.

6. Remove floor plates and covers to provide accessto the hydraulic pump and transmission.

7. Close shut-off valves on hydraulic tank.

8. Disconnect the drive shaft at the differential.

9. Remove the drive shaft between the transmis-sion and the differential.

10. Disconnect the wiring harness on top of thetransmission.

11. Disconnect the wires at the solenoids on thetransmission control valve.

12. Disconnect the wires at the pressure and temper-ature sending unit on the transmission.

13. Place tags on lines for identification.

14. Remove the drain plug from the transmissionsump.

15. Drain the oil.


17. Disconnect the hoses at the hydraulic pumps.


7


NOTE: The hydraulic pumps are fastened to thetransmission with 4 capscrew each.

The drive shaft of the hydraulic pump is engaged insplines in the drive gear.

The drive shaft of the hydraulic pump will slide fromthe drive gear when the hydraulic pump is removed.

19. Remove the hydraulic pumps.

20. Disconnect and remove the dipstick assembly.

21. Install blocks and a jack under the flywheel endof the engine as a support.

22. Disconnect exhaust system to avoid possibledamage.

23. Remove engine hood and ballast cover.

24. Disconnect the air cleaner intake elbow.

25. Drain coolant from the cooling system.

26. Disconnect cooling lines.

27. Remove the radiator and transmission oil cooler.

28. Remove the tubing between the engine and aircleaner.

29. Disconnect fuel lines at the fuel filter.

30. Disconnect the throttle linkage.

31. Disconnect wires and wiring harnesses at the en-gine.

32. Disconnect the heater hoses at the engine.

NOTE: Verify that the lifting device has a capacity ofat least 1360 kg (3000 lb).

33. Connect a lifting device to the engine.

34. Remove the capscrews that hold the enginemount at the fan end of the engine. See Figure 6.

35. Remove the capscrews that hold the two rear en-gine mount brackets to the frame.

NOTE: Verify all the connections to the engine ortransmission have been removed.

36. Carefully lift the engine and transmission as-sembly from the frame.

1. REAR MOUNT (FAN END OF ENGINE)2. FRONT MOUNT

Figure 6. Engine Mounts

TRANSMISSION, DISASSEMBLEMake sure to keep the parts for each clutch togetherduring disassembly. Make a note of the order of thefriction discs and separator plates of each clutch.Also make a note of which way each bearing sealis facing for correct installation. Disassemble thetransmission as follows:

1. Remove torque converter assembly from trans-mission. If necessary, disassemble torque con-verter as described in Torque Converter, Disas-semble.

2. Remove solenoid dust cover from transmissioncontrol valve. Remove screws and lockwashersthat fasten control valve cover. Remove cover as-sembly of control valve, seal plate, and inner andouter gaskets. Remove control valve housing andgasket.

3. Remove screws that fasten stator support. Ro-tate stator support so curved "cutout" section isaligned with pump drive gear to allow removal.See Figure 3. Remove stator support.

4. Use a crane and sling to support torque con-verter housing. Remove capscrews that fastentorque converter housing to transmission case.Remove torque converter housing with thereverse/second- and fourth-speed clutch assem-blies attached.

5. Remove snap ring that fastens front bearing forthe fourth clutch to the torque converter housing.

8


It can be necessary to use a prybar to remove thefourth-speed clutch assembly from housing.

6. Remove snap ring that fastens the front bearingfor the second and reverse clutch to the torqueconverter housing. See Figure 15. It can be nec-essary to use a prybar to remove the second andreverse clutch assembly from housing.

7. Remove output shaft nut, washers, yoke, seal,and yoke from output shaft. Remove seal andspacer. Remove bearing cap nuts and lockwash-ers for rear bearing of output shaft. Removebearing cap and O-ring. See Figure 7.

8. Remove bearing cap nuts and lockwashers forbearing of the third-speed shaft. Remove bearingcap, O-ring, rings, and washer. See Figure 10.

9. Remove bearing cap nuts and lockwashers for thebearing of the first-speed (low) shaft. Removebearing cap, shims, O-ring, and ring. See Fig-ure 17. Keep cap and shims together. If cap,clutch, front or rear bearings, transmission case,or rear cover are not replaced, the same shimswill be used during assembly.

10. Remove clutch pressure and lube tubes andO-rings at the holes under bearing cap for thefirst-speed shaft bearing.

11. Remove locating rings for the rear bearings of thethird-speed and output shafts.

12. Remove nuts, screws, and lockwashers that fas-ten the rear cover of the transmission. Removeoil screen plug and oil screen. Tap on the end ofthe output shaft and clutch shafts while pryingcover off to remove cover. Using aligning studscan help in the removal. Remove cover gasket.

13. Remove retaining ring for the fourth-speed hub.Remove hub. Remove three retaining rings forthe second-speed hub. Remove hub.

14. Use a bearing puller to remove the rear bearingof the output shaft. Remove first-speed clutchand output shaft simultaneously. Remove frontbearing for output shaft.

15. Remove clutch assembly of the third-speedclutch.

16. Remove oil baffle screws, lockwashers, and oilbaffle from cover. Remove bolts and lockwashers

of the suction tube. Remove suction tube andO-ring.

17. Have another person release the bearing snapring for the rear bearing of the forward shaft.Use a hammer that has a soft face to tap the endof the shaft for removal.

18. Remove forward clutch assembly. See Figure 12.Remove outer race of the rear bearing of the in-put shaft. Remove bearing cup and oil bafflespacer of the first-speed shaft.

Output Shaft, Disassemble and AssembleNOTE: The following procedures describe the disas-sembly of each of the shaft assemblies and clutches.These assemblies have been removed from the trans-mission as assemblies in the previous procedures.Disassemble only the shaft or clutch assembly nec-essary to make repairs.

CAUTIONInspect all bearings for damage and wear.Bearings are normally replaced during a ma-jor disassembly and assembly such as this.

Inspect clutch plates for wear of friction mate-rial and damage to the separator plates.

Make sure to keep all parts of each clutch as-sembly together. Some of these parts look thesame, but are not. Using the wrong part cancause incorrect operation or damage.

Always use new seals, seal rings, and snaprings during assembly. Apply a thin coat ofmultipurpose grease #2 to all seals before in-stallation. Fill all seal grooves with this samegrease.

The following procedure describes the disassemblyand assembly of the output shaft. See Figure 7:

1. Remove inner race of the front bearing of the out-put shaft.

2. Remove front retaining ring for the output gear.Remove spacers and gear from shaft. If neces-sary, remove rear retaining ring.

9


1. SEPARATOR DISC (TEETHOUTSIDE)

2. FRICTION DISC (TEETHINSIDE)

3. BACKING PLATE4. RING5. SEAL6. SPRING

7. SPRING RETAINER8. HUB9. TRANSMISSION HOUSING10. BEARING11. RETAINER12. SPACER13. OUTPUT GEAR14. REAR COVER

15. CLUTCH DRUM AND GEARFOR FOURTH SPEED

16. PISTON17. OUTPUT SHAFT18. BEARING CAP19. O-RING20. PLUG21. YOKE

Figure 7. Fourth-Speed Shaft and Output Shaft

3. If removed, install rear retaining ring on outputshaft. Install spacers and gear with long hubtoward rear. Install front retaining ring.

4. Install retainer and press front bearing on out-put shaft with race shoulder facing gear. Installbearing and outer race on inner race.

5. Install clutch hub on shaft using retaining rings.

Fourth-Speed Shaft, Disassemble andAssembleThe following procedure describes the disassemblyand assembly of the fourth-speed shaft: See Figure 7and Figure 8.

1. Remove oil sealing rings from the fourth-clutchshaft. Remove snap ring for front bearing andremove bearing using a bearing puller. Removeother ring.

10


2. Remove snap ring for the backing plate of theclutch disc and remove backing plate. Removeall friction and separator discs.

3. Remove seal. Compress wave spring and removeretaining ring from its groove. Release wavespring and remove snap ring and retainer for thespring. Remove wave spring and thrust washer.Turn assembly over and tap shaft on a block ofwood to remove seals and piston.

4. Make sure the bleed valve is clean in the pistonremoved in Step 3. Install inner and outer sealrings on piston. Lock ring joint and apply greaseto stabilize it in the ring groove. Carefully posi-tion piston in drum without damaging seal rings.

5. Install seal, thrust washer, wave spring, springretainer, and retainer snap ring on shaft. Com-press wave spring and install retainer snap ringin shaft groove. Install a separator disc (teeth onoutside) in clutch drum.

6. Alternately install six friction discs and the otherfive separator discs in drum. The last disc mustbe a friction disc.

7. Install backing plate and snap ring in drum.

8. Press front bearing against shoulder on shaftwith snap ring groove toward drum. Install snapring. Install grease in groove for seal rings andinstall seals in grooves.

Third-Speed Shaft, Disassemble andAssembleThe following procedure describes the disassemblyand assembly of the third-speed shaft (see Figure 9and Figure 10):

1. Remove sealing ring from shaft. Remove snapring for rear bearing. Use a bearing puller toremove rear bearing.

2. Remove retaining ring for outer bearing of thethird gear. Use a hammer that has a soft faceto tap the third gear with the outer bearing fromclutch drum.

3. Remove snap ring for clutch backing plate. Re-move backing plate.

1. HUB2. RING3. SPRING RETAINER4. SPRING5. SEAL6. BACKING PLATE7. FRICTION DISC

(TEETH INSIDE)

8. SEPARATOR DISC(TEETH OUTSIDE)

9. PISTON10. CLUTCH SHAFT,

DRUM, AND GEARFOR FOURTHSPEED

11. BEARING

Figure 8. Fourth-Speed Clutch

11


1. SPRING RETAINER2. SPRING3. RETAINING RING4. RING5. BEARING6. GEAR AND HUB7. SNAP RING8. BACKING PLATE

9. FRICTION DISC(TEETH INSIDE)


11. PISTON12. SEAL13. CLUTCH SHAFT,

DRUM, AND GEARFOR THIRD SPEED

Figure 9. Third-Speed Clutch Assembly

4. Use a bearing puller to remove inner bearing forthe third-speed gear. Remove snap ring for innerbearing.

5. Remove all friction and separator discs. Com-press wave spring and remove retaining ringfrom its groove. Release wave spring and re-move snap ring and retainer for the spring.Remove wave spring.

6. Remove clutch piston and seals.

7. Make sure the bleed valve is clean in the pistonremoved in Step 6. Install inner and outer sealrings on piston. Lock ring joint and apply greaseto stabilize it in ring groove. Carefully positionpiston in drum without damaging seal rings.

8. Put retainer for wave spring, wave spring, wavespring retainer, and snap ring for retainer onshaft. Compress wave spring and install retainerring for spring into groove of shaft. Make sure re-tainer ring is completely in groove.

9. Install snap ring for inner bearing on shaft. In-stall a separator disc (teeth on outside) in clutchdrum.

10. Alternately install 12 friction discs and the other11 separator discs in drum. The last disc must bea friction disc.


12. Install inner bearing for the third-speed gear.This bearing does not have an oil shield. Care-fully install the third gear and hub. Make surethe hub splines engage the splines of all frictiondiscs. To avoid damage, do not force the hubthrough the discs.

13. Install outer bearing of the third gear. This bear-ing has an oil shield. The oil shield must faceaway from the gear. Install retaining ring forbearing.

14. Install rear bearing on shaft. The groove in thebearing must be toward the end of the shaft. In-stall snap ring for bearing. Install oil seal ring inthe groove near the end of the shaft. Use greaseto hold the oil seal ring in place.

12


1. TRANSMISSION HOUSING2. REAR COVER3. BEARING4. WASHER5. RING6. O-RING7. BEARING CAP8. PLUG9. HUB AND GEAR

10. RETAINING RING11. SPRING12. SPRING RETAINER13. BACKING PLATE14. FRICTION DISC (TEETH INSIDE)15. SEPARATOR DISC (TEETH OUTSIDE)16. PISTON17. SEAL18. CLUTCH DRUM, SHAFT, AND GEAR

Figure 10. Third-Speed Shaft

13


Forward Shaft and Clutch, Disassembleand AssembleThe following procedure describes the disassemblyand assembly of the forward shaft and clutch (seeFigure 11 and Figure 12):

1. Remove piston rings from forward clutch shaft.Remove retainer ring for inner race of front bear-ing. Use prybars to remove bearing inner race.Remove retainer ring for outer bearing.

2. Use prybars to remove clutch gear/hub and outerbearing together.

3. Use a bearing puller to remove inner bearing forhub.

4. Remove retainer ring for clutch backing plate.Remove backing plate. DO NOT LOSE THEBALL AND SPRING OF THE BACKINGPLATE. Remove all friction and separator discs.

5. Compress disc springs and remove retainingrings from grooves. Release disc springs andremove snap ring and retainer for spring. Re-move disc springs. Make sure to keep these discsprings together and with the other clutch parts.Remove clutch piston and seals.

6. Remove retainer ring and thrust washer for rearbearing. Not all units have the thrust washer.Use a bearing puller to remove rear bearing.

7. Get a section of pipe that has approximately thesame outer diameter as the bearing outer race.Use the pipe and a hammer or a press to installrear bearing. The groove in the bearing mustbe toward the end of the shaft. If installed, putthrust washer on shaft. Install retaining ring forrear bearing.

8. Install inner and outer seal rings on piston. Lockring joint and apply grease to stabilize it in ringgroove. Carefully position piston in drum with-out damaging seal rings.

9. Install one friction disc (teeth on inner diame-ter). Install one separator disc, then alternatelyinstall the other 10 friction discs and the othernine separator plates. The first and last clutchdisc must be a friction disc. This is the sequenceof installation when the clutch has an iron pis-ton.

1. RETAINER2. SPRING3. RING4. BEARING5. CLUTCH HUB AND

GEAR6. PISTON RING7. CLUTCH DRUM

AND GEAR

8. SEAL9. PISTON10. SEPARATOR DISC

(TEETH OUTSIDE)11. FRICTION DISC

(TEETH INSIDE)12. BACKING PLATE13. SNAP RING

Figure 11. Forward Clutch Assembly

14


1. RETAINER2. SPRING3. RING4. BEARING5. CLUTCH HUB AND GEAR6. PISTON RING7. CLUTCH DRUM AND GEAR

8. SEAL9. PISTON10. SEPARATOR DISC (TEETH OUTSIDE)11. FRICTION DISC (TEETH INSIDE)12. BACKING PLATE13. SNAP RING14. TRANSMISSION HOUSING

Figure 12. Forward Clutch and Shaft Assembly

10. Install detent spring and ball in backing plate.See Figure 13. Install backing plate in clutchdrum making sure not to lose the spring or ball.Compress clutch discs and disc springs and in-stall retainer ring for backing plate.

11. Install disc springs and retainer for piston. Makesure the disc spring with the large diameter istoward the piston.

12. Compress disc springs and install rings fully ingrooves. Install inner bearing and ring. Thisbearing does not have a shield in it. Carefullyinstall hub and gear in drum. Make sure hubsplines engage splines of all friction discs. Toavoid damage, do not force hub through the discs. 1. CLUTCH PLATE

2. RETAINER RING3. DETENT SPRING

4. DETENT BALL5. CLUTCH DRUM

Figure 13. Detent

15


13. Install rings in outer bearing with shield towardgear. Install inner race of front bearing. Thelarge diameter must be toward gear. Install re-tainer for front bearing.

14. Put grease in groove for piston rings. Install pis-ton rings in grooves. Align piston rings at centerof groove.

Reverse and Second-Speed Shaft andClutch, Disassemble and AssembleThe following procedure describes the disassemblyand assembly of the reverse and second-speed shaftand clutch (see Figure 14 and Figure 15):

1. Remove piston rings at the reverse clutch end ofshaft. Remove retaining ring for front bearing.Use prybars to move front bearing enough to in-stall bearing puller. Use bearing puller to removefront bearing.

2. Remove retainer ring for outer bearing of hubgear. Use pry bars to carefully pry hub gear upfor clearance to install a gear puller. Remove hubgear and outer bearing.

3. Remove retainer ring for clutch backing plate.Remove backing plate. DO NOT LOSE THEBALL AND SPRING OF THE BACKINGPLATE.

4. Remove all clutch discs. Use a bearing puller toremove inner bearing.

5. Compress disc springs and remove retaining ringfrom its groove. Release disc springs and re-move retainer ring and retainer for spring. Re-move disc springs. Make sure to keep these discsprings together and with the other clutch parts.Remove clutch piston.

6. Put a coat of grease on seal rings and installseal rings on piston. Carefully position piston indrum without damaging seal rings.

7. Install disc springs for piston. Make sure discspring with the large diameter is toward piston.Install retainer ring for disc springs. Install re-tainer for spring retainer ring. Compress discsprings and install retainer ring fully in groove.Use a press to install inner bearing. This bearingdoes not have a shield in it.

1. SEAL2. PISTON3. SEPARATOR DISC

(TEETH OUTSIDE)4. FRICTION DISC

(TEETH INSIDE)5. BACKING PLATE6. SNAP RING7. RETAINER

8. SPRING9. RING10. BEARING11. CLUTCH HUB AND

GEAR12. PISTON RING13. CLUTCH DRUM

AND GEAR

Figure 14. Reverse and Second-Speed Clutch

16


1. PISTON RING2. RING3. BEARING4. SNAP RING5. REVERSE CLUTCH HUB AND GEAR6. SPRING7. SPRING RETAINER8. BACKING PLATE

9. FRICTION DISC (TEETH INSIDE)10. SEPARATOR DISC (TEETH OUTSIDE)11. PISTON12. SEAL13. CLUTCH DRUM AND GEAR14. HUB AND GEAR FOR SECOND-SPEED CLUTCH15. TRANSMISSION HOUSING

Figure 15. Reverse and Second-Speed Shaft

8. Install one friction disc (teeth on inner diame-ter). Install one separator disc, then alternatelyinstall the other 10 friction discs and the othernine separator plates. The first and last clutchdisc must be a friction disc. This is the sequenceof installation when the clutch has an iron pis-ton.

9. Install detent spring and ball in backing plate.See Figure 13. Install backing plate in clutchdrum making sure not to lose the spring or ball.

Compress clutch discs and disc springs and in-stall retainer ring for backing plate.

10. Carefully install hub and gear in drum. Makesure hub splines engage splines of all frictiondiscs. To avoid damage, do not force hub throughthe discs.

11. Install outer bearing with shield toward gear. In-stall retainer ring for outer bearing. Install front

17


bearing. The groove in the bearing must be to-ward gear. Install retainer ring for front bearing.

12. Put grease in groove for sealing rings. Installsealing rings in grooves. Align sealing rings atcenter of groove.

13. Remove snap ring for backing plate of secondclutch. Remove backing plate and all clutchdiscs.

14. Compress wave spring and remove retaining ringfrom its groove. Release wave spring and removesnap ring and retainer for spring. Remove wavespring and thrust washer. Remove second clutchpiston.

15. Make sure the bleed valve is clean in the second-gear piston removed in Step 14. Install inner andouter seal rings on piston. Lock ring joint andapply grease to stabilize it in ring groove. Care-fully position second-gear piston in drum withoutdamaging seal rings.

16. Put thrust washer, wave spring, wave spring re-tainer, and snap ring for retainer on shaft. Com-press wave spring and install retainer ring forspring into the groove of the shaft. Make sureretainer ring is completely in groove.

17. Install a separator disc (teeth on outside) inclutch drum. Alternately install the six frictiondiscs and the other five separator discs in drum.The clutch disc next to the piston is a separatordisc. The last clutch disc is a friction disc.


First-Speed Shaft and Clutch, Disassembleand AssembleThe following procedure describes the disassemblyand assembly of the first-speed shaft and clutch (seeFigure 16 and Figure 17):

1. Remove seal rings near end of shaft at taperedroller bearing. Use prybars to carefully move ta-pered roller bearing for clearance to use a bearingpuller. Use the bearing puller to remove taperedroller bearing. Remove bearing thrust washer.

2. Use a gear puller to remove first-speed gear withouter bearing.

1. BEARING2. WASHER3. HUB AND GEAR4. RING5. SPACER6. RING7. SPRING WASHERS8. BACKING PLATE9. FRICTION DISC

(TEETH INSIDE)


11. PISTON12. PISTON SEAL13. SEAL14. CLUTCH SHAFT,

DRUM, AND GEARFOR FIRST SPEED

15. THIRD-SPEEDGEAR

Figure 16. First-Speed Clutch

18


1. TRANSMISSION HOUSING2. REAR COVER3. O-RING4. BEARING CAP5. RING6. SHIM SET7. PLUG8. BACKING PLATE9. SPRING WASHERS10. SPACER11. BEARING

12. HUB AND GEAR13. WASHER14. THIRD-SPEED GEAR15. CLUTCH SHAFT, DRUM, AND GEAR FOR FIRST

SPEED16. SEAL17. PISTON SEAL18. PISTON19. SEPARATOR DISC (TEETH OUTSIDE)20. FRICTION DISC (TEETH INSIDE)

Figure 17. First-Speed Shaft

19


3. Remove snap ring for backing plate. Removebacking plate and all clutch discs.

4. Use a bearing puller to remove inner bearing ofthe first-speed gear. Remove spacer.

5. Compress wave spring and remove retaining ringfrom its groove. Release wave spring and removesnap ring and retainer for spring. Remove wavespring and the other wave spring ring. Removepiston and seals for the first-speed clutch.

6. Use a gear puller to remove driven gear togetherwith front bearing.

7. Install driven gear on clutch shaft with long hubof gear toward end of shaft. Use a press to installtapered roller bearing. The small diameter of thebearing must be toward the end of the shaft.

8. Install inner and outer seal rings on clutch pis-ton. Lock ring joint and apply grease to stabi-lize it in the ring groove. Carefully position thefirst-speed piston in drum without damaging sealrings.

9. Put retainer for wave spring, wave spring, wavespring retainer, and snap ring for retainer onshaft. Compress wave spring and install retainerring for spring into the groove of shaft. Makesure retainer ring is completely in groove.

10. Install a separator disc (teeth on outside) inclutch drum. Alternately install the 10 frictiondiscs and the other nine separator discs in thedrum. The last disc is a friction disc. Installbacking plate and snap ring in drum.

11. Install gear spacer and inner bearing. The bear-ing does not have an oil shield. Use a press to in-stall bearing. Carefully install hub gear. Makesure hub splines engage splines of all frictiondiscs. To avoid damage, do not force the hubthrough the discs.

12. Install outer bearing for hub gear. This bearinghas an oil shield. The shield must be toward theend of the shaft. Install washer. Use a press toinstall tapered roller bearing. The small diame-ter of the bearing must be toward end of shaft.

NOTE: The two oil seal rings at the end of the shaftwill be installed after the clearance adjustment forthe tapered roller bearings is complete.

Input Shaft, Disassemble and AssembleThe following procedure describes the disassemblyand assembly of the input shaft (see Figure 3):

1. Remove piston ring from input shaft.

2. Remove bearing snap ring and bearing washer.

3. Use prybars to move bearing enough to installa bearing puller. Use bearing puller to removebearing. Use a press to install bearing withgroove in bearing away from gear.

4. Install bearing washer and snap ring. Fill groovefor piston ring with grease. Install piston in cen-ter of groove.

SPEED SENSOR, INSTALLTemporarily install bushings for speed sensors. Usea depth micrometer to measure the depth at eachspeed sensor bushing. Add shims to get the correctdimensions as shown in Figure 18. Clean threads ofbushing and housing using Loctite cleaner. Installshims under the head of the bushing. Use Loctite

number 270 or number 262 on both the bushing andhousing threads. Install shims and tighten bushingsto 61 to 68 Nm (45 to 50 lbf ft). After the Loctite

has set, install speed sensors and tighten them to54 Nm (40 lbf ft).

20


1. SPEED SENSOR LOCATION2. TRANSMISSION3. SHIM LOCATION

4. DEPTH MICROMETER5. BUSHING

Figure 18. Speed Sensor Installation

21


TRANSMISSION, CLEAN AND INSPECT


Clean the parts of the transmission in solvent. Dryparts with compressed air. Inspect splines and gearteeth for damage. Inspect shafts, bearings, andbearing surfaces for scratches, wear, or damage.Make sure separator plates are smooth. Inspect fric-tion discs for burned or damaged friction material.Clean holes that have threads and capscrews wherea thread-locking compound is used.

TRANSMISSION, ASSEMBLENOTE: If a new transmission or converter housingwill be used, install speed sensors in new housing.See the procedure in Speed Sensor, Install and Fig-ure 18.

1. Install new O-ring on suction tube for transmis-sion pump. Install tube in transmission case.Install screws and washers for suction tube.Tighten screws.

2. Set oil baffle in transmission case. Install andtighten oil baffle screws.

3. Set froward clutch assembly into rear bearingbore of transmission case. Push rear bearingthrough bore far enough to install outer locatingring. Push bearing back in bore until locatingring is against shoulder of bore.

4. Install third-speed clutch assembly.

5. Install locating ring in front bearing bore for lowclutch bearing. Install spacer (oil baffle) andfront bearing cup as shown in Figure 19.

NOTE: The first-speed clutch and the output shaftmust be installed simultaneously. Another personcan be helpful during this installation.

6. Install the first-speed clutch and output shaft intransmission housing. Make sure they are fullyin position in the housing. Install rear bearingon output shaft. The groove in the bearing forthe snap ring must be toward the rear.

1. LOCATING RING2. SPACER (OIL BAFFLE)3. BEARING CUP4. TRANSMISSION HOUSING

Figure 19. Bearing Installation Detail

7. Install new gasket and O-ring on rear of trans-mission housing. A thin coat of grease will helphold gasket in place on housing. Install align-ing studs to help align rear cover. Install rearcover, tapping cover with a hammer that has asoft face. Install cover screws and washers andtighten screws.

8. Install locating ring for bearing outer race of out-put shaft. Install spacer for output flange on out-put shaft.

9. Apply a thin coat of Loctite 683 (green) on outerdiameter of oil seal. Press seal in bearing cupof output shaft with lip of seal toward bearing.Use new O-rings and install bearing cap for theoutput shaft bearing. Install lockwashers andnuts and tighten nuts.

10. Install output flange, O-ring, washer, and elas-tic flange nut. Use a bar to prevent flange fromturning and tighten flange nut to torque speci-fied in Table 1.

Table 1. Flange Nut Torque

Thread Size Nm lbf ft

1" - 20 203 - 271 150 - 200

1 1/4" - 18 271 - 339 200 - 250

1 1/2" - 18 407 - 474 300 - 350

1 1/4" - 12 543 - 610 400 - 450

22


11. Install locating ring for rear bearing of the third-speed shaft. Install new O-ring on bearing cap.Install bearing cap, lockwashers, and nuts onstuds. Tighten nuts.

12. Install screen assembly for oil sump and in-stall plug. Tighten plug to 13 to 20 Nm (10 to15 lbf ft).

13. Make sure the shim pack is correct for the bear-ings of the first-speed clutch as described inFirst-Speed Shaft Bearings Adjustment. In-stall new O-rings on clutch pressure and lubetransfer tubes and install tubes in rear coverof transmission at rear bearing of first-speedclutch. Fill grooves of oil sealing rings withgrease. Install sealing rings and move sealingrings to the center of the grooves. Install shimpack on studs and install bearing cap, washers,and nuts. Tighten nuts.

14. Turn transmission housing so that rear cover isto the rear. Install disc hub of the second-speedclutch on shaft of the first-speed clutch. Installretainer ring for hub. Install retainer for retainerring. Install snap ring for retainer ring of re-tainer. See Figure 20.

1. DISC HUB2. SNAP RING FOR RETAINER OF RETAINER

RING3. HUB RETAINER RING4. CLUTCH SHAFT5. RETAINER FOR RETAINER RING

Figure 20. Retainer Ring Detail

15. Install bearing outer race for input shaft. Installa new converter housing gasket and O-rings ontransmission housing. A thin coat of grease willhelp hold the gasket in place on the housing.

16. Install pilot bearing for the second and thirdclutches on the shafts. Use grease to keep bear-ings in position.

17. Leave the passage for the first-speed clutchopen for internal lube tube installation. Installplug for external lube tube installation. SeeFigure 21. Tighten plug to 9.5 to 13.5 Nm (7 to10 lbf ft).

1. CONVERTER HOUSING2. PASSAGE OPEN FOR INTERNAL LUBE

INSTALLATION

Figure 21. Low-Speed Clutch Lube Passage

18. Install alignment studs and install converterhousing on transmission housing while rotat-ing output shaft. Rotation of the output shaftwill help the clutch hub (Step 14) and discs toalign correctly. Do NOT push the two housingstogether too hard. Allow hub to align and enterclutch discs. Install and tighten bolts that fastenhousings together.

19. Fill the groove for the oil sealing ring of the sta-tor support using grease. Install sealing ring. In-stall inner race of impeller hub bearing on statorsupport. Align notch in stator support with pumpgear and install support on input shaft. Alignmount holes of stator support with holes in hous-ing and install and tighten screws to fasten sta-tor support.

23


20. Install impeller and oil baffle assembly in con-verter housing. Install retaining ring for oil baf-fle. Make sure the turbine and dowel pin are inplace and install turbine on stator support. In-stall snap ring (thicker snap ring) to fasten thereaction member.

21. Install turbine snap ring (thinner snap ring). In-stall new impeller O-ring on impeller cover. In-stall impeller cover and turbine assembly on in-put shaft. Install impeller cover, lockwashers,and screws that fasten impeller cover. Tightenscrews.

22. Install snap ring (thickest snap ring) for tur-bine hub. Install new O-ring on bearing capfor impeller. Stack drive plates so that all thefingers are aligned. Concave sides are towardflywheel and the weld nuts are toward the cover.Align holes of backing ring and drive plates. In-stall drive plates, backing ring, and place bolts.Tighten the 0.4375-inch place bolts to 71 to77 Nm (52 to 57 lbf ft). Tighten the 0.3750-inchplace bolts to 45 to 49 Nm (33 to 36 lbf ft).

CONTROL VALVE

Clean and Inspect


Clean all parts in solvent. Inspect spools, bores, andsprings for damage. Make sure spools move freely inthe bores.

Assemble and InstallLubricate all parts with transmission oil. Always usenew O-rings and gaskets. During assembly, makesure all spools move freely in their bores. Connectwires to solenoids as marked during removal.

1. Put gasket for control valve on converter housingon alignment studs. Install control valve assem-bly on studs. Install the two valves to housingscrews.

CAUTIONMake sure mount screws for control valve areinstalled in the correct location to preventdamage. All of the screws are not the same.

2. Install a seal plate gasket, seal plate, and theother seal plate gasket on studs against controlvalve. Install control valve cover and screws.Items 1, 2, 3, 4, and 5 are 3/8 - 16 x 4-1/4 inchcapscrews. Items 12, 13, and 14 are 3/8 - 16 x1 inch capscrews. Items 6 and 7 are flanged 12point 3/8 - 16 x 3 inch capscrews. Items 8, 9,10, and 11 are flanged 12 point 3/8 - 16 x 1-1/4inch capscrews. Tighten screws in the sequence(A through N) shown in Figure 22.

3. Install solenoid protection cover, washers, andnuts. Tighten stud nuts in the sequence shownin Figure 22.

Figure 22. Control Valve Installation (BottomView)

24


4. Install new O-ring on housing for pressure regu-lator valve. Install regulator valve and chargingpump on converter housing. Install lockwash-ers and screws. Tighten screws. Install suc-tion tube, O-ring, adapter fitting, adapter flange,flange screws, and lockwashers. Tighten screws.

INSTALL, TRANSMISSION1. Install the mounts on transmission housing. See

Figure 5. Connect a lifting device with a mini-mum capacity of 725 kg (1600 lb) to the liftingeyes on the transmission.

2. Install two 89 mm (3.5 in.) long guide studs in theengine flywheel housing. Rotate engine flywheelto align a mounting hole for the drive plates withthe access hole of flywheel housing. Check endplay of flywheel.

3. Install a 102 mm (4 in.) locating stud in a driveplate nut. Align locating stud of drive plate withflywheel screw hole at the access hole.

4. Use the lifting device to put transmission as-sembly into the approximate position. Aligndrive plates on flywheel and converter housingwith flywheel housing. Install housing screws tofasten converter and flywheel housings together.Remove housing studs and install all housingscrews. Tighten all screws.

5. Install nuts and bolts for transmission mounts.Tighten nut for transmission mount to 120 Nm(90 lbf ft).

6. Remove locating stud in drive plates. Installscrew to fasten drive plates to flywheel. A screw-driver or pry bar can be used to hold the driveplates against the flywheel to install the screw.Rotate flywheel and install each drive platescrew in turn. After all screws are installed,tighten all M10 screws to 61 Nm (48 lbf ft).Check that flywheel end play is within 0.03 mm(0.001 in.) of the end play of Step 2.

7. Connect drive shafts to transmission. Make sureto align the marks. Tighten capscrews for inputyoke to 68 Nm (50 lbf ft). Tighten capscrews foroutput yoke to 163 Nm (120 lbf ft).

8. Connect oil lines and dipstick tube at transmis-sion. Connect wiring harness at transmission.

INSTALL, TRANSMISSION AND ENGINEASSEMBLYNOTE: Verify that the lifting device has a capacity ofat least 1360 kg (3000 lb).

1. Connect a lifting device to the engine.

2. Carefully lower the engine and transmission intothe frame.

3. Install the capscrews that hold the 2 rear enginemount brackets to the frame.

4. Install the capscrews that hold the engine mountat the fan end of the engine. See Figure 6.

5. Connect the heater hoses at the engine.

6. Connect wires and wiring harnesses at the en-gine.

7. Connect the throttle linkage.

8. Connect the fuel lines at the fuel filter.

9. Install the tubing between the engine and aircleaner.

10. Install the radiator and transmission oil cooler.

11. Connect cooling lines.

12. Fill cooling system with coolant.

13. Connect the air cleaner intake elbow.

14. Install engine hood and ballast cover.

15. Connect exhaust system.

16. Connect and install dipstick assembly.

NOTE: The drive shaft of the hydraulic pump willslide into the drive gear before the hydraulic pumpsare installed.

17. Install the drive shaft of the hydraulic pump.

NOTE: The hydraulic pumps are fastened to thetransmission with 4 capscrews.

18. Install hydraulic pumps.

19. Remove plugs and caps on open fittings.

20. Connect the hoses at the hydraulic pumps.

21. Remove identification tags on lines.

25

Automatic Powershift Control (APC 100) 1300 SRM 635

22. Replace the drain plug from the transmissionsump.

23. Replace the transmission oil.

24. Connect the wires at the pressure and tempera-ture sending unit on the transmission.

25. Connect the wires at the solenoids on the trans-mission control valve.

26. Connect the wiring harness on top of the trans-mission.

27. Replace the drive shaft between the transmissionand the differential.

28. Connect the drive shaft at the differential.

29. Open shut-off valves on the hydraulic tank.

30. Replace floor plates and covers.

NOTE: When replacing battery cables, replace theground cable last.

31. Connect the cables to the battery.

32. Start engine.

33. Operate hydraulic functions and check for leaks.

CLEAN OIL SYSTEM OF TRANSMISSIONAFTER MAJOR REPAIRNOTE: The complete oil system of the transmissionmust be cleaned after every major repair. This clean-ing is necessary to make sure the transmission oper-ates correctly.

Clean the system as follows:

1. Drain the entire system completely.

2. Disconnect and clean all oil lines for the trans-mission. If possible, remove oil lines completelyto clean them.

3. Remove filter elements and clean filter can. In-stall new filter elements.

4. Use oil and compressed air with flow opposite thenormal direction to flush the oil cooler. Do NOTuse flushing compounds.

5. Assemble all components and oil lines. Fill trans-mission with the correct oil to the LOW mark(dipstick or lower fill plug). Install new gasketsand hydraulic pumps for the hydraulic systems ofthe lift truck to the flange on the transmission.Connect hydraulic lines as necessary. See theHydraulic System. Fill hydraulic tank of lifttruck with correct amount and type of hydraulicoil.

6. Operate engine at idle speed for two minutesto fill all hydraulic lines and filters. Checkfor leaks. Check oil level of transmission withengine operating. Add oil as necessary to theLOW mark. If necessary, install the fill and levelplugs.

7. Operate engine at stall until oil is 82 to 93 C (180to 200 F) and check for leaks. See Torque Con-verter Stall Speed Check.

Automatic Powershift Control (APC 100)FUNCTIONAL DESCRIPTIONThe APC 100 control unit performs the followingfunctions (see Figure 23 and Table 2): Direction Change Protection

FORWARD to REVERSE/REVERSE to FOR-WARD - When the gear selector direction is re-versed, throttle reduction is automatically applied,setting engine speed to idle. The transmission willdownshift as the vehicle slows until first gearis obtained. The transmission will then changedirections and shift to first gear.NEUTRAL to FORWARD or REVERSE - Nei-ther forward nor reverse can be selected when theengine speed is too high (more than 1000 rpm).

FORWARD, NEUTRAL, FORWARD - Whendriving in a certain direction and when putting thegear selector in NEUTRAL and back in the samedirection, NEUTRAL will be selected until theengine speed is low enough (less than 1000 rpm).

Overspeed ControlNo shifts will be made that can cause overspeedingof the transmission or the engine. A light on theinstrument panel indicates overspeeding.

Turbine Sensor FailureSince automatic shifting is based on a speed ratio,a failure of the torque converter turbine results ina speed ratio of zero, causing the transmission todownshift. The control unit prevents downshifts

26

1300 SRM 635 Automatic Powershift Control (APC 100)

that would cause excess speed while driving due toa turbine failure.

Automatic ShiftingAn automatic shift to a higher gear is made whenthe throttle pedal is pressed, the turbine speed ex-ceeds a minimum speed, and the speed ration hasreached a certain value. No upshifts are allowed inthe braking mode (throttle pedal released).An automatic shift to a lower gear is made whenthe tractive effort in the lower gear exceeds thetractive effort in the higher gear.

DeclutchThe transmission shifts to neutral under certainconditions for load handling procedures.

The following paragraphs describe the pin connec-tions at the APC 100 control unit.

1. Diagnostic LEDs (See Figure 23)

a. RED LED - ON when internal failure pre-vents correct operation.

b. GREEN LED - Light reflects the position ofthe idle/not idle switch (pin no. 23). Whenthe throttle is at idle, the light is OFF. Thelight is ON when the throttle is pressed.

c. YELLOW LED - ON when turbine rpm=0(truck not moving) or when engine rpm=0(engine stopped).

2. Switch Descriptions

a. Idle/Not Idle (pin no. 23). Switch open -throttle pedal is depressed. Switch closed -engine is idling, throttle pedal released.

b. Automatic/Manual (pin no. 9). Switch open- APC 100 is shifting automatically. Switchclosed - APC 100 in manual mode, operatordecides when to shift. Downshifts or direc-tion changes at high speeds are inhibited.

c. Declutch Request (pin no. 8). Switch open -no declutch is applied. Switch closed - whendeclutch is requested, the control unit willshift the transmission to NEUTRAL whenvehicle speeds are less than a preset value,depending on the unit. When the request isdropped, the direction is engaged again.

d. Parking Brake request (pin no. 27). Switchopen - parking brake is not applied. Switchclosed - when parking brake is applied, con-trol unit will shift the transmission to NEU-TRAL.

e. Second Gear Start Request (pin no. 7). 24volts applied - transmission starts in firstgear when transmission control lever is setfor second gear or lower. No voltage applied- transmission starts in second gear whentransmission control lever is set for fourthgear.

A. FRONT COVER B. REAR COVER

1. INDICATOR LIGHTSRED - INTERNAL MALFUNCTIONYELLOW - ZERO RPM, ENGINE OR TORQUECONVERTERGREEN - THROTTLE PEDAL DEPRESSED

2. CONNECTOR FOR LIFT TRUCK HARNESS3. CONNECTOR FOR CHECKOUT KIT

Figure 23. APC 100 Control Unit

27


Table 2. APC 100 Control Module (Pin Connections)

Pin No. Function Pin No. Function

1 Forward Switch (input) 17-19 Not Used

2 Range Switch 1 (input) 20 Reverse Switch (input)

3 Range Switch 3 (input) 21 Range Switch 2 (input)

4-6 Not Used 22 Not Used

7 Second Gear Start 22* Third Gear Limit - Twist Locks (input)

8 Declutch Request (input) 23 Idle/Not Idle

9 Manual/Automatic 24-25 Not Used

10-11 Not Used 26 Checkout Speed Ratio Display Request

11* Ground 27 Parking Brake

12 Forward Solenoid (output) 28, 29 Engine Speed Sensor (input)

13 Reverse Solenoid (output) 30, 31 Turbine Speed Sensor (input)

14 Range Solenoid 1 (output) 32-35 Not Used

15 Range Solenoid 2 (output) 34* 24 km/h (15 mph) limit (output)

16 Range Solenoid 3 (output) 36 Throttle Reduction (output)

17* 24-volt Supply 37 Overspeed Warning Light (output)

*A227 units only.

28


FUSESThe APC 100 uses two fuses to protect its circuits.See Figure 24. The 315 mA fuse is located behind thefront cover. To check or replace the 10A fuse, removethe rear cover and pull out the circuit board. Be sureto replace the fuses with the same type.

1. 315 mA FAST ACTING2. 10A FAST FUSE

Figure 24. APC 100 Control Unit FusesLocation

TRANSMISSION CONTROL LEVERThe transmission control lever (Figure 25) is in-stalled on the steering column. If the unit does notoperate correctly, check the wiring and connectors.See the schematic in Figure 26 and Figure 27 andTable 3. Check the operation of the APC 100 controlunit. If the control lever does not operate, install anew lever.

NOTE: RS45-30CH, RS46-35CH, RS45-25IH,RS46-30IH (A222) SHOWN.

Figure 25. Transmission Control Lever

29


Figure 26. Transmission Control Electrical Schematic

30


Legend for Figure 26

NOTE: H36.00-48.00E [H800-1050E (D117)] SHOWN.NOTE: *CLARK GEAR SELECTOR SHOWN. HOBBS GEAR SELECTOR SHOWN IN FIGURE 27.

NOTE: HOBBS GEAR SELECTOR USED ON MODEL H36.00-48.00E [H800-1050E (D117)].Figure 27. Electrical Schematic for Hobbs Gear Selector

Table 3. Hobbs Gear Selector Connections

Contact Description Wire

F Forward DE

N Neutral DH

R Reverse DA

SW1 Direction Selector Switch

SW2 Neutral Switch

SW3 Speed Selector Switch

SW4 Speed Selector Switch

31

First-Speed Shaft Bearings Adjustment 1300 SRM 635

Table 3. Hobbs Gear Selector Connections (Continued)

Contact Description Wire

1 First Gear Position DJ, DG, and DC

2 Second Gear Position DJ and DG

3 Third Gear Position DJ

4 Fourth Gear Position None

Supply +12 to 24 VDC CB and DB

First-Speed Shaft Bearings AdjustmentIf the cap, clutch, front or rear bearings, transmis-sion case, or rear cover is replaced, the clearance forthe bearings must be adjusted using shims at the cap.If none of these parts were replaced, the old shim setcan be used without doing this procedure.

Adjust the bearings as follows:

1. Move transmission assembly so rear of transmis-sion is up. If the bearing cap for the first-speedshaft is installed, remove bearing cap. Make surethe cap O-ring, clutch pressure sleeve, and oilseal ring are removed.

2. Use a micrometer depth gauge C to measure thethickness of the bearing cap at positions A and Bas shown in Figure 28. Thickness D is dimensionE minus dimension F. Add the two dimensions (Dat A and B) together and divide by 2 to get theaverage thickness of the bearing cap.

Example: 22.12 mm (0.871 in.)

+22.17 mm (0.873 in.)

44.29 mm (1.744 in.)

2 = 22.14 mm (0.872 in.)

For the example, average thickness is 22.14 mm(0.872 in.).

3. Lubricate the bearing and the bore of the bearingcap. Install bearing cap on studs. Install all fournuts.

4. Rotate the output shaft to help seat thetapered roller bearings while the nuts aretightened. Tighten the nuts in a cross sequenceto 20 to 27 Nm (15 to 20 lbf ft). Use a soft-facedhammer to lightly hit the rear cover of the trans-mission while tightening nuts.

5. Remove the two nuts from cover that are 180apart. These nuts are NOT the nuts G shownin Figure 28. Loosen the other two nuts (G) untilthey can be rotated with your fingers.

6. Set the micrometer depth gauge C firmly againstraised machined surfaces A and B of the bearingcap as shown in Figure 28.

7. Use a torque wrench to alternately tightennuts G from 1.13 Nm (10 lbf in) to 11.3 Nm(100 lbf in) in 1.13 Nm (10 lbf in) steps. Rotateoutput shaft while tightening nuts. Measure thedepth at A and B at each step. The difference be-tween A and B must not be greater than 0.13 mm(0.005 in.) at any step. If the difference is greaterat any step, start over at the beginning of thisstep. Add the two measurements and divide by 2to get the average depth. Use the following chartto record the average measurement at each step.See Table 4.

32

1300 SRM 635 First-Speed Shaft Bearings Adjustment

Table 4. Example Torque Values atDimensions Shown

Torque Value Gap Dimension

Nm lbf in mm in.

1.1 10 23.39 0.921

2.3 20 23.32 0.918

3.4 30 23.27 0.916

4.5 40 23.22 0.914

5.6 50 23.16 0.912

6.8 60 23.14 0.911

7.9 70 23.06 0.908

9.1 80 22.99 0.905

10.2 90 22.96 0.904

11.3 100 22.91 0.902

8. Draw a straight line through the points on thechart as shown in Figure 29. The value where theline crosses the zero line minus the average valuerecorded for the thickness of the bearing cap ofStep 2 is the no-end-play, no-preload shim dimen-sion. Add 0.15 0.02 mm (0.006 0.001 in.) tothis dimension for the final shim gap dimension(total shim thickness). See the example chart

(Figure 29). In the example, the line crossesthe zero line at 23.42 mm (0.922 in.). The av-erage thickness of the bearing cap is 22.14 mm(0.872 in.). Subtracting the thickness from thezero point value equals 1.28 mm (0.050 in.) forthe shim gap with no preload or end play. Add0.15 0.02 mm (0.006 0.001 in.) to this dimen-sion for the final shim gap dimension (total shimthickness) of 1.41 to 1.45 mm (0.055 to 0.057 in.).

NOTE: There is a blank graph included for plottingthe actual measured values. If you need more, copythe graphs before using them. See Figure 30.

9. Select shims for the total shim thickness found inStep 8. Measure the thickness of the shim packto make sure it is correct.

10. Remove bearing cap. Install a new oil sealingring and new O-rings on clutch pressure sleeveand bearing cap. Install pressure sleeve. In-stall the correct shim pack and bearing cap onstuds. Install lockwashers and nuts. Alternatelytighten nuts to 55.6 to 61.0 Nm (41 to 45 lbf ft).Rotate output shaft to make sure bearings areseated and check the torque of the nuts again.

11. Install lubrication line from bearing cap to checkport for lubricating pressure in front housing.

Figure 28. Adjusting Bearing Clearance

33

First-Speed Shaft Bearings Adjustment 1300 SRM 635

Figure 29. Example Values Chart

Figure 30. Plotting Chart

34

1300 SRM 635 Transmission Oil Pressures Check

Torque Converter Stall Speed CheckThis stall check is a measurement of maximum en-gine rpm with the engine working against the torqueconverter at full stall. This test will help find prob-lems in the transmission, torque converter, or engine.

1. Make sure the coolant level in the cooling systemis correct. Make sure the oil level in the trans-mission is correct.

2. Put the lift truck against a wall or other objectthat cannot move. The parking brake can alsobe applied and blocks installed at the wheels toprevent wheel movement. The wheels must notturn during this test.

3. Connect a tachometer to the engine. Make surethe parking brake is engaged. Also apply thebrakes.

CAUTIONDo not keep the lift truck in a stall condition formore than 30 seconds at a time. Transmissiondamage will occur at 120 C (250 F).

4. Select the highest gear. With the engine runningin FORWARD or REVERSE, slowly increaseengine speed to approximately one-half throttleand hold that throttle position for no more than30 seconds at a time. Repeat this process un-til the oil temperature of the transmission (con-verter outlet) is 83 to 94 C (180 to 200 F).

5. The correct stall speed is approximately1900 rpm.

6. If the reading is 50 to 200 rpm below the speci-fications, the engine does not produce full power.The problem can be the engine, fuel system, orother engine systems.

7. If the reading is 50 to 200 rpm above the specifi-cations, the transmission or torque converter canbe the problem. A high reading in only one direc-tion or speed range indicates a problem in thatclutch assembly.

Transmission Oil Pressures CheckNOTE: If the correct pressure cannot be reached, seethe Troubleshooting at the end of this section. Dur-ing all pressure checks, the drive wheels must beraised from the floor.

Attach pressure gauges to the check ports. Checkthat the oil level in the transmission is correct. Op-erate the transmission in all ranges and directionsuntil the oil in the transmission is 83 to 94 C (180 to200 F). Connect a tachometer to the engine. Be sureto use the hydraulic schematic shown in Figure 31.

CLUTCH PRESSURES CHECK1. Connect gauges to port S. See Table 5.

2. Run the engine at idle (400 to 600 rpm) and 83to 94 C (180 to 200 F) transmission oil tempera-ture, with brake pedals up and park brake set.All clutch pressures must be within 34.5 kPa(5 psi) of each other.

3. Operate the transmission in both directions andat each of the speed ranges. The correct oil pres-sure is 1655 to 2068 kPa (240 to 300 psi) for allof the direction and range clutches.

4. If a clutch pressure is not within the specifica-tions of Step 2, repair that clutch.

TORQUE CONVERTER (TORQUECONVERTER REGULATOR) OILPRESSURE CHECK1. Connect a gauge to the check port.

2. Make sure the transmission oil temperature is83 to 94 C (180 to 200 F), the brake pedals areup, and the park brake is set. The correct oilpressure is 172 kPa (25 psi) min. @ 2000 rpmand 483 kPa (70 psi) @ governed speed.

35

Transmission Oil Pressures Check 1300 SRM 635

Table 5. Transmission Pressures

Port Pressure Check Pressure

FC (@ Control Valve) Forward Clutch Pack 1655 to 2068 kPa (240 to 300 psi)*

RC (@ Control Valve) Reverse Clutch Pack 1655 to 2068 kPa (240 to 300 psi)*

S (Top of Transmission) First-Gear Clutch Pack 1655 to 2068 kPa (240 to 300 psi)*

2C (@ Control Valve) Second-Gear Clutch Pack 1655 to 2068 kPa (240 to 300 psi)*

S (Top of Transmission) Third-Gear Clutch Pack 1655 to 2068 kPa (240 to 300 psi)*

S (Top of Transmission) Fourth-Gear Clutch Pack 1655 to 2068 kPa (240 to 300 psi)*

R (AQ to Heat Exchanger) Torque Converter Regulator 172 kPa (25 psi) min @ 2000 rpm483 kPa (70 psi) @ gov. speed**

*At engine idle (400 to 600 rpm) and 83 to 94 C (180 to 200 F) transmission oil temp., brake pedals up, andpark brake set. All clutch pressures must be within 34.5 kPa (5 psi) of each other or repair clutch.** 83 to 94 C (180 to 200 F) transmission oil temp., brake pedals up, and park brake set.

1. Port S2. Port R

36

1300 SRM 635 Troubleshooting

Troubleshooting

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

Transmission oil tempera-ture is too hot.

Type of oil is not correct or oil level isnot correct.

Check oil type and level.

Oil cooler or oil lines have a restric-tion.

Check and clean oil lines and oilcooler.

Clutches do not engage completely. Check oil pressure and repair as nec-essary.

Torque converter does not operatecorrectly.

Check stall speed and repair as nec-essary.

Bearings or shafts in the transmis-sion are damaged.

Replace damaged parts.

Lift truck is operating in the wrongspeed range for a long period of time.

Have operator change operation.

One or more clutches do notengage or engage slowly.

Oil level is not correct or oil is thewrong type.


Friction discs in the clutch are worn. Replace damaged parts.

Transmission has internal oil leaks. Check oil pressure to locate problem.Replace damaged parts.

Oil pressure is not correct. Check oil pressure to locate problem.

Control valve does not operate cor-rectly.

Repair control valve.

Solenoid(s) or electrical circuit isdamaged.

Install new solenoid or repair wiring.

Gears in transmission are damaged. Replace damaged parts.

External oil line(s) is damaged, hasa restriction, or is disconnected.

Check and repair oil lines.

Main oil pressure is low. There is a restriction in the oil filter. Install new oil filter.

Regulator for torque converter cir-cuit does not operate correctly.

Check and adjust regulator.

Oil level is not correct or oil is thewrong type.


37

Troubleshooting 1300 SRM 635


Main oil pressure is low.(Cont.)

Oil pump is worn or damaged. Repair oil pump.

There is a leak between the oil pumpand the regulator.

Check for and repair internal leaks.

Torque converter is too hot,or performance is not to spec-ifications.

Oil pressure is not correct. Check oil pressure to locate problem.Replace damaged parts.

There is a restriction in the coolingcircuit.

Check and repair cooling circuit.

Lift truck is operating in the wrongspeed range for a long period of time.

Have operator change operation.

Torque converter makes toomuch noise.

Bearings are damaged. Replace damaged parts.

Torque converter drive plate is looseor damaged.

Repair or replace drive plate.

Oil pressure in the torqueconverter circuit is low.

Transmission pump is worn. Replace pump.

Relief valve for torque converter isopen.

Check and repair.

Oil pressure in the torqueconverter circuit is high.

There is a restriction in the torqueconverter circuit.

Check passages for restrictions.

TRANSMISSION CONTROLLER (APC 100)None of the display LEDs areon when key switch is on.

There is no power to the controller. Check and repair wiring as neces-sary.

Fuse in controller is damaged. Replace fuse.

The red light is on continu-ously.

There is no power to the controller. Check and repair wiring as neces-sary.

The wiring harness is damaged. Repair wiring as necessary.

The controller is damaged. Replace controller.

38

1300 SRM 635 Diagrams, Schematics, or Arrangements


The transmission remains inNEUTRAL when power isavailable to the controller.

The 10-amp fuse is damaged. Replace fuse.

The transmission remains ina certain gear.

The transmission controller is dam-aged.

Override the controller and drive thevehicle manually.

39

Diagrams, Schematics, or Arrangements 1300 SRM 635

40

1300 SRM 635 Diagrams, Schematics, or Arrangements

Figure 31. Transmission Hydraulic Diagram

41

NOTES

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42

TECHNICAL PUBLICATIONS

1300 SRM 635 11/03 (4/03)(1/00)(9/98) Printed in U.S.A.

tocFour-Speed Powershift TransmissionSafety Precautions Maintenance and RepairGeneralTorque Converter RepairTorque Converter, RemoveTorque Converter, DisassembleClean and InspectTorque Converter, AssembleTorque Converter (Turbine) Housing, DisassembleRelief Valve for Lube Pressure, Disassemble and AssembleOil Sealing Rings Sleeve, ReplaceTorque Converter Housing, AssembleTorque Converter, Install

Transmission RepairRemove, Transmission OnlyRemove, Transmission and Engine AssemblyTransmission, DisassembleOutput Shaft, Disassemble and AssembleFourth-Speed Shaft, Disassemble and AssembleThird-Speed Shaft, Disassemble and AssembleForward Shaft and Clutch, Disassemble and AssembleReverse and Second-Speed Shaft and Clutch, Disassemble and AssemFirst-Speed Shaft and Clutch, Disassemble and AssembleInput Shaft, Disassemble and Assemble

Speed Sensor, InstallTransmission, Clean and InspectTransmission, AssembleControl ValveClean and InspectAssemble and Install

Install, Transmission Install, Transmission and Engine AssemblyClean Oil System of Transmission after Major Repair

Automatic Powershift Control (APC 100)Functional DescriptionFusesTransmission Control Lever

First-Speed Shaft Bearings AdjustmentTorque Converter Stall Speed CheckTransmission Oil Pressures CheckClutch Pressures CheckTorque Converter (Torque Converter Regulator) Oil Pressure Check

TroubleshootingTransmission Controller (APC 100)

tablesTable 1. Flange Nut TorqueTable 2. APC 100 Control Module (Pin Connections)Table 3. Hobbs Gear Selector ConnectionsTable 4. Example Torque Values at Dimensions ShownTable 5. Transmission Pressures

hyster-897949-11-03-srm0635

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