HYSTER ZF-WG161 Transmission Repair Manual PN 4034066 - PDF DOWNLOAD

TRANSMISSION REPAIR (ZF-WG161)

PART NO. 4034066

1300 SRM 1456

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SAFETY PRECAUTIONS MAINTENANCE AND REPAIR •

• • • • • • • • • • • • • •

The Service Manuals are updated on a regular basis, but may not reflect recent design changes to the product. Updated technical service information may be available from your local authorized Hyster® dealer. Service Manuals provide general guidelines for maintenance and service and are intended for use by trained and experienced technicians. Failure to properly maintain equipment or to follow instructions contained in the Service Manual could result in damage to the products, personal injury, property damage or death.

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 hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury and property damage.

On the lift truck, the WARNING symbol and word are on orange background. The CAUTION symbol and word are on yellow background.

Table of Contents

TABLE OF CONTENTS Series Code / Model Designation Reference Table ................................................................................................ 1 Special Tools List .....................................................................................................................................................2 Transmission Repair ............................................................................................................................................... 3 Remove ................................................................................................................................................................ 3 Disassemble .........................................................................................................................................................7 Transmission Housing, Disassemble .............................................................................................................8 Oil Pump, Disassemble ................................................................................................................................ 15 Forward Clutch, Disassemble ...................................................................................................................... 21 Reverse Clutch, Disassemble ....................................................................................................................... 26 First Speed Clutch, Disassemble ................................................................................................................. 32 Second Speed Clutch, Disassemble ..............................................................................................................37 Third Speed Clutch, Disassemble ................................................................................................................42 Input Shaft, Disassemble ............................................................................................................................. 46 Clean and Inspect ............................................................................................................................................. 46 Housings ........................................................................................................................................................47 Oil Seals and Gaskets ...................................................................................................................................47 Bearings ........................................................................................................................................................ 47 Gears and Shafts .......................................................................................................................................... 47 Assemble ............................................................................................................................................................48 Input Shaft, Assemble .................................................................................................................................. 48 Third Speed Clutch, Assemble .....................................................................................................................48 Second Speed Clutch, Assemble ...................................................................................................................55 First Speed Clutch, Assemble ...................................................................................................................... 62 Reverse Clutch, Assemble ............................................................................................................................ 70 Forward Clutch, Assemble ........................................................................................................................... 77 Oil Pump, Assemble ..................................................................................................................................... 85 Transmission Housing, Assemble ................................................................................................................86 Transmission Oil Filter Assembly Replacement .............................................................................................95 Remove .......................................................................................................................................................... 95 Clean ..............................................................................................................................................................96 Inspect ........................................................................................................................................................... 96 Install ............................................................................................................................................................ 96 Install .................................................................................................................................................................97 Control Valve Replacement ................................................................................................................................ 102 Remove ............................................................................................................................................................ 102 Install ...............................................................................................................................................................103 Control Valve Repair ...........................................................................................................................................104 Disassemble .....................................................................................................................................................104 Clean ................................................................................................................................................................108 Inspect ............................................................................................................................................................. 108 Assemble ..........................................................................................................................................................109 This section is for the following models:

©2015 HYSTER COMPANY

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"THE QUALITY KEEPERS" HYSTER APPROVED PARTS

1300 SRM 1456

Series Code / Model Designation Reference Table

Series Code / Model Designation Reference Table This table consist of the following Series Codes used in this manual.

Series Code

European Model

Americas Model

H019

H13.00-16.0XM-6, H10.00-12.0XM-12EC

H300-360HD2, H360HD2-EC

J007

H8.00-12.00XM-6

H190-280HD2

J019

H13.00-16.00XM-6, H10.00-12.00XM-12EC

H300-360HD2, H360HD2-EC

K007

H8.00-12.00XM-6, H10.00XMS-6

H190-280HD2, H230HDS

K019

H13.00-16.00XM-6

H210-250-48HD2, H300-360HD2

K019EC

H6.00-7.00XM-12EC

H360HD2-EC

L007

H8.00-12.00XM-6

H190-280HD2, H250HD2

A238

H16.00XM-9, H18XM-7.5, H16XM-12, H18XM-9

H360-36HD, H360-48HD

B238

H16.00XM-9, H18XM-7.5, H16XM-12, H18XM-9

H360-36HD, H360-48HD

1

Special Tools List

1300 SRM 1456

Special Tools List The following list consists of the special tools required to perform the assembly procedures outlined in this manual.

Item

2

Figure

Nomenclature

Part Number

1

Clutch Pack Spring Compression Tool

Hyster P/N 4612858

2

Holding Fixture Assembly

Hyster P/N 4612859

3

Shaft Seal Mounting Tool

Hyster P/N 4612860

4

Grip Handle

Hyster P/N 4612861

5

Pump Seal Mounting Tool

Hyster P/N 4612862

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Transmission Repair

Transmission Repair REMOVE 1. Tilt the mast fully forward.

2. Turn the key to OFF position to shutdown the engine.

3. Apply the parking brake.

4. Tilt the operator compartment up to gain access to the transmission. See the section Operator's Cab 0100SRM1390.

5. Disconnect the cables at the battery. Disconnect the ground cable first and then the positive cable.

CAUTION The drive shaft for this truck is a two piece model, consisting of a male splined drive shaft, a female splined slip yoke and a universal joint on both ends where it connects to the drive axle and transmission.

Drive shafts are balanced and configured at the time of manufacture. It is recommended that an alignment mark is made on the drive shaft indicating the position of the universal joint and drive shaft prior to removal.

During removal, it may be possible for the drive shaft to split apart into two pieces. Reassemble the drive shaft using the alignment mark made prior to removal.

Failure to assemble and install the drive shaft properly may lead to: •

Vibration of the drive shaft and/or truck

•

Premature failure of the universal joints on the drive shaft

•

Excessive vibration levels in the transmission

•

Excessive vibration levels in the drive axle

NOTE: Use a marker of some type to indicate position and orientation of drive shaft prior to removal.

6. Disconnect the drive shaft at the transmission.

See Figure 1.

7. Disconnect the wiring harnesses on the transmission and wires for the sensors on the transmission. Put identification tags on the wires so they can be correctly connected again. See Figure 2.

3

Transmission Repair

1.

2.

3.

4.

5.

FRAME (REFERENCE) DIPSTICK ASSEMBLY DRIVE SHAFT OUTPUT YOKE TRANSMISSION MOUNT

1300 SRM 1456

6.

7.

8.

9.

TRANSMISSION TORQUE CONVERTER CAPSCREWS CAPSCREWS

Figure 1. Transmission Arrangement

4

1300 SRM 1456

1.

2.

3.

4.

Transmission Repair

TRANSMISSION INTERNAL SPEED SENSOR TRANSMISSION TURBINE SPEED SENSOR DIFFERENTIAL PRESSURE SWITCH TRANSMISSION CONTROL VALVE CONNECTOR

5. ENGINE SPEED SENSOR 6. TORQUE CONVERTER TEMPERATURE SENSOR

Figure 2. Transmission Wire Connectors and Sensors

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Transmission Repair

1300 SRM 1456

CAUTION Disposal of lubricants and fluids must meet local environmental regulations.

8. Place a suitable container under the transmission sump and remove the transmission sump drain plug and drain the transmission oil [approximately 20 liter (21 qt)].

9. Disconnect the oil lines from the transmission to the thermostat valve. Drain the oil into a drain pan. Put plugs and caps on open lines and fittings.

10. Disconnect the oil hoses at the hydraulic pumps. Install plugs and caps on open lines and fittings.

11. The hydraulic pumps are connected to the transmission with four capscrews. Attach a lifting device to hold the hydraulic pumps, remove the capscrews, and the hydraulic pumps. The drive shaft of the hydraulic pump is engaged in the splines of the drive gear. The drive shaft of the hydraulic pump will slide out of the drive gear when the hydraulic pump is removed.

1. LIFTING EYES Figure 3. View of Transmission

12. Install blocks and a jack under the flywheel end of the engine as a support. If the support is under the engine oil sump, make sure that the support is across the width of the oil sump so the weight of the engine does not damage the oil sump.

13. Connect a lifting device, with a lifting capacity of at least 1200 kg (2650 lb), to the two lifting eyes located on the top of the transmission. See Figure 3.

14. Remove the access plug to gain access to the flywheel ring gear. See Figure 4.

15. Remove the access plate to gain access to the capscrews that connect the flywheel to the drive plates. See Figure 4.

16. Insert a flywheel rotation tool into the access plug hole and rotate the flywheel until one of the capscrews is visible through the access plate hole. See Figure 4.

6

1.

2.

3.

4.

ACCESS HOLE TO ROTATE FLYWHEEL ACCESS PLUG CONVERTER HOUSING ACCESS PLATE TO FLYWHEEL CAPSCREWS

Figure 4. Access Plug for Drive Plate Capscrews

1300 SRM 1456

Transmission Repair

17. Remove the capscrew. Rotate the flywheel and remove the remaining capscrews until all four of the capscrews have been removed.

18. Raise the lifting device to hold the weight of the transmission only. Remove the twelve capscrews that fasten the torque converter housing to the flywheel housing.

19. Remove the two 3/4 × 31/2-inch bolts that fasten the transmission mount to the frame.

CAUTION Keep the transmission level when the transmission is separated from the engine so the drive plate is not damaged.

20. Make sure that all connections have been removed and carefully lift the transmission assembly from the frame and engine.

DISASSEMBLE Figure 5. ZF ERGOPOWER Transmission Figure 5 shows a view of the ZF ERGOPOWER transmission.

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Transmission Repair

1300 SRM 1456

Transmission Housing, Disassemble STEP 1.

Remove the oil filter assembly and control valve assembly from the transmission. See Transmission Oil Filter Assembly Replacement, Remove and Control Valve Replacement, Remove.

1. OIL FILTER ASSEMBLY 2. CONTROL VALVE ASSEMBLY 3. TRANSMISSION STEP 2.

Remove the converter pressure back-up valve and differential pressure switch from the transmission housing. DO NOT remove the pressure relief valve.

1. CONVERTER PRESSURE BACK-UP VALVE 2. DIFFERENTIAL PRESSURE SWITCH 3. PRESSURE RELIEF VALVE

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1300 SRM 1456

Transmission Repair

STEP 3.

Remove the engine speed sensor, and oil fill tube with dipstick from the transmission.

1. ENGINE SPEED SENSOR 2. OIL FILL TUBE WITH DIPSTICK STEP 4.

Remove the internal speed sensor, turbine speed sensor, and output speed sensor from the transmission.

1. INTERNAL SPEED SENSOR 2. TURBINE SPEED SENSOR 3. OUTPUT SPEED SENSOR

9

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• You can download the complete manual from: www.heydownloads.com by clicking the link below

• Please note: If there is no response to CLICKING the link, please download this PDF first and then click on it.

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DOWNLOAD THE COMPLETE MANUAL