FOUR-SPEED POWERSHIFT TRANSMISSION 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 PRECAUTIONS MAINTENANCE AND REPAIR • When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and that the load being lifted is balanced. Make sure the crane, cables, and chains 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 repair on 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 PUT THE LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance 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 parts must meet or exceed the specifications of the original equipment manufacturer. • Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using 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 fuel are flammable. Be sure to follow the necessary safety precautions when handling these fuels and when working on these fuel systems. • Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the area. Make sure the area is well ventilated. NOTE: The following symbols and words indicate safety information in this manual:
WARNING Indicates a condition that can cause immediate death or injury!
CAUTION Indicates a condition that can cause property damage!
Four-Speed Powershift Transmission
Table of Contents
TABLE OF CONTENTS General ............................................................................................................................................................... Torque Converter Repair ................................................................................................................................... Torque Converter, Remove ............................................................................................................................ Torque Converter, Disassemble .................................................................................................................... Clean and Inspect .......................................................................................................................................... Torque Converter, Assemble ......................................................................................................................... Torque Converter (Turbine) Housing, Disassemble..................................................................................... Relief Valve for Lube Pressure, Disassemble and Assemble....................................................................... Oil Sealing Rings Sleeve, Replace ................................................................................................................ Torque Converter Housing, Assemble .......................................................................................................... Torque Converter, Install .............................................................................................................................. Transmission Repair .......................................................................................................................................... Remove, Transmission Only.......................................................................................................................... Remove, Transmission and Engine Assembly.............................................................................................. Transmission, Disassemble ........................................................................................................................... Output Shaft, Disassemble and Assemble............................................................................................... Fourth-Speed Shaft, Disassemble and Assemble .................................................................................... Third-Speed Shaft, Disassemble and Assemble ...................................................................................... Forward Shaft and Clutch, Disassemble and Assemble ......................................................................... Reverse and Second-Speed Shaft and Clutch, Disassemble and Assemble ........................................... First-Speed Shaft and Clutch, Disassemble and Assemble .................................................................... Input Shaft, Disassemble and Assemble.................................................................................................. Speed Sensor, Install ..................................................................................................................................... Transmission, Clean and Inspect.................................................................................................................. Transmission, Assemble ................................................................................................................................ Control Valve.................................................................................................................................................. Clean and Inspect...................................................................................................................................... Assemble and Install................................................................................................................................. Install, Transmission .................................................................................................................................... Install, Transmission and Engine Assembly................................................................................................ Clean Oil System of Transmission after Major Repair................................................................................ Automatic Powershift Control (APC 100)......................................................................................................... Functional Description .................................................................................................................................. Fuses .............................................................................................................................................................. Transmission Control Lever.......................................................................................................................... First-Speed Shaft Bearings Adjustment........................................................................................................... Torque Converter Stall Speed Check ................................................................................................................ Transmission Oil Pressures Check ................................................................................................................... Clutch Pressures Check ................................................................................................................................ Torque Converter (Torque Converter Regulator) Oil Pressure Check ........................................................ Troubleshooting.................................................................................................................................................. Diagrams, Schematics, or Arrangements ......................................................................................................... Figure 31. Transmission Hydraulic Diagram..........................................................................................
1 2 2 2 2 2 5 5 5 6 6 6 6 7 8 9 10 11 14 16 18 20 20 22 22 24 24 24 25 25 26 26 26 29 29 32 35 35 35 35 37 39 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
"THE QUALITY KEEPERS" HYSTER APPROVED PARTS
1300 SRM 635
General
General This four-speed powershift transmission is an HR-36000 series transmission manufactured by Spicer-Clark. This section has the repair procedures for the torque converter, transmission, control valve, and the oil pump for the transmission. See the section Four-Speed Powershift Transmission Description and Operation 1300 SRM 634 for information on the operation of this transmission. The transmission assembly is shown in Figure 1.
1. 2. 3. 4. 5. 6. 7.
TRANSMISSION OIL PUMP FORWARD CLUTCH THIRD CLUTCH REAR COVER FIRST CLUTCH OUTPUT YOKE OUTPUT GEAR
8. 9. 10. 11. 12. 13.
ALWAYS replace all seals, O-rings, metal seal rings, gaskets, and snap rings with new ones. Lubricate all seals with clean transmission oil before installation. Lubricate metal seal rings with multipurpose grease #2 before installation. Use care with seals especially during installation to prevent damage. If possible, use magnaflux to check all gears and shafts. Check gear teeth for wear, pitting, chipping, nicks, cracks, or scoring. If gears show spots where hardened surface has worn through, replace gear. Make sure shafts are not bent or the splines twisted.
TRANSMISSION HOUSING OIL SUMP AND PAN FOURTH CLUTCH SECOND CLUTCH REVERSE CLUTCH IMPELLER HUB GEAR
14. TORQUE CONVERTER HOUSING 15. TURBINE OF TORQUE CONVERTER 16. INPUT SHAFT AND GEAR 17. PUMP DRIVE GEAR
Figure 1. Transmission (HR-36000)
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Torque Converter Repair
1300 SRM 635
Torque Converter Repair TORQUE CONVERTER, REMOVE The torque converter is removed during removal of the transmission. See Remove, Transmission Only procedures for the transmission.
TORQUE CONVERTER, DISASSEMBLE If it is necessary to disassemble the torque converter, do so as follows and as shown in Figure 2: 1. Remove capscrews and lockwashers that fasten drive 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 fastens the turbine hub. One ring is thicker than the hub locating ring. NOTE: Use a drain pan for the oil in the converter section that did not drain during initial drain of oil. 3. Remove screws and washers that fasten impeller cover. Use a screwdriver at the slots to remove impeller cover, turbine, and turbine hub. Remove large O-ring for the cover. 4. Remove locating snap ring from under turbine hub. This ring is thinner than the retainer ring of Step 2. Remove snap ring that fastens stator to stator support. The stator support is fastened to the stator with a dowel. Do not remove spacer if stator or spacer will not be replaced. 5. Remove retainer for oil baffle (Figure 3). Use a special removal tool to remove impeller and oil baffle. The special removal tool is very similar to a gear puller, but is for larger diameter parts.
8. Remove screws and washers that fasten hub to impeller. Remove backing ring. Remove impeller from hub. Remove O-ring between hub and impeller. 9. Straighten locking tabs for hub bolts. Remove turbine-to-hub bolts and washers. Remove turbine hub. If necessary, disassemble turbine and impeller cover. Install blocks under the edges of the impeller cover to suspend the turbine and hub. Remove bearing snap ring and spacer. Use a drift and hammer to remove turbine and hub from impeller cover bearing.
CLEAN AND INSPECT WARNING Cleaning solvents can be flammable and toxic and can cause skin irritation. When using cleaning solvents, always follow the solvent manufacturer’s recommended safety precautions. Clean the parts of the torque converter in solvent. Dry parts with compressed air. Inspect splines and gear teeth for damage. Inspect shafts, bearings, and bearing surfaces for scratches, wear, or damage. Clean holes that have threads and capscrews where a thread-locking compound is used.
TORQUE CONVERTER, ASSEMBLE If the turbine and impeller cover were not disassembled, go to Step 3. If disassembled, assemble turbine and impeller cover as follows (see Figure 2):
6. Remove screws and washers that fasten stator support to converter housing. Rotate stator support so there is clearance between stator support and pump drive gear. The "cutout" in the stator support allows this clearance.
1. Align holes in turbine and turbine hub and install lock tabs, hub bolts, and washers. Tighten hub bolts to 122 to 134 N•m (90 to 99 lbf ft). Bend a corner of lock tab over bolt heads.
7. Remove snap ring for the impeller hub gear (Figure 3). Remove hub gear from impeller hub. Remove oil baffle, oil seal, and baffle seal ring.
2. Align impeller cover over turbine and hub. Install bearing for impeller cover in cover and over turbine hub. Install new O-ring. Install spacer on 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. 2. 3. 4. 5. 6. 7. 8.
TURBINE HUB SNAP RING REACTION MEMBER SPACER BEARING IMPELLER HUB O-RING IMPELLER
9. 10. 11. 12. 13. 14. 15. 16.
BACKING RING BEARING COVER RING IMPELLER COVER LOCK TAB TURBINE FLYWHEEL DRIVE PLATES
1. 2. 3. 4. 5. 6. 7. 8. 9.
SNAP RING BEARING BEARING SUPPORT HYDRAULIC PUMP GEAR TURBINE HOUSING SPRING PISTON RING SLEEVE STATOR SUPPORT
10. 11. 12. 13. 14. 15. 16. 17.
TUBE WASHER INPUT SHAFT RETAINER BAFFLE SEAL RING OIL SEAL IMPELLER GEAR
Figure 3. Input Shaft and Pump Drive Gears
4
1300 SRM 635 3. Make sure the surface of impeller hub and holes for screws are clean and dry. Put new O-ring on impeller hub. If removed, use a drift or press the same size as the bearing and install hub bearing and snap ring in hub.
Torque Converter Repair
RELIEF VALVE FOR LUBE PRESSURE, DISASSEMBLE AND ASSEMBLE If the unit has this relief valve, disassemble, clean, or replace and assemble the valve as shown in Figure 4.
4. Align holes in impeller with hub holes. Do NOT damage O-ring. The two dimples that are 180 degrees apart on backing ring must be installed toward engine flywheel. Install backing ring and install new special self-locking screws and washers. Tighten screws to 79 to 87 N•m (58 to 64 lbf ft).
CAUTION Make sure the total time to install and tighten the special screws is less than 15 minutes. If any screw is removed for any reason, it must be replaced. The epoxy left in the hub hole must be removed with a tap and cleaned with solvent. Make sure the hole is dry before installing a new screw. 5. Put a thin coat of Loctite© 638 on the outer diameter 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 without damaging oil seal. Install a new sealing ring for oil baffle. Install hub gear on impeller hub and install snap ring.
TORQUE CONVERTER (TURBINE) HOUSING, DISASSEMBLE If necessary, disassemble converter housing assembly as follows: 1. Remove snap ring for front bearing of input shaft. Use a hammer with a soft face to lightly hit input shaft to remove it and bearing from housing. 2. Put a mark on each pump gear for correct location during installation. Remove bearing support screws and lockwashers for the drive (center) gear. Remove drive gear and bearing assembly. Remove other two pump gear and bearing assemblies using the same procedure.
1. 2. 3. 4.
HOUSING WASHER SPRING SEAT
5. PLUNGER 6. VALVE SEAT RETAINER 7. RETAINING RING
Figure 4. Relief Valve Assembly
OIL SEALING RINGS SLEEVE, REPLACE There is a sleeve at the front end of the forward, reverse, and fourth-gear clutch shafts. Remove the sleeves ONLY if they are to be replaced. 1. Remove locating ring for front bearing of clutch shaft. 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 the sleeve during installation. Make sure the notch in the new sleeve is aligned with the sleeve lock notch. 5. Put sleeve lock in position. Install capscrew and washer. Tighten capscrew. 6. Install locating ring for front bearing of clutch shaft in ring groove.
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Transmission Repair
1300 SRM 635
TORQUE CONVERTER HOUSING, ASSEMBLE Assemble converter housing assembly as follows and as shown in Figure 3: 1. Install two pump drive gears as marked during disassembly. Install transmission pump gear at center location. Tighten all mount capscrews. 2. Install input shaft and gear. Use a hammer with a soft face to tap shaft so bearing snap ring can be installed. Install snap ring and continue to tap shaft so snap ring is against shoulder in housing. 3. Open locating ring for the front bearing of the reverse clutch. See Figure 15. Use a hammer
with a soft face to tap shaft of the reverse and second clutch until locating ring is completely in groove of converter housing. 4. Open locating ring for the front bearing of the fourth-speed clutch. See Figure 7. Use a hammer with a soft face to tap shaft of the fourth-speed clutch until locating ring is completely in groove of converter housing. 5. Install the front bearing of the forward clutch.
TORQUE CONVERTER, INSTALL The torque converter is assembled in the torque converter housing and is installed with the transmission. See Install, Transmission .
Transmission Repair REMOVE, TRANSMISSION ONLY NOTE: The transmission can be removed from under the lift truck or as a complete assembly with the engine. If an inspection pit is not available, the truck must be raised 500 mm (19.7 in.) from the ground to provide easier access and removal.
12. Disconnect the wires at the pressure and temperature sending unit on the transmission. 13. Place tags on lines for identification. 14. Remove the drain plug from the transmission sump.
1. Place truck on level surface.
15. Drain the oil.
2. Shut down engine.
16. Put plugs and caps on open fittings.
3. Apply parking brake.
17. Disconnect the hoses at the hydraulic pumps.
4. Operate all hydraulics to release pressure in the system.
18. Put plugs and caps on open fittings.
NOTE: When removing battery cables, remove ground cable first.
NOTE: The hydraulic pumps are fastened to the transmission with 4 capscrew each.
5. Disconnect the cables at the battery.
The drive shaft of the hydraulic pump is engaged in splines in the drive gear.
6. Remove floor plates and covers to provide access to the hydraulic pump and transmission.
The drive shaft of the hydraulic pump will slide from the drive gear when the hydraulic pump is removed.
7. Close shut-off valves on hydraulic tank.
19. Remove the hydraulic pumps.
8. Disconnect the drive shaft at the differential.
20. Disconnect and remove the dipstick assembly.
9. Remove the drive shaft between the transmission and the differential.
21. Install blocks and a jack under the flywheel end of the engine as a support.
10. Disconnect the wiring harness on top of the transmission.
22. Disconnect exhaust system to avoid possible damage.
11. Disconnect the wires at the solenoids on the transmission control valve.
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1300 SRM 635
Transmission Repair
WARNING Verify the lifting device has the minimum capacity of 725 kg (1600 lb). 23. Connect a lifting device to the transmission. 24. Remove the transmission mounts to the frame. See Figure 5.
29. Carefully, to avoid damage to the flex plate, lower the transmission assembly past the cross member support.
REMOVE, TRANSMISSION AND ENGINE ASSEMBLY NOTE: The transmission can be removed from under the lift truck or as a complete assembly with the engine. If an inspection pit is not available, the truck must be raised 500 mm (19.7 in.) from the ground to provide 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 the system. NOTE: When removing battery cables, remove ground cable first. 5. Disconnect the cables at the battery. 6. Remove floor plates and covers to provide access to the hydraulic pump and transmission.
NOTE: RS45-30CH, RS46-35CH, RS45-25IH, RS4630IH (A222) SHOWN. 1. TRANSMISSION HOUSING 2. TRANSMISSION MOUNT
3. FRAME MOUNT 4. FRAME BRACKET 5. ISOLATOR
7. Close shut-off valves on hydraulic tank. 8. Disconnect the drive shaft at the differential. 9. Remove the drive shaft between the transmission and the differential.
Figure 5. Transmission Mount
10. Disconnect the wiring harness on top of the transmission.
25. Remove the 8 bolts securing the drive plates to the torque converter.
11. Disconnect the wires at the solenoids on the transmission control valve.
26. Remove all fasteners between engine flywheel housing and torque convertor housing.
12. Disconnect the wires at the pressure and temperature sending unit on the transmission.
27. Verify all the connections have been removed.
13. Place tags on lines for identification.
28. Carefully slide back the transmission from the frame approximately 40 mm (1.60 in.) to permit the transmission to be lowered.
14. Remove the drain plug from the transmission sump. 15. Drain the oil.
WARNING The transmission is heavy, verify that the lifting devices are securely positioned.
16. Put plugs and caps on open fittings. 17. Disconnect the hoses at the hydraulic pumps. 18. Put plugs and caps on open fittings.
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Transmission Repair
1300 SRM 635
NOTE: The hydraulic pumps are fastened to the transmission with 4 capscrew each. The drive shaft of the hydraulic pump is engaged in splines in the drive gear. The drive shaft of the hydraulic pump will slide from the 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 end of the engine as a support. 22. Disconnect exhaust system to avoid possible damage. 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 air cleaner. 29. Disconnect fuel lines at the fuel filter. 30. Disconnect the throttle linkage. 31. Disconnect wires and wiring harnesses at the engine. 32. Disconnect the heater hoses at the engine. NOTE: Verify that the lifting device has a capacity of at least 1360 kg (3000 lb).
1. REAR MOUNT (FAN END OF ENGINE) 2. FRONT MOUNT Figure 6. Engine Mounts
TRANSMISSION, DISASSEMBLE Make sure to keep the parts for each clutch together during disassembly. Make a note of the order of the friction discs and separator plates of each clutch. Also make a note of which way each bearing seal is facing for correct installation. Disassemble the transmission as follows: 1. Remove torque converter assembly from transmission. If necessary, disassemble torque converter as described in Torque Converter, Disassemble. 2. Remove solenoid dust cover from transmission control valve. Remove screws and lockwashers that fasten control valve cover. Remove cover assembly of control valve, seal plate, and inner and outer gaskets. Remove control valve housing and gasket.
33. Connect a lifting device to the engine. 34. Remove the capscrews that hold the engine mount at the fan end of the engine. See Figure 6. 35. Remove the capscrews that hold the two rear engine mount brackets to the frame. NOTE: Verify all the connections to the engine or transmission have been removed. 36. Carefully lift the engine and transmission assembly from the frame.
3. Remove screws that fasten stator support. Rotate stator support so curved "cutout" section is aligned with pump drive gear to allow removal. See Figure 3. Remove stator support. 4. Use a crane and sling to support torque converter housing. Remove capscrews that fasten torque converter housing to transmission case. Remove torque converter housing with the reverse/second- and fourth-speed clutch assemblies attached. 5. Remove snap ring that fastens front bearing for the fourth clutch to the torque converter housing.
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1300 SRM 635
Transmission Repair
It can be necessary to use a prybar to remove the fourth-speed clutch assembly from housing.
of the suction tube. Remove suction tube and O-ring.
6. Remove snap ring that fastens the front bearing for the second and reverse clutch to the torque converter housing. See Figure 15. It can be necessary to use a prybar to remove the second and reverse clutch assembly from housing.
17. Have another person release the bearing snap ring for the rear bearing of the forward shaft. Use a hammer that has a soft face to tap the end of the shaft for removal.
7. Remove output shaft nut, washers, yoke, seal, and yoke from output shaft. Remove seal and spacer. Remove bearing cap nuts and lockwashers for rear bearing of output shaft. Remove bearing cap and O-ring. See Figure 7. 8. Remove bearing cap nuts and lockwashers for bearing of the third-speed shaft. Remove bearing cap, O-ring, rings, and washer. See Figure 10. 9. Remove bearing cap nuts and lockwashers for the bearing of the first-speed (low) shaft. Remove bearing cap, shims, O-ring, and ring. See Figure 17. Keep cap and shims together. If cap, clutch, front or rear bearings, transmission case, or rear cover are not replaced, the same shims will be used during assembly. 10. Remove clutch pressure and lube tubes and O-rings at the holes under bearing cap for the first-speed shaft bearing. 11. Remove locating rings for the rear bearings of the third-speed and output shafts. 12. Remove nuts, screws, and lockwashers that fasten the rear cover of the transmission. Remove oil screen plug and oil screen. Tap on the end of the output shaft and clutch shafts while prying cover off to remove cover. Using aligning studs can help in the removal. Remove cover gasket. 13. Remove retaining ring for the fourth-speed hub. Remove hub. Remove three retaining rings for the second-speed hub. Remove hub. 14. Use a bearing puller to remove the rear bearing of the output shaft. Remove first-speed clutch and output shaft simultaneously. Remove front bearing for output shaft. 15. Remove clutch assembly of the third-speed clutch.
18. Remove forward clutch assembly. See Figure 12. Remove outer race of the rear bearing of the input shaft. Remove bearing cup and oil baffle spacer of the first-speed shaft.
Output Shaft, Disassemble and Assemble NOTE: The following procedures describe the disassembly of each of the shaft assemblies and clutches. These assemblies have been removed from the transmission as assemblies in the previous procedures. Disassemble only the shaft or clutch assembly necessary to make repairs.
CAUTION Inspect all bearings for damage and wear. Bearings are normally replaced during a major disassembly and assembly such as this. Inspect clutch plates for wear of friction material and damage to the separator plates. Make sure to keep all parts of each clutch assembly together. Some of these parts look the same, but are not. Using the wrong part can cause incorrect operation or damage. Always use new seals, seal rings, and snap rings during assembly. Apply a thin coat of multipurpose grease #2 to all seals before installation. Fill all seal grooves with this same grease. The following procedure describes the disassembly and assembly of the output shaft. See Figure 7: 1. Remove inner race of the front bearing of the output shaft. 2. Remove front retaining ring for the output gear. Remove spacers and gear from shaft. If necessary, remove rear retaining ring.
16. Remove oil baffle screws, lockwashers, and oil baffle from cover. Remove bolts and lockwashers
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Transmission Repair
1300 SRM 635
1. SEPARATOR DISC (TEETH OUTSIDE) 2. FRICTION DISC (TEETH INSIDE) 3. BACKING PLATE 4. RING 5. SEAL 6. SPRING
7. 8. 9. 10. 11. 12. 13. 14.
SPRING RETAINER HUB TRANSMISSION HOUSING BEARING RETAINER SPACER OUTPUT GEAR REAR COVER
15. CLUTCH DRUM AND GEAR FOR FOURTH SPEED 16. PISTON 17. OUTPUT SHAFT 18. BEARING CAP 19. O-RING 20. PLUG 21. YOKE
Figure 7. Fourth-Speed Shaft and Output Shaft 3. If removed, install rear retaining ring on output shaft. Install spacers and gear with long hub toward rear. Install front retaining ring. 4. Install retainer and press front bearing on output shaft with race shoulder facing gear. Install bearing and outer race on inner race. 5. Install clutch hub on shaft using retaining rings.
10
Fourth-Speed Shaft, Disassemble and Assemble The following procedure describes the disassembly and assembly of the fourth-speed shaft: See Figure 7 and Figure 8. 1. Remove oil sealing rings from the fourth-clutch shaft. Remove snap ring for front bearing and remove bearing using a bearing puller. Remove other ring.
1300 SRM 635
Transmission Repair
2. Remove snap ring for the backing plate of the clutch disc and remove backing plate. Remove all friction and separator discs. 3. Remove seal. Compress wave spring and remove retaining ring from its groove. Release wave spring and remove snap ring and retainer for the spring. Remove wave spring and thrust washer. Turn assembly over and tap shaft on a block of wood to remove seals and piston. 4. Make sure the bleed valve is clean in the piston removed in Step 3. Install inner and outer seal rings on piston. Lock ring joint and apply grease to stabilize it in the ring groove. Carefully position piston in drum without damaging seal rings. 5. Install seal, thrust washer, wave spring, spring retainer, and retainer snap ring on shaft. Compress wave spring and install retainer snap ring in shaft groove. Install a separator disc (teeth on outside) in clutch drum. 6. Alternately install six friction discs and the other five separator discs in drum. The last disc must be a friction disc. 7. Install backing plate and snap ring in drum. 8. Press front bearing against shoulder on shaft with snap ring groove toward drum. Install snap ring. Install grease in groove for seal rings and install seals in grooves.
Third-Speed Shaft, Disassemble and Assemble The following procedure describes the disassembly and assembly of the third-speed shaft (see Figure 9 and Figure 10): 1. Remove sealing ring from shaft. Remove snap ring for rear bearing. Use a bearing puller to remove rear bearing. 2. Remove retaining ring for outer bearing of the third gear. Use a hammer that has a soft face to tap the third gear with the outer bearing from clutch drum.
1. 2. 3. 4. 5. 6. 7.
HUB RING SPRING RETAINER SPRING SEAL BACKING PLATE FRICTION DISC (TEETH INSIDE)
8. SEPARATOR DISC (TEETH OUTSIDE) 9. PISTON 10. CLUTCH SHAFT, DRUM, AND GEAR FOR FOURTH SPEED 11. BEARING
Figure 8. Fourth-Speed Clutch
3. Remove snap ring for clutch backing plate. Remove backing plate.
11
Transmission Repair
1300 SRM 635 4. Use a bearing puller to remove inner bearing for the third-speed gear. Remove snap ring for inner bearing. 5. Remove all friction and separator discs. Compress wave spring and remove retaining ring from its groove. Release wave spring and remove 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 piston removed in Step 6. Install inner and outer seal rings on piston. Lock ring joint and apply grease to stabilize it in ring groove. Carefully position piston in drum without damaging seal rings. 8. Put retainer for wave spring, wave spring, wave spring retainer, and snap ring for retainer on shaft. Compress wave spring and install retainer ring for spring into groove of shaft. Make sure retainer ring is completely in groove. 9. Install snap ring for inner bearing on shaft. Install a separator disc (teeth on outside) in clutch drum. 10. Alternately install 12 friction discs and the other 11 separator discs in drum. The last disc must be a friction disc. 11. Install backing plate and snap ring in drum. 12. Install inner bearing for the third-speed gear. This bearing does not have an oil shield. Carefully install the third gear and hub. Make sure the hub splines engage the splines of all friction discs. To avoid damage, do not force the hub through the discs.
1. 2. 3. 4. 5. 6. 7. 8.
SPRING RETAINER SPRING RETAINING RING RING BEARING GEAR AND HUB SNAP RING BACKING PLATE
9. FRICTION DISC (TEETH INSIDE) 10. SEPARATOR DISC (TEETH OUTSIDE) 11. PISTON 12. SEAL 13. CLUTCH SHAFT, DRUM, AND GEAR FOR THIRD SPEED
Figure 9. Third-Speed Clutch Assembly
12
13. Install outer bearing of the third gear. This bearing has an oil shield. The oil shield must face away from the gear. Install retaining ring for bearing. 14. Install rear bearing on shaft. The groove in the bearing must be toward the end of the shaft. Install snap ring for bearing. Install oil seal ring in the groove near the end of the shaft. Use grease to hold the oil seal ring in place.
1300 SRM 635
1. 2. 3. 4. 5. 6. 7. 8. 9.
TRANSMISSION HOUSING REAR COVER BEARING WASHER RING O-RING BEARING CAP PLUG HUB AND GEAR
Transmission Repair
10. 11. 12. 13. 14. 15. 16. 17. 18.
RETAINING RING SPRING SPRING RETAINER BACKING PLATE FRICTION DISC (TEETH INSIDE) SEPARATOR DISC (TEETH OUTSIDE) PISTON SEAL CLUTCH DRUM, SHAFT, AND GEAR
Figure 10. Third-Speed Shaft
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Transmission Repair
1300 SRM 635
Forward Shaft and Clutch, Disassemble and Assemble The following procedure describes the disassembly and assembly of the forward shaft and clutch (see Figure 11 and Figure 12): 1. Remove piston rings from forward clutch shaft. Remove retainer ring for inner race of front bearing. Use prybars to remove bearing inner race. Remove retainer ring for outer bearing. 2. Use prybars to remove clutch gear/hub and outer bearing together. 3. Use a bearing puller to remove inner bearing for hub. 4. Remove retainer ring for clutch backing plate. Remove backing plate. DO NOT LOSE THE BALL AND SPRING OF THE BACKING PLATE. Remove all friction and separator discs. 5. Compress disc springs and remove retaining rings from grooves. Release disc springs and remove snap ring and retainer for spring. Remove disc springs. Make sure to keep these disc springs together and with the other clutch parts. Remove clutch piston and seals. 6. Remove retainer ring and thrust washer for rear bearing. Not all units have the thrust washer. Use a bearing puller to remove rear bearing. 7. Get a section of pipe that has approximately the same outer diameter as the bearing outer race. Use the pipe and a hammer or a press to install rear bearing. The groove in the bearing must be toward the end of the shaft. If installed, put thrust washer on shaft. Install retaining ring for rear bearing. 8. Install inner and outer seal rings on piston. Lock ring joint and apply grease to stabilize it in ring groove. Carefully position piston in drum without damaging seal rings. 9. Install one friction disc (teeth on inner diameter). Install one separator disc, then alternately install the other 10 friction discs and the other nine separator plates. The first and last clutch disc must be a friction disc. This is the sequence of installation when the clutch has an iron piston.
14
1. 2. 3. 4. 5.
RETAINER SPRING RING BEARING CLUTCH HUB AND GEAR 6. PISTON RING 7. CLUTCH DRUM AND GEAR
8. SEAL 9. PISTON 10. SEPARATOR DISC (TEETH OUTSIDE) 11. FRICTION DISC (TEETH INSIDE) 12. BACKING PLATE 13. SNAP RING
Figure 11. Forward Clutch Assembly
1300 SRM 635
1. 2. 3. 4. 5. 6. 7.
Transmission Repair
RETAINER SPRING RING BEARING CLUTCH HUB AND GEAR PISTON RING CLUTCH DRUM AND GEAR
8. 9. 10. 11. 12. 13. 14.
SEAL PISTON SEPARATOR DISC (TEETH OUTSIDE) FRICTION DISC (TEETH INSIDE) BACKING PLATE SNAP RING 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 clutch drum making sure not to lose the spring or ball. Compress clutch discs and disc springs and install retainer ring for backing plate. 11. Install disc springs and retainer for piston. Make sure the disc spring with the large diameter is toward the piston. 12. Compress disc springs and install rings fully in grooves. Install inner bearing and ring. This bearing does not have a shield in it. Carefully install hub and gear in drum. Make sure hub splines engage splines of all friction discs. To avoid damage, do not force hub through the discs.
1. CLUTCH PLATE 2. RETAINER RING 3. DETENT SPRING
4. DETENT BALL 5. CLUTCH DRUM
Figure 13. Detent
15
Transmission Repair
1300 SRM 635
13. Install rings in outer bearing with shield toward gear. Install inner race of front bearing. The large diameter must be toward gear. Install retainer for front bearing. 14. Put grease in groove for piston rings. Install piston rings in grooves. Align piston rings at center of groove.
Reverse and Second-Speed Shaft and Clutch, Disassemble and Assemble The following procedure describes the disassembly and assembly of the reverse and second-speed shaft and clutch (see Figure 14 and Figure 15): 1. Remove piston rings at the reverse clutch end of shaft. Remove retaining ring for front bearing. Use prybars to move front bearing enough to install bearing puller. Use bearing puller to remove front bearing. 2. Remove retainer ring for outer bearing of hub gear. Use pry bars to carefully pry hub gear up for clearance to install a gear puller. Remove hub gear and outer bearing. 3. Remove retainer ring for clutch backing plate. Remove backing plate. DO NOT LOSE THE BALL AND SPRING OF THE BACKING PLATE. 4. Remove all clutch discs. Use a bearing puller to remove inner bearing. 5. Compress disc springs and remove retaining ring from its groove. Release disc springs and remove retainer ring and retainer for spring. Remove disc springs. Make sure to keep these disc springs together and with the other clutch parts. Remove clutch piston. 6. Put a coat of grease on seal rings and install seal rings on piston. Carefully position piston in drum without damaging seal rings. 7. Install disc springs for piston. Make sure disc spring with the large diameter is toward piston. Install retainer ring for disc springs. Install retainer for spring retainer ring. Compress disc springs and install retainer ring fully in groove. Use a press to install inner bearing. This bearing does not have a shield in it.
1. SEAL 2. PISTON 3. SEPARATOR DISC (TEETH OUTSIDE) 4. FRICTION DISC (TEETH INSIDE) 5. BACKING PLATE 6. SNAP RING 7. RETAINER
8. 9. 10. 11.
SPRING RING BEARING CLUTCH HUB AND GEAR 12. PISTON RING 13. CLUTCH DRUM AND GEAR
Figure 14. Reverse and Second-Speed Clutch
16
1300 SRM 635
1. 2. 3. 4. 5. 6. 7. 8.
Transmission Repair
PISTON RING RING BEARING SNAP RING REVERSE CLUTCH HUB AND GEAR SPRING SPRING RETAINER BACKING PLATE
9. 10. 11. 12. 13. 14. 15.
FRICTION DISC (TEETH INSIDE) SEPARATOR DISC (TEETH OUTSIDE) PISTON SEAL CLUTCH DRUM AND GEAR HUB AND GEAR FOR SECOND-SPEED CLUTCH TRANSMISSION HOUSING
Figure 15. Reverse and Second-Speed Shaft 8. Install one friction disc (teeth on inner diameter). Install one separator disc, then alternately install the other 10 friction discs and the other nine separator plates. The first and last clutch disc must be a friction disc. This is the sequence of installation when the clutch has an iron piston. 9. Install detent spring and ball in backing plate. See Figure 13. Install backing plate in clutch drum making sure not to lose the spring or ball.
Compress clutch discs and disc springs and install retainer ring for backing plate. 10. Carefully install hub and gear in drum. Make sure hub splines engage splines of all friction discs. To avoid damage, do not force hub through the discs. 11. Install outer bearing with shield toward gear. Install retainer ring for outer bearing. Install front
17
Transmission Repair
1300 SRM 635
bearing. The groove in the bearing must be toward gear. Install retainer ring for front bearing. 12. Put grease in groove for sealing rings. Install sealing rings in grooves. Align sealing rings at center of groove. 13. Remove snap ring for backing plate of second clutch. Remove backing plate and all clutch discs. 14. Compress wave spring and remove retaining ring from its groove. Release wave spring and remove snap ring and retainer for spring. Remove wave spring and thrust washer. Remove second clutch piston. 15. Make sure the bleed valve is clean in the secondgear piston removed in Step 14. Install inner and outer seal rings on piston. Lock ring joint and apply grease to stabilize it in ring groove. Carefully position second-gear piston in drum without damaging seal rings. 16. Put thrust washer, wave spring, wave spring retainer, and snap ring for retainer on shaft. Compress wave spring and install retainer ring for spring into the groove of the shaft. Make sure retainer ring is completely in groove. 17. Install a separator disc (teeth on outside) in clutch drum. Alternately install the six friction discs and the other five separator discs in drum. The clutch disc next to the piston is a separator disc. The last clutch disc is a friction disc. 18. Install backing plate and snap ring in drum.
First-Speed Shaft and Clutch, Disassemble and Assemble The following procedure describes the disassembly and assembly of the first-speed shaft and clutch (see Figure 16 and Figure 17): 1. Remove seal rings near end of shaft at tapered roller bearing. Use prybars to carefully move tapered roller bearing for clearance to use a bearing puller. Use the bearing puller to remove tapered roller bearing. Remove bearing thrust washer. 2. Use a gear puller to remove first-speed gear with outer bearing.
18
1. 2. 3. 4. 5. 6. 7. 8. 9.
BEARING WASHER HUB AND GEAR RING SPACER RING SPRING WASHERS BACKING PLATE FRICTION DISC (TEETH INSIDE)
10. SEPARATOR DISC (TEETH OUTSIDE) 11. PISTON 12. PISTON SEAL 13. SEAL 14. CLUTCH SHAFT, DRUM, AND GEAR FOR FIRST SPEED 15. THIRD-SPEED GEAR
Figure 16. First-Speed Clutch
1300 SRM 635
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
TRANSMISSION HOUSING REAR COVER O-RING BEARING CAP RING SHIM SET PLUG BACKING PLATE SPRING WASHERS SPACER BEARING
Transmission Repair
12. 13. 14. 15. 16. 17. 18. 19. 20.
HUB AND GEAR WASHER THIRD-SPEED GEAR CLUTCH SHAFT, DRUM, AND GEAR FOR FIRST SPEED SEAL PISTON SEAL PISTON SEPARATOR DISC (TEETH OUTSIDE) FRICTION DISC (TEETH INSIDE)
Figure 17. First-Speed Shaft
19
Transmission Repair 3. Remove snap ring for backing plate. Remove backing plate and all clutch discs. 4. Use a bearing puller to remove inner bearing of the first-speed gear. Remove spacer.
1300 SRM 635 12. Install outer bearing for hub gear. This bearing has an oil shield. The shield must be toward the end of the shaft. Install washer. Use a press to install tapered roller bearing. The small diameter of the bearing must be toward end of shaft.
5. Compress wave spring and remove retaining ring from its groove. Release wave spring and remove snap ring and retainer for spring. Remove wave spring and the other wave spring ring. Remove piston and seals for the first-speed clutch.
NOTE: The two oil seal rings at the end of the shaft will be installed after the clearance adjustment for the tapered roller bearings is complete.
6. Use a gear puller to remove driven gear together with front bearing.
The following procedure describes the disassembly and assembly of the input shaft (see Figure 3):
7. Install driven gear on clutch shaft with long hub of gear toward end of shaft. Use a press to install tapered roller bearing. The small diameter of the bearing must be toward the end of the shaft.
1. Remove piston ring from input shaft.
8. Install inner and outer seal rings on clutch piston. Lock ring joint and apply grease to stabilize it in the ring groove. Carefully position the first-speed piston in drum without damaging seal rings. 9. Put retainer for wave spring, wave spring, wave spring retainer, and snap ring for retainer on shaft. Compress wave spring and install retainer ring for spring into the groove of shaft. Make sure retainer ring is completely in groove. 10. Install a separator disc (teeth on outside) in clutch drum. Alternately install the 10 friction discs and the other nine separator discs in the drum. The last disc is a friction disc. Install backing plate and snap ring in drum. 11. Install gear spacer and inner bearing. The bearing does not have an oil shield. Use a press to install bearing. Carefully install hub gear. Make sure hub splines engage splines of all friction discs. To avoid damage, do not force the hub through the discs.
20
Input Shaft, Disassemble and Assemble
2. Remove bearing snap ring and bearing washer. 3. Use prybars to move bearing enough to install a bearing puller. Use bearing puller to remove bearing. Use a press to install bearing with groove in bearing away from gear. 4. Install bearing washer and snap ring. Fill groove for piston ring with grease. Install piston in center of groove.
SPEED SENSOR, INSTALL Temporarily install bushings for speed sensors. Use a depth micrometer to measure the depth at each speed sensor bushing. Add shims to get the correct dimensions as shown in Figure 18. Clean threads of bushing and housing using Loctite© cleaner. Install shims under the head of the bushing. Use Loctite® number 270 or number 262 on both the bushing and housing threads. Install shims and tighten bushings to 61 to 68 N•m (45 to 50 lbf ft). After the Loctite® has set, install speed sensors and tighten them to 54 N•m (40 lbf ft).
1300 SRM 635
1. SPEED SENSOR LOCATION 2. TRANSMISSION 3. SHIM LOCATION
Transmission Repair
4. DEPTH MICROMETER 5. BUSHING Figure 18. Speed Sensor Installation
21
Transmission Repair
1300 SRM 635
TRANSMISSION, CLEAN AND INSPECT WARNING Cleaning solvents can be flammable and toxic and can cause skin irritation. When using cleaning solvents, always follow the solvent manufacturer’s recommended safety precautions. Clean the parts of the transmission in solvent. Dry parts with compressed air. Inspect splines and gear teeth for damage. Inspect shafts, bearings, and bearing surfaces for scratches, wear, or damage. Make sure separator plates are smooth. Inspect friction discs for burned or damaged friction material. Clean holes that have threads and capscrews where a thread-locking compound is used.
1. 2. 3. 4.
LOCATING RING SPACER (OIL BAFFLE) BEARING CUP TRANSMISSION HOUSING Figure 19. Bearing Installation Detail
TRANSMISSION, ASSEMBLE NOTE: If a new transmission or converter housing will be used, install speed sensors in new housing. See the procedure in Speed Sensor, Install and Figure 18. 1. Install new O-ring on suction tube for transmission pump. Install tube in transmission case. Install screws and washers for suction tube. Tighten screws. 2. Set oil baffle in transmission case. Install and tighten oil baffle screws. 3. Set froward clutch assembly into rear bearing bore of transmission case. Push rear bearing through bore far enough to install outer locating ring. Push bearing back in bore until locating ring is against shoulder of bore. 4. Install third-speed clutch assembly. 5. Install locating ring in front bearing bore for low clutch bearing. Install spacer (oil baffle) and front bearing cup as shown in Figure 19. NOTE: The first-speed clutch and the output shaft must be installed simultaneously. Another person can be helpful during this installation. 6. Install the first-speed clutch and output shaft in transmission housing. Make sure they are fully in position in the housing. Install rear bearing on output shaft. The groove in the bearing for the snap ring must be toward the rear.
22
7. Install new gasket and O-ring on rear of transmission housing. A thin coat of grease will help hold gasket in place on housing. Install aligning studs to help align rear cover. Install rear cover, tapping cover with a hammer that has a soft face. Install cover screws and washers and tighten screws. 8. Install locating ring for bearing outer race of output shaft. Install spacer for output flange on output shaft. 9. Apply a thin coat of Loctite® 683 (green) on outer diameter of oil seal. Press seal in bearing cup of output shaft with lip of seal toward bearing. Use new O-rings and install bearing cap for the output shaft bearing. Install lockwashers and nuts and tighten nuts. 10. Install output flange, O-ring, washer, and elastic flange nut. Use a bar to prevent flange from turning and tighten flange nut to torque specified in Table 1. Table 1. Flange Nut Torque Thread Size
N•m
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
1300 SRM 635 11. Install locating ring for rear bearing of the thirdspeed shaft. Install new O-ring on bearing cap. Install bearing cap, lockwashers, and nuts on studs. Tighten nuts. 12. Install screen assembly for oil sump and install plug. Tighten plug to 13 to 20 N•m (10 to 15 lbf ft). 13. Make sure the shim pack is correct for the bearings of the first-speed clutch as described in First-Speed Shaft Bearings Adjustment. Install new O-rings on clutch pressure and lube transfer tubes and install tubes in rear cover of transmission at rear bearing of first-speed clutch. Fill grooves of oil sealing rings with grease. Install sealing rings and move sealing rings to the center of the grooves. Install shim pack on studs and install bearing cap, washers, and nuts. Tighten nuts.
Transmission Repair 16. Install pilot bearing for the second and third clutches on the shafts. Use grease to keep bearings in position. 17. Leave the passage for the first-speed clutch open for internal lube tube installation. Install plug for external lube tube installation. See Figure 21. Tighten plug to 9.5 to 13.5 N•m (7 to 10 lbf ft).
14. Turn transmission housing so that rear cover is to the rear. Install disc hub of the second-speed clutch on shaft of the first-speed clutch. Install retainer ring for hub. Install retainer for retainer ring. Install snap ring for retainer ring of retainer. See Figure 20.
1. CONVERTER HOUSING 2. PASSAGE OPEN FOR INTERNAL LUBE INSTALLATION Figure 21. Low-Speed Clutch Lube Passage
1. DISC HUB 2. SNAP RING FOR RETAINER OF RETAINER RING 3. HUB RETAINER RING 4. CLUTCH SHAFT 5. RETAINER FOR RETAINER RING Figure 20. Retainer Ring Detail 15. Install bearing outer race for input shaft. Install a new converter housing gasket and O-rings on transmission housing. A thin coat of grease will help hold the gasket in place on the housing.
18. Install alignment studs and install converter housing on transmission housing while rotating output shaft. Rotation of the output shaft will help the clutch hub (Step 14) and discs to align correctly. Do NOT push the two housings together too hard. Allow hub to align and enter clutch discs. Install and tighten bolts that fasten housings together. 19. Fill the groove for the oil sealing ring of the stator support using grease. Install sealing ring. Install inner race of impeller hub bearing on stator support. Align notch in stator support with pump gear and install support on input shaft. Align mount holes of stator support with holes in housing and install and tighten screws to fasten stator support.
23
Transmission Repair 20. Install impeller and oil baffle assembly in converter housing. Install retaining ring for oil baffle. Make sure the turbine and dowel pin are in place and install turbine on stator support. Install snap ring (thicker snap ring) to fasten the reaction member. 21. Install turbine snap ring (thinner snap ring). Install new impeller O-ring on impeller cover. Install impeller cover and turbine assembly on input shaft. Install impeller cover, lockwashers, and screws that fasten impeller cover. Tighten screws. 22. Install snap ring (thickest snap ring) for turbine hub. Install new O-ring on bearing cap for impeller. Stack drive plates so that all the fingers are aligned. Concave sides are toward flywheel and the weld nuts are toward the cover. Align holes of backing ring and drive plates. Install drive plates, backing ring, and place bolts. Tighten the 0.4375-inch place bolts to 71 to 77 N•m (52 to 57 lbf ft). Tighten the 0.3750-inch place bolts to 45 to 49 N•m (33 to 36 lbf ft).
1300 SRM 635
CAUTION Make sure mount screws for control valve are installed in the correct location to prevent damage. All of the screws are not the same. 2. Install a seal plate gasket, seal plate, and the other seal plate gasket on studs against control valve. Install control valve cover and screws. Items 1, 2, 3, 4, and 5 are 3/8 - 16 x 4-1/4 inch capscrews. Items 12, 13, and 14 are 3/8 - 16 x 1 inch capscrews. Items 6 and 7 are flanged 12 point 3/8 - 16 x 3 inch capscrews. Items 8, 9, 10, and 11 are flanged 12 point 3/8 - 16 x 1-1/4 inch capscrews. Tighten screws in the sequence (A through N) shown in Figure 22. 3. Install solenoid protection cover, washers, and nuts. Tighten stud nuts in the sequence shown in Figure 22.
CONTROL VALVE Clean and Inspect WARNING Cleaning solvents can be flammable and toxic and can cause skin irritation. When using cleaning solvents, always follow the solvent manufacturer’s recommended safety precautions. Clean all parts in solvent. Inspect spools, bores, and springs for damage. Make sure spools move freely in the bores.
Assemble and Install Lubricate all parts with transmission oil. Always use new O-rings and gaskets. During assembly, make sure all spools move freely in their bores. Connect wires to solenoids as marked during removal. 1. Put gasket for control valve on converter housing on alignment studs. Install control valve assembly on studs. Install the two valves to housing screws.
24
Figure 22. Control Valve Installation (Bottom View)
1300 SRM 635 4. Install new O-ring on housing for pressure regulator valve. Install regulator valve and charging pump on converter housing. Install lockwashers and screws. Tighten screws. Install suction tube, O-ring, adapter fitting, adapter flange, flange screws, and lockwashers. Tighten screws.
INSTALL, TRANSMISSION 1. Install the mounts on transmission housing. See Figure 5. Connect a lifting device with a minimum capacity of 725 kg (1600 lb) to the lifting eyes on the transmission. 2. Install two 89 mm (3.5 in.) long guide studs in the engine flywheel housing. Rotate engine flywheel to align a mounting hole for the drive plates with the access hole of flywheel housing. Check end play of flywheel. 3. Install a 102 mm (4 in.) locating stud in a drive plate nut. Align locating stud of drive plate with flywheel screw hole at the access hole. 4. Use the lifting device to put transmission assembly into the approximate position. Align drive plates on flywheel and converter housing with flywheel housing. Install housing screws to fasten converter and flywheel housings together. Remove housing studs and install all housing screws. Tighten all screws. 5. Install nuts and bolts for transmission mounts. Tighten nut for transmission mount to 120 N•m (90 lbf ft). 6. Remove locating stud in drive plates. Install screw to fasten drive plates to flywheel. A screwdriver or pry bar can be used to hold the drive plates against the flywheel to install the screw. Rotate flywheel and install each drive plate screw in turn. After all screws are installed, tighten all M10 screws to 61 N•m (48 lbf ft). Check that flywheel end play is within 0.03 mm (0.001 in.) of the end play of Step 2.
Transmission Repair
INSTALL, TRANSMISSION AND ENGINE ASSEMBLY NOTE: Verify that the lifting device has a capacity of at least 1360 kg (3000 lb). 1. Connect a lifting device to the engine. 2. Carefully lower the engine and transmission into the frame. 3. Install the capscrews that hold the 2 rear engine mount brackets to the frame. 4. Install the capscrews that hold the engine mount at 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 engine. 7. Connect the throttle linkage. 8. Connect the fuel lines at the fuel filter. 9. Install the tubing between the engine and air cleaner. 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 will slide into the drive gear before the hydraulic pumps are installed. 17. Install the drive shaft of the hydraulic pump.
7. Connect drive shafts to transmission. Make sure to align the marks. Tighten capscrews for input yoke to 68 N•m (50 lbf ft). Tighten capscrews for output yoke to 163 N•m (120 lbf ft).
NOTE: The hydraulic pumps are fastened to the transmission with 4 capscrews.
8. Connect oil lines and dipstick tube at transmission. Connect wiring harness at transmission.
19. Remove plugs and caps on open fittings.
18. Install hydraulic pumps.
20. Connect the hoses at the hydraulic pumps. 21. Remove identification tags on lines.
25
Automatic Powershift Control (APC 100) 22. Replace the drain plug from the transmission sump. 23. Replace the transmission oil.
1300 SRM 635 Clean the system as follows: 1. Drain the entire system completely.
24. Connect the wires at the pressure and temperature sending unit on the transmission.
2. Disconnect and clean all oil lines for the transmission. If possible, remove oil lines completely to clean them.
25. Connect the wires at the solenoids on the transmission control valve.
3. Remove filter elements and clean filter can. Install new filter elements.
26. Connect the wiring harness on top of the transmission.
4. Use oil and compressed air with flow opposite the normal direction to flush the oil cooler. Do NOT use flushing compounds.
27. Replace the drive shaft between the transmission and 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 the ground cable last. 31. Connect the cables to the battery. 32. Start engine. 33. Operate hydraulic functions and check for leaks.
CLEAN OIL SYSTEM OF TRANSMISSION AFTER MAJOR REPAIR NOTE: The complete oil system of the transmission must be cleaned after every major repair. This cleaning is necessary to make sure the transmission operates correctly.
5. Assemble all components and oil lines. Fill transmission with the correct oil to the LOW mark (dipstick or lower fill plug). Install new gaskets and hydraulic pumps for the hydraulic systems of the lift truck to the flange on the transmission. Connect hydraulic lines as necessary. See the Hydraulic System. Fill hydraulic tank of lift truck with correct amount and type of hydraulic oil. 6. Operate engine at idle speed for two minutes to fill all hydraulic lines and filters. Check for leaks. Check oil level of transmission with engine operating. Add oil as necessary to the LOW mark. If necessary, install the fill and level plugs. 7. Operate engine at stall until oil is 82 to 93 C (180 to 200 F) and check for leaks. See Torque Converter Stall Speed Check.
Automatic Powershift Control (APC 100) FUNCTIONAL DESCRIPTION The APC 100 control unit performs the following functions (see Figure 23 and Table 2): • Direction Change Protection FORWARD to REVERSE/REVERSE to FORWARD - When the gear selector direction is reversed, throttle reduction is automatically applied, setting engine speed to idle. The transmission will downshift as the vehicle slows until first gear is obtained. The transmission will then change directions and shift to first gear. NEUTRAL to FORWARD or REVERSE - Neither forward nor reverse can be selected when the engine speed is too high (more than 1000 rpm). 26
FORWARD, NEUTRAL, FORWARD - When driving in a certain direction and when putting the gear selector in NEUTRAL and back in the same direction, NEUTRAL will be selected until the engine speed is low enough (less than 1000 rpm). • Overspeed Control No shifts will be made that can cause overspeeding of the transmission or the engine. A light on the instrument panel indicates overspeeding. • Turbine Sensor Failure Since automatic shifting is based on a speed ratio, a failure of the torque converter turbine results in a speed ratio of zero, causing the transmission to downshift. The control unit prevents downshifts
1300 SRM 635
Automatic Powershift Control (APC 100)
that would cause excess speed while driving due to a turbine failure. • Automatic Shifting An automatic shift to a higher gear is made when the throttle pedal is pressed, the turbine speed exceeds a minimum speed, and the speed ration has reached a certain value. No upshifts are allowed in the braking mode (throttle pedal released). An automatic shift to a lower gear is made when the tractive effort in the lower gear exceeds the tractive effort in the higher gear. • Declutch The transmission shifts to neutral under certain conditions for load handling procedures. The following paragraphs describe the pin connections at the APC 100 control unit. 1. Diagnostic LEDs (See Figure 23) a. RED LED - ON when internal failure prevents correct operation. b. GREEN LED - Light reflects the position of the idle/not idle switch (pin no. 23). When the throttle is at idle, the light is OFF. The light 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. Switch closed - APC 100 in manual mode, operator decides when to shift. Downshifts or direction changes at high speeds are inhibited. c. Declutch Request (pin no. 8). Switch open no declutch is applied. Switch closed - when declutch is requested, the control unit will shift the transmission to NEUTRAL when vehicle speeds are less than a preset value, depending on the unit. When the request is dropped, the direction is engaged again. d. Parking Brake request (pin no. 27). Switch open - parking brake is not applied. Switch closed - when parking brake is applied, control unit will shift the transmission to NEUTRAL. e. Second Gear Start Request (pin no. 7). 24 volts applied - transmission starts in first gear when transmission control lever is set for second gear or lower. No voltage applied - transmission starts in second gear when transmission control lever is set for fourth gear.
A. FRONT COVER
B. REAR COVER
1. INDICATOR LIGHTS RED - INTERNAL MALFUNCTION YELLOW - ZERO RPM, ENGINE OR TORQUE CONVERTER GREEN - THROTTLE PEDAL DEPRESSED
2. CONNECTOR FOR LIFT TRUCK HARNESS 3. CONNECTOR FOR CHECKOUT KIT
Figure 23. APC 100 Control Unit
27
Automatic Powershift Control (APC 100)
1300 SRM 635
Table 2. APC 100 Control Module (Pin Connections) Pin No.
Function
Function
1
Forward Switch (input)
17-19
2
Range Switch 1 (input)
20
Reverse Switch (input)
3
Range Switch 3 (input)
21
Range Switch 2 (input)
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
4-6
10-11
24-25
Not Used
Not Used
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
Pin No.
1300 SRM 635
Automatic Powershift Control (APC 100)
FUSES
TRANSMISSION CONTROL LEVER
The APC 100 uses two fuses to protect its circuits. See Figure 24. The 315 mA fuse is located behind the front cover. To check or replace the 10A fuse, remove the rear cover and pull out the circuit board. Be sure to replace the fuses with the same type.
The transmission control lever (Figure 25) is installed on the steering column. If the unit does not operate correctly, check the wiring and connectors. See the schematic in Figure 26 and Figure 27 and Table 3. Check the operation of the APC 100 control unit. If the control lever does not operate, install a new lever.
NOTE: RS45-30CH, RS46-35CH, RS45-25IH, RS46-30IH (A222) SHOWN. 1. 315 mA FAST ACTING 2. 10A FAST FUSE
Figure 25. Transmission Control Lever
Figure 24. APC 100 Control Unit Fuses Location
29
Automatic Powershift Control (APC 100)
Figure 26. Transmission Control Electrical Schematic
30
1300 SRM 635
1300 SRM 635
Automatic Powershift Control (APC 100) 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 Adjustment If the cap, clutch, front or rear bearings, transmission case, or rear cover is replaced, the clearance for the bearings must be adjusted using shims at the cap. If none of these parts were replaced, the old shim set can be used without doing this procedure. Adjust the bearings as follows: 1. Move transmission assembly so rear of transmission is up. If the bearing cap for the first-speed shaft is installed, remove bearing cap. Make sure the cap O-ring, clutch pressure sleeve, and oil seal ring are removed. 2. Use a micrometer depth gauge C to measure the thickness of the bearing cap at positions A and B as shown in Figure 28. Thickness D is dimension E minus dimension F. Add the two dimensions (D at A and B) together and divide by 2 to get the average 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 bearing cap. Install bearing cap on studs. Install all four nuts.
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4. Rotate the output shaft to help seat the tapered roller bearings while the nuts are tightened. Tighten the nuts in a cross sequence to 20 to 27 N•m (15 to 20 lbf ft). Use a soft-faced hammer to lightly hit the rear cover of the transmission while tightening nuts. 5. Remove the two nuts from cover that are 180 apart. These nuts are NOT the nuts G shown in Figure 28. Loosen the other two nuts (G) until they can be rotated with your fingers. 6. Set the micrometer depth gauge C firmly against raised machined surfaces A and B of the bearing cap as shown in Figure 28. 7. Use a torque wrench to alternately tighten nuts G from 1.13 N•m (10 lbf in) to 11.3 N•m (100 lbf in) in 1.13 N•m (10 lbf in) steps. Rotate output shaft while tightening nuts. Measure the depth at A and B at each step. The difference between A and B must not be greater than 0.13 mm (0.005 in.) at any step. If the difference is greater at any step, start over at the beginning of this step. Add the two measurements and divide by 2 to get the average depth. Use the following chart to record the average measurement at each step. See Table 4.
1300 SRM 635
First-Speed Shaft Bearings Adjustment
Table 4. Example Torque Values at Dimensions Shown Torque Value
Gap Dimension
N•m
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 the chart as shown in Figure 29. The value where the line crosses the zero line minus the average value recorded for the thickness of the bearing cap of Step 2 is the no-end-play, no-preload shim dimension. Add 0.15 ±0.02 mm (0.006 ±0.001 in.) to this dimension for the final shim gap dimension (total shim thickness). See the example chart
(Figure 29). In the example, the line crosses the zero line at 23.42 mm (0.922 in.). The average thickness of the bearing cap is 22.14 mm (0.872 in.). Subtracting the thickness from the zero point value equals 1.28 mm (0.050 in.) for the shim gap with no preload or end play. Add 0.15 ±0.02 mm (0.006 ±0.001 in.) to this dimension for the final shim gap dimension (total shim thickness) of 1.41 to 1.45 mm (0.055 to 0.057 in.). NOTE: There is a blank graph included for plotting the actual measured values. If you need more, copy the graphs before using them. See Figure 30. 9. Select shims for the total shim thickness found in Step 8. Measure the thickness of the shim pack to make sure it is correct. 10. Remove bearing cap. Install a new oil sealing ring and new O-rings on clutch pressure sleeve and bearing cap. Install pressure sleeve. Install the correct shim pack and bearing cap on studs. Install lockwashers and nuts. Alternately tighten nuts to 55.6 to 61.0 N•m (41 to 45 lbf ft). Rotate output shaft to make sure bearings are seated and check the torque of the nuts again. 11. Install lubrication line from bearing cap to check port for lubricating pressure in front housing.
Figure 28. Adjusting Bearing Clearance
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First-Speed Shaft Bearings Adjustment
1300 SRM 635
Figure 29. Example Values Chart
Figure 30. Plotting Chart
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1300 SRM 635
Transmission Oil Pressures Check
Torque Converter Stall Speed Check This stall check is a measurement of maximum engine rpm with the engine working against the torque converter at full stall. This test will help find problems in the transmission, torque converter, or engine. 1. Make sure the coolant level in the cooling system is correct. Make sure the oil level in the transmission is correct. 2. Put the lift truck against a wall or other object that cannot move. The parking brake can also be applied and blocks installed at the wheels to prevent wheel movement. The wheels must not turn during this test. 3. Connect a tachometer to the engine. Make sure the parking brake is engaged. Also apply the brakes.
CAUTION Do not keep the lift truck in a stall condition for more than 30 seconds at a time. Transmission damage will occur at 120 C (250 F).
4. Select the highest gear. With the engine running in FORWARD or REVERSE, slowly increase engine speed to approximately one-half throttle and hold that throttle position for no more than 30 seconds at a time. Repeat this process until the oil temperature of the transmission (converter outlet) is 83 to 94 C (180 to 200 F). 5. The correct 1900 rpm.
stall
speed
is
approximately
6. If the reading is 50 to 200 rpm below the specifications, the engine does not produce full power. The problem can be the engine, fuel system, or other engine systems. 7. If the reading is 50 to 200 rpm above the specifications, the transmission or torque converter can be the problem. A high reading in only one direction or speed range indicates a problem in that clutch assembly.
Transmission Oil Pressures Check NOTE: If the correct pressure cannot be reached, see the Troubleshooting at the end of this section. During all pressure checks, the drive wheels must be raised from the floor.
3. Operate the transmission in both directions and at each of the speed ranges. The correct oil pressure is 1655 to 2068 kPa (240 to 300 psi) for all of the direction and range clutches.
Attach pressure gauges to the check ports. Check that the oil level in the transmission is correct. Operate the transmission in all ranges and directions until the oil in the transmission is 83 to 94 C (180 to 200 F). Connect a tachometer to the engine. Be sure to use the hydraulic schematic shown in Figure 31.
4. If a clutch pressure is not within the specifications of Step 2, repair that clutch.
TORQUE CONVERTER (TORQUE CONVERTER REGULATOR) OIL PRESSURE CHECK
CLUTCH PRESSURES CHECK
1. Connect a gauge to the check port.
1. Connect gauges to port S. See Table 5.
2. Make sure the transmission oil temperature is 83 to 94 C (180 to 200 F), the brake pedals are up, and the park brake is set. The correct oil pressure is 172 kPa (25 psi) min. @ 2000 rpm and 483 kPa (70 psi) @ governed speed.
2. Run the engine at idle (400 to 600 rpm) and 83 to 94 C (180 to 200 F) transmission oil temperature, with brake pedals up and park brake set. All clutch pressures must be within 34.5 kPa (5 psi) of each other.
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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 rpm 483 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, and park 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 S 2. Port R
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1300 SRM 635
Troubleshooting
Troubleshooting PROBLEM Transmission oil temperature is too hot.
One or more clutches do not engage or engage slowly.
Main oil pressure is low.
POSSIBLE CAUSE
PROCEDURE OR ACTION
Type of oil is not correct or oil level is not correct.
Check oil type and level.
Oil cooler or oil lines have a restriction.
Check and clean oil lines and oil cooler.
Clutches do not engage completely.
Check oil pressure and repair as necessary.
Torque converter does not operate correctly.
Check stall speed and repair as necessary.
Bearings or shafts in the transmission are damaged.
Replace damaged parts.
Lift truck is operating in the wrong speed range for a long period of time.
Have operator change operation.
Oil level is not correct or oil is the wrong type.
Check oil type and level.
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 correctly.
Repair control valve.
Solenoid(s) or electrical circuit is damaged.
Install new solenoid or repair wiring.
Gears in transmission are damaged.
Replace damaged parts.
External oil line(s) is damaged, has a restriction, or is disconnected.
Check and repair oil lines.
There is a restriction in the oil filter.
Install new oil filter.
Regulator for torque converter circuit does not operate correctly.
Check and adjust regulator.
Oil level is not correct or oil is the wrong type.
Check oil type and level.
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Troubleshooting
PROBLEM Main oil pressure is low. (Cont.)
Torque converter is too hot, or performance is not to specifications.
Torque converter makes too much noise.
Oil pressure in the torque converter circuit is low.
Oil pressure in the torque converter circuit is high.
1300 SRM 635
POSSIBLE CAUSE
PROCEDURE OR ACTION
Oil pump is worn or damaged.
Repair oil pump.
There is a leak between the oil pump and the regulator.
Check for and repair internal leaks.
Oil pressure is not correct.
Check oil pressure to locate problem. Replace damaged parts.
There is a restriction in the cooling circuit.
Check and repair cooling circuit.
Lift truck is operating in the wrong speed range for a long period of time.
Have operator change operation.
Bearings are damaged.
Replace damaged parts.
Torque converter drive plate is loose or damaged.
Repair or replace drive plate.
Transmission pump is worn.
Replace pump.
Relief valve for torque converter is open.
Check and repair.
There is a restriction in the torque converter circuit.
Check passages for restrictions.
TRANSMISSION CONTROLLER (APC 100) None of the display LEDs are on when key switch is on.
The red light is on continuously.
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There is no power to the controller.
Check and repair wiring as necessary.
Fuse in controller is damaged.
Replace fuse.
There is no power to the controller.
Check and repair wiring as necessary.
The wiring harness is damaged.
Repair wiring as necessary.
The controller is damaged.
Replace controller.
1300 SRM 635
PROBLEM
Diagrams, Schematics, or Arrangements
POSSIBLE CAUSE
PROCEDURE OR ACTION
The transmission remains in NEUTRAL when power is available to the controller.
The 10-amp fuse is damaged.
Replace fuse.
The transmission remains in a certain gear.
The transmission controller is damaged.
Override the controller and drive the vehicle manually.
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Diagrams, Schematics, or Arrangements
40
1300 SRM 635
1300 SRM 635
Diagrams, Schematics, or Arrangements
Figure 31. Transmission Hydraulic Diagram
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NOTES ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________
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TECHNICAL PUBLICATIONS 1300 SRM 635
11/03 (4/03)(1/00)(9/98) Printed in U.S.A.
