Hyster F187 (S60FT) Forklift Service Repair Manual

SERVICE REPAIR S40FT S50FT S60FT S70FT S55FTS [F187]

1300 SRM 1129

General

General This section has the repair procedures for the transmission.

SERIAL NUMBER The transmission serial number is located on the right side of the transmission control valve directly below the floor plate. See Figure 1.

A. EARLY LIFT TRUCK MODELS EXCEPT H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005, P005) MODELS B. NEWER LIFT TRUCK MODELS Figure 1. Transmission Serial Number Location

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1

Charge Pump Repair

1300 SRM 1129

Charge Pump Repair REMOVE NOTE: The charge pump can be removed from the transmission while it is still in the lift truck but, for the sake of clarity, the following procedures are shown with the transmission removed from the lift truck.

Remove four mounting capscrews, washers, transmission charge pump, and gasket from the torque converter housing. Discard the gasket. See Figure 2.

INSPECT Inspect the splines on the shaft of the transmission charge pump for damage or worn areas that could affect the operation of the pump. If the splines are damaged, replace the transmission charge pump.

INSTALL

NOTE: THE TRANSMISSION IS SHOWN REMOVED FROM THE LIFT TRUCK FOR CLARITY.

Install new gasket, transmission charge pump, four mounting capscrews, and washers in the torque converter housing. Tighten capscrews to 19 N•m (168 lbf in).

A. EARLY LIFT TRUCK MODELS EXCEPT H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005, P005) MODELS B. NEWER LIFT TRUCK MODELS 1.

2.

3.

4.

CAPSCREW CHARGE PUMP GASKET TORQUE CONVERTER HOUSING Figure 2. Transmission Charge Pump

2

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1300 SRM 1129

Torque Converter Replace

Torque Converter Replace REMOVE WARNING Make sure the engine and transmission are held in position so that they will not fall and cause an injury and damage to the equipment.

CAUTION Be careful that you do not damage parts of the torque converter or transmission when the transmission is separated from the engine.

Keep the transmission and engine in alignment until they are completely separated so parts of the transmission are not damaged.

Use a crane or lifting device to separate the transmission from the engine.

1. Remove the engine and transmission as a unit from the lift truck. See the section Frame 100 SRM 1243 for S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT; S80, 100FTBCS; S120FTS; S120FTPRS) (G004) and H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005, P005) lift trucks, and Frame 100 SRM 1120 for S30FT, S35FT, S40FTS (E010); H1.6FT, H1.8FT, 2.0FTS (H30FT, H35FT, H40FTS) (F001); S2.0-3.5FT (S40-70FT, S55FTS) (F187); H2.0-3.5FT (H40-70FT) (L177) lift trucks.

CAUTION Use care when disconnecting the wiring harness connectors from electrical connectors on the transmission and control valve. The connectors on the transmission and control valve are easily damaged.

NOTE: When disconnecting wiring harness connectors during disassembly, tag each connector to aid in connecting the wiring harness during reassembly.

2. Put the engine and transmission on solid blocks on a work surface. Disconnect the connectors of the transmission wiring harness from the control valve and transmission. Remove the transmission wiring harness from the transmission. See Figure 3.

WARNING Make sure that the engine/transmission assembly is stable before attempting to rotate the engine.

Use a flashlight to see the bolts as they are rotated into view through the access hole. Do not use your fingers to check for alignment of the bolts with the access hole.

3. Move each bolt into view through the access hole of the flywheel housing by rotating the crankshaft. Remove the four capscrews that attach the flywheel to the torque converter. See Figure 4.

4. Remove the access cover from the torque converter housing. Install a lifting eye bolt into the rear access cover bolt hole, and connect a lifting device to the eye bolt. Remove the 10 capscrews that hold the torque converter housing to the flywheel housing on the engine. Carefully separate the transmission from the engine.

NOTE: The torque converter cannot be repaired and must be replaced as a unit, if damaged.

5. Carefully remove the torque converter from the stator support. See Figure 5.

6. Remove the plug, suction screen spring, and suction screen from the torque converter housing, and drain the oil from the transmission.

7. Remove the transmission charge pump and transmission oil filter from the torque converter housing.

NOTE: Step 8, Step 9, and the NOTE below apply to early lift truck models except H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005, P005) models.

8. Remove the dipstick from the dipstick tube, and disconnect the vent tube assembly from the transmission housing.

NOTE: The dipstick tube must be removed before the torque converter housing can be removed from the front cover housing.

9. Remove the dipstick tube from the torque converter housing.

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3

Torque Converter Replace

1300 SRM 1129

A. EARLY LIFT TRUCK MODELS EXCEPT H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005, P005) MODELS

B. NEWER LIFT TRUCK MODELS

1.

2.

3.

4.

5. CAPSCREW 6. ACCESS COVER 7. CONTROL VALVE

GM 2.4L ENGINE CAPSCREW TRANSMISSION WIRING HARNESS TRANSMISSION

Figure 3. Engine-Transmission Combination

4

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1300 SRM 1129

Torque Converter Replace

Figure 4. Torque Converter Bolt Access

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5

Torque Converter Replace

1300 SRM 1129 Legend for Figure 4

A. B. C. D. E.

GM 2.4L ENGINE MAZDA ENGINE YANMAR ENGINE GM 4.3L ENGINE ILLUSTRATES NEW DIPSTICK AND BREATHER LOCATION AND NEW FITTING DESIGN USED

F.

ON ENGINE AND TRANSMISSIONS SHOWN IN ILLUSTRATIONS A THROUGH D, EXCEPT WHEN D IS USED ON H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005, P005) LIFT TRUCK MODELS CUMMINS 4.5L DIESEL ENGINE

1. ACCESS HOLE

2. FLYWHEEL HOUSING

A. EARLY LIFT TRUCK MODELS EXCEPT H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005, P005) MODELS

B. NEWER LIFT TRUCK MODELS

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

TRANSMISSION OIL FILTER DIPSTICK DIPSTICK TUBE TRANSMISSION HOUSING VENT TUBE ASSEMBLY TORQUE CONVERTER HOUSING TRANSMISSION OIL TEMPERATURE SENSOR SUCTION SCREEN SUCTION SCREEN SPRING

PLUG CAPSCREW WASHER SMALL ACCESS COVER TORQUE CONVERTER TRANSMISSION CHARGE PUMP STATOR SUPPORT PILOT HUB

Figure 5. Torque Converter Removal

6

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1300 SRM 1129

Torque Converter Replace

10. If damaged, remove the small access cover from the torque converter housing.

NOTE: Perform Step 11 only if repair of the of the transmission chain drive is required. If the transmission clutch packs are in need of further repair, see Clutch Packs Repair.

11. Remove 12 capscrews from the transmission housing and four mounting capscrews from the front of the torque converter housing. Using a small pry bar in the designated pry points, remove the torque converter housing from the front cover housing. Discard the O-rings and gasket. See Figure 6 and Figure 7.

INSTALL 1. Install new O-rings and gasket and using four capscrews, install the torque converter housing on the front cover housing and 12 capscrews on the transmission housing. Tighten capscrews to 38 N•m (28 lbf ft). See Figure 7.

2. If removed, install the small access cover on the torque converter housing. Tighten capscrews to 7.9 N•m (69 lbf in). See Figure 8.

NOTE: The information in Step 3 and Step 4 applies only to early lift truck models except for H4.0FT5/ FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005, P005) models.

3. Clean the surface of the dipstick tube and dipstick hole in the torque converter housing. Apply adhesive (Hyster P/N 264159) to the entire surface of the hole in the housing. Insert the dipstick tube until the collar bottoms on the housing and orient the tab against the housing flange.

4. Install the dipstick into the dipstick tube, and connect the vent tube assembly to the transmission housing.

5. Install a new transmission oil filter on the torque converter housing.

6. Install the transmission charge pump on the torque converter housing. Tighten capscrews to 19 N•m (168 lbf in).

A. EARLY LIFT TRUCK MODELS EXCEPT H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005, P005) MODELS B. NEWER LIFT TRUCK MODELS 1.

2.

3.

4.

PRY POINTS TORQUE CONVERTER HOUSING FRONT COVER HOUSING TRANSMISSION HOUSING Figure 6. Pry Point Location

8. Install the torque converter onto the input shaft and stator support of the transmission. Make sure the splines are aligned and the converter engages fully.

9. Lubricate the pilot hub on the torque converter with antiseize compound. See Figure 8.

10. If removed, install a lifting eye bolt into the rear access cover bolt hole, and connect a lifting device to the eye bolt. Align the torque converter housing with the flywheel housing. Make sure the pilot hub on the torque converter engages the flywheel.

7. Install the suction screen, suction screen spring, and plug into the torque converter housing.

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7

Torque Converter Replace

1300 SRM 1129

A. EARLY LIFT TRUCK MODELS EXCEPT H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005, P005) MODELS

B. NEWER LIFT TRUCK MODELS

1. CAPSCREW 2. WASHER 3. TORQUE CONVERTER HOUSING

4. GASKET 5. FRONT COVER HOUSING

Figure 7. Torque Converter Housing

8

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1300 SRM 1129

Torque Converter Replace housing to the flywheel housing. Tighten the capscrews to 38 N•m (28 lbf ft). See Figure 9.

CAUTION Be careful that you do not damage parts of the torque converter or transmission when the transmission is joined to the engine. Keep the transmission and engine in alignment until they are completely joined so parts of the transmission are not damaged. Use a crane or lifting device to join the transmission to the engine.

CAUTION Use care when connecting the wiring harness connectors to electrical connectors on the transmission and control valve. The connectors on the transmission and control valve are easily damaged.

11. Install the transmission to the engine. Install the capscrews that connect the torque converter

12. Install the transmission wiring harness on the transmission. Connect the connectors of the transmission wiring harness to the control valve and transmission. See Figure 9.

A. EARLY LIFT TRUCK MODELS EXCEPT H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005, P005) MODELS

B. NEWER LIFT TRUCK MODELS

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

TRANSMISSION OIL FILTER DIPSTICK DIPSTICK TUBE TRANSMISSION HOUSING VENT TUBE ASSEMBLY

Confidential/Proprietary - Do Not Copy or Duplicate

TORQUE CONVERTER HOUSING TRANSMISSION OIL TEMPERATURE SENSOR SUCTION SCREEN SUCTION SCREEN SPRING PLUG

9

Torque Converter Replace 11.

12.

13.

14.

1300 SRM 1129

CAPSCREW WASHER SMALL ACCESS COVER TORQUE CONVERTER

15. TRANSMISSION CHARGE PUMP 16. STATOR SUPPORT 17. PILOT HUB Figure 8. Torque Converter Installation

13. Rotate the engine crankshaft to position the flywheel mounting holes in line with the torque converter mounting holes. Install the capscrews that hold the torque converter to the flywheel, after coating the threads with Loctite™ 242,

through the access hole of the flywheel housing.

See Figure 10. Tighten the capscrews to 56 N•m (41 lbf ft). Remove the lifting eye bolt, and install the access cover on the torque converter housing.

A. EARLY LIFT TRUCK MODELS EXCEPT H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT

(H80, 90, 100, 110, 120FT) (N005, P005) MODELS

10

Confidential/Proprietary - Do Not Copy or Duplicate

1300 SRM 1129

Torque Converter Replace

B. NEWER LIFT TRUCK MODELS 1.

2.

3.

4.

GM 2.4L ENGINE CAPSCREW TRANSMISSION WIRING HARNESS TRANSMISSION

5. CAPSCREW 6. ACCESS COVER 7. CONTROL VALVE

Figure 9. Engine-Transmission Combination

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11

Torque Converter Replace

1300 SRM 1129

Figure 10. Torque Converter Bolt Access

12

Confidential/Proprietary - Do Not Copy or Duplicate

1300 SRM 1129

Front Cover Housing and Chain Drive Repair Legend for Figure 10

A. B. C. D. E.

GM 2.4L ENGINE MAZDA ENGINE YANMAR ENGINE GM 4.3L ENGINE ILLUSTRATES NEW DIPSTICK AND BREATHER LOCATION AND NEW FITTING DESIGN USED

1. ACCESS HOLE

WARNING Make sure the engine and transmission are held in position so that they will not fall and cause an injury and damage to the equipment.

14. Install the engine and transmission as a unit into the lift truck. See the section Frame 100 SRM 1243 for S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT; S80, 100FTBCS; S120FTS; S120FTPRS) (G004) and H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005, P005) lift trucks, and Frame 100 SRM 1120 for S30FT, S35FT, S40FTS (E010); H1.6FT, H1.8FT, 2.0FTS (H30FT, H35FT, H40FTS) (F001); S2.03.5FT (S40-70FT, S55FTS) (F187); H2.0-3.5FT (H40-70FT) (L177) lift trucks.

F.

ON ENGINE AND TRANSMISSIONS SHOWN IN ILLUSTRATIONS A THROUGH D, EXCEPT WHEN D IS USED ON H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005, P005) LIFT TRUCK MODELS CUMMINS 4.5L DIESEL ENGINE

2. FLYWHEEL HOUSING 15. Fill the transmission to the correct level using the correct transmission fluid and procedure given in the section Periodic Maintenance 8000 SRM 1150 for S2.0-3.5FT (S40-70FT, S55FTS) (F187); H2.0-3.5FT (H40-70FT) (L177) lift trucks, Periodic Maintenance 8000 SRM 1207 for S30FT, S35FT, S40FTS (E010); H1.6FT, H1.8FT, 2.0FTS (H30FT, H35FT, H40FTS) (F001) lift trucks, and Periodic Maintenance 8000 SRM 1248 for S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT; S80, 100FTBCS; S120FTS; S120FTPRS) (G004) and H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005, P005) lift trucks.

Front Cover Housing and Chain Drive Repair REMOVE WARNING Make sure the engine and transmission are held in position so that they will not fall and cause an injury and damage to the equipment.

CAUTION Keep the transmission and engine in alignment until they are completely separated so parts of the transmission are not damaged. Use a crane or lifting device to separate the transmission from the engine.

1. Remove the engine and transmission as a unit from the lift truck. See the section Frame 100 SRM 1243 for S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT; S80, 100FTBCS; S120FTS; S120FTPRS) (G004) and H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005, P005) lift trucks, and Frame 100 SRM 1120 for S30FT, S35FT, S40FTS (E010); H1.6FT,

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H1.8FT, 2.0FTS (H30FT, H35FT, H40FTS) (F001); S2.0-3.5FT (S40-70FT, S55FTS) (F187); H2.0-3.5FT (H40-70FT) (L177) lift trucks.

CAUTION To prevent possible damage to the transmission assembly when placing the assembly on a work surface, place blocks under the back side of the transmission housing for additional support.

CAUTION Use care when disconnecting the wiring harness connectors from electrical connectors on the transmission and control valve. The connectors on the transmission and control valve are easily damaged.

NOTE: When disconnecting wiring harness connectors during disassembly, tag each connector to aid in connecting the wiring harness during reassembly.

13

Front Cover Housing and Chain Drive Repair 2. Put the engine and transmission on solid blocks on a work surface. Disconnect the connectors of the transmission wiring harness from the control

A. EARLY LIFT TRUCK MODELS EXCEPT H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005, P005) MODELS 1.

2.

3.

4.

GM 2.4L ENGINE CAPSCREW TRANSMISSION WIRING HARNESS TRANSMISSION

1300 SRM 1129 valve and transmission. Remove the transmission wiring harness from the transmission. See Figure 11.

B. NEWER LIFT TRUCK MODELS

5. CAPSCREW 6. ACCESS COVER 7. CONTROL VALVE

Figure 11. Engine-Transmission Combination

14

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