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• 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:
Indicates a hazardous situation which, if not avoided, could result in death or serious injury.
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.
This table consist of the following Series Codes used in this manual.
Series Code
H019
J007
J019
K007
K019
K019EC
L007
A238
B238
European Model
H13.00-16.0XM-6, H10.00-12.0XM-12EC
H8.00-12.00XM-6
H13.00-16.00XM-6, H10.00-12.00XM-12EC
H8.00-12.00XM-6, H10.00XMS-6
H13.00-16.00XM-6
H6.00-7.00XM-12EC
H8.00-12.00XM-6
H16.00XM-9, H18XM-7.5, H16XM-12, H18XM-9
H16.00XM-9, H18XM-7.5, H16XM-12, H18XM-9
Americas Model
H300-360HD2, H360HD2-EC
H190-280HD2
H300-360HD2, H360HD2-EC
H190-280HD2, H230HDS
H210-250-48HD2, H300-360HD2
H360HD2-EC
H190-280HD2, H250HD2
H360-36HD, H360-48HD
H360-36HD, H360-48HD
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The following list consists of the special tools required to perform the assembly procedures outlined in this manual.
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.
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.
1.FRAME (REFERENCE)
2.DIPSTICK ASSEMBLY
3.DRIVE SHAFT
4.OUTPUT YOKE
5.TRANSMISSION MOUNT
6.TRANSMISSION
7.TORQUE CONVERTER
8.CAPSCREWS
9.CAPSCREWS
1.TRANSMISSION INTERNAL SPEED SENSOR
2.TRANSMISSION TURBINE SPEED SENSOR
3.DIFFERENTIAL PRESSURE SWITCH
4.TRANSMISSION CONTROL VALVE CONNECTOR
5.ENGINE SPEED SENSOR
6.TORQUE CONVERTER TEMPERATURE SENSOR
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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.
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.
Figure 3. View of Transmission
1.ACCESS HOLE TO ROTATE FLYWHEEL
2.ACCESS PLUG
3.CONVERTER HOUSING
4.ACCESS PLATE TO FLYWHEEL CAPSCREWS
Figure 4. Access Plug for Drive Plate Capscrews
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.
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.
Figure 5 shows a view of the ZF ERGOPOWER transmission.
Figure 5. ZF ERGOPOWER Transmission
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
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
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STEP 5.
Remove the torque converter from the transmission. Remove capscrews from torque converter bell housing and transmission.
1.TORQUE CONVERTER
2.TORQUE CONVERTER BELL HOUSING
3.CAPSCREW
4.TRANSMISSION
STEP 6.
Remove the torque converter bell housing with oil pump, and gasket from the transmission housing. Remove the stator hollow shaft from the input shaft.
1.TORQUE CONVERTER BELL HOUSING
2.GASKET
3.TRANSMISSION HOUSING
4.STATOR HOLLOW SHAFT
5.INPUT SHAFT
STEP 7.
Remove the oil pump from the torque converter bell housing.
1.OIL PUMP
2.TORQUE CONVERTER BELL HOUSING
STEP 8.
Remove two capscrews, output flange, and output shaft seal from the transmission housing. Discard the seal.
1.CAPSCREW
2.OUTPUT FLANGE
3.OUTPUT SHAFT SEAL
STEP 9.
Remove the retaining ring and O-ring from the transmission housing. Discard the O-ring.
1.RETAINING RING
2.O-RING
STEP 10.
Remove the PTO shaft from the housing. Remove the retaining ring. Using a press, remove the bearing from the PTO shaft.
1.PTO SHAFT
2.HOUSING
3.RETAINING RING
4.BEARING
WARNING
To prevent the possibility of injury to personnel, use a lifting device of sufficient lifting capacity while performing the following step.
NOTE: Make sure that the guide pins have been removed before removing the rear transmission cover.
STEP 11.
Remove the capscrews, washers, and rear transmission cover from the front transmission cover.
1.CAPSCREW
2.WASHER
3.REAR TRANSMISSION COVER
4.FRONT TRANSMISSION COVER
5.GUIDE PIN
STEP 12.
Remove capscrews, suction tube, screen, and tubes from the front transmission cover. Remove and discard the O-rings from the tubes.
1.CAPSCREW
2.SUCTION TUBE
3.SCREEN
4.TUBE
5.GUIDE PIN
6.O-RING
WARNING
To prevent the possibility of injury to personnel, use a lifting device of sufficient lifting capacity while performing the following step.
STEP 13.
Remove the clutch packs and input shaft from the front transmission cover in the order given in the legend.
1.CLUTCH, 3RD SPEED/OUTPUT
2.CLUTCH, 2ND SPEED
3.CLUTCH, REVERSE
4.CLUTCH, FORWARD
5.INPUT SHAFT
6.CLUTCH, 1ST SPEED
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STEP 14.
Remove capscrews and screen from front transmission cover.
1.CAPSCREW
2.SCREEN
NOTE: Perform STEP 15 only if any of the tubes are damaged.
STEP 15.
Remove the system pressure tubes from the rear transmission cover in the order of the legend. Prior to removal of the tubes remove the holding segment from the tubes.
1.CLUTCH, 3RD SPEED/OUTPUT
2.CLUTCH, 1ST SPEED
3.CLUTCH, 2ND SPEED
4.CLUTCH, REVERSE
5.CLUTCH, FORWARD
6.HOLDING SEGMENT
7.REAR TRANSMISSION COVER
Oil Pump, Disassemble
STEP 1.
Remove the O-ring and capscrews from the oil pump. Discard the O-ring.
1.O-RING
2.CAPSCREWS
3.OIL PUMP
STEP 2.
Remove the cover, inner rotor, and outer rotor from the oil pump housing. Inspect the pump housing, inner rotor outer rotor, and cover for wear marks. If any wear is shown, replace the oil pump.
1.COVER
2.INNER ROTOR
3.OUTER ROTOR
4.OIL PUMP HOUSING
STEP 3.
Remove and discard the shaft seal from the oil pump housing.
1.SHAFT SEAL
2.OIL PUMP HOUSING
1.PISTON RING
2.THREADED STUD
3.TAPERED ROLLER BEARING
4.CLUTCH SHAFT
5.BALL BEARING
6.IDLER GEAR
7.NEEDLE BEARING
8.RETAINING RING
9.END SHIM
10.OUTER FRICTION DISC
11.INNER DISC
12.FRICTION DISC
13."L" RING
14.GUIDE RING
15.COMPRESSION SPRING
16.OUTER O-RING
17.INNER O-RING
18.PISTON
19.CLUTCH PACK CARRIER
20.WASHER
21.SNAP RING
1.PISTON RING
2.THREADED STUD
3.TAPERED ROLLER BEARING
4.CLUTCH SHAFT
5.GEAR
6.NEEDLE BEARING
7.IDLER GEAR
8.BALL BEARING
9.RETAINING RING
10.END SHIM
11.OUTER FRICTION DISC
12.INNER DISC
13.FRICTION DISC
14."L" RING
15.GUIDE RING
16.COMPRESSION SPRING
17.OUTER O-RING
18.INNER O-RING
19.PISTON
20.CLUTCH PACK CARRIER
21.WASHER
22.SNAP RING
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1.PISTON RING
2.THREADED STUD
3.TAPERED ROLLER BEARING
4.CLUTCH SHAFT
5.AXIAL NEEDLE BEARING
6.NEEDLE BEARINGS
7.IDLER GEAR
8.RETAINING RING
9.END SHIM
10.OUTER FRICTION DISC
11.INNER DISC
12.FRICTION DISC
13.SNAP RING
14.GUIDE RING
15.COMPRESSION SPRING
16.PISTON
17.INNER O-RING
18.OUTER O-RING
19.CLUTCH PACK CARRIER
20.SEALING CAP
21.AXIAL WASHER
22.RUNNING DISC
1.PISTON RING
2.THREADED STUD
3.TAPERED ROLLER BEARING
4.CLUTCH SHAFT
5.AXIAL NEEDLE BEARING
6.IDLER GEAR
7.NEEDLE BEARINGS
8.RETAINING RING
9.END SHIM
10.OUTER FRICTION DISC
11.INNER DISC
12.FRICTION DISC
13.SNAP RING
14.GUIDE RING
15.COMPRESSION SPRING
16.PISTON
17.INNER O-RING
18.OUTER O-RING
19.CLUTCH PACK CARRIER
20.AXIAL WASHER
21.RUNNING DISC
1.PISTON RING
2.PLUG
3.TAPERED ROLLER BEARING
4.AXIAL NEEDLE BEARING
5.IDLER GEAR
6.NEEDLE BEARING
7.SNAP RING
8.END SHIM
9.OUTER FRICTION DISC
10.INNER DISC
11.FRICTION DISC
12.SNAP RING
13.GUIDE RING
14.COMPRESSION SPRING
15.PISTON
16.INNER O-RING
17.OUTER O-RING
18.CLUTCH PACK CARRIER
19.CLUTCH SHAFT
20.PISTON RING
21.RUNNING DISC
22.AXIAL WASHER
23.THREADED STUD
24.CAP
25.PISTON RING
26.SEAL
NOTE: As each clutch assembly is disassembled, ensure that all of the components of that assembly are kept separate from any other clutch assemblies to prevent the possibility of parts being assembled to an incorrect clutch assembly.
STEP 1.
Remove the threaded stud, and unsnap piston ring. Using a bearing puller, remove the tapered roller bearing from the clutch shaft.
1.THREADED STUD
2.PISTON RING
3.TAPERED ROLLER BEARING
4.CLUTCH SHAFT
STEP 2.
Remove the clutch pack carrier from the clutch shaft.
1.CLUTCH PACK CARRIER
2.CLUTCH SHAFT
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STEP 3.
Remove the snap ring. Using a press, remove the clutch shaft from the idler gear.
1.SNAP RING
2.CLUTCH SHAFT
3.IDLER GEAR
STEP 4.
Remove snap ring and roller bearing from the idler gear.
1.SNAP RING
2.ROLLER BEARING
3.IDLER GEAR
STEP 5.
Remove the needle bearing from the clutch shaft.
1.NEEDLE BEARING 2.CLUTCH SHAFT
STEP 6.
Remove the piston ring. Using a bearing puller, remove the tapered roller bearing from the clutch shaft.
1.PISTON RING
2.TAPERED ROLLER BEARING
3.CLUTCH SHAFT
STEP 7.
Remove the retaining ring from the clutch pack carrier.
1.RETAINING RING
2.CLUTCH PACK CARRIER
STEP 8.
Remove the end shim and disc set from the clutch pack carrier.
1.END SHIM
2.DISC SET
3.CLUTCH PACK CARRIER
WARNING
The spring has a force of 1700 ±147 N (382 ±33 lbf).
STEP 9.
Using a spring compression tool, Hyster P/N 4612858, compress the spring and remove the "L" ring.
1.COMPRESSION TOOL
2.COMPRESSION SPRING
3."L" RING
STEP 10.
Slowly release the compression spring and remove the guide ring, compression spring, and washer from the clutch pack carrier.
1.GUIDE RING
2.COMPRESSION SPRING
3.CLUTCH PACK CARRIER
4.WASHER
NOTE: Use compressed air to aid in the removal of the piston.
STEP 11.
Remove piston from clutch pack carrier.
1.PISTON
2.CLUTCH PACK CARRIER
STEP 12.
Remove and discard inner and outer O-rings from the piston.
1.INNER O-RING
2.OUTER O-RING
3.PISTON
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Reverse Clutch, Disassemble
STEP 1.
Remove the threaded stud and piston ring. Using a bearing puller, remove the tapered roller bearing from the clutch shaft.
1.THREADED STUD
2.PISTON RING
3.TAPERED ROLLER BEARING
4.CLUTCH SHAFT
STEP 2.
Remove the clutch pack carrier from the clutch shaft.
1.CLUTCH PACK CARRIER
2.CLUTCH SHAFT
STEP 3.
Remove the snap ring. Using a press, remove the clutch shaft from the idler gear.
1.SNAP RING
2.CLUTCH SHAFT
3.IDLER GEAR
STEP 4.
Remove snap ring and bearing from the idler gear.
1.SNAP RING
2.BEARING
3.IDLER GEAR
STEP 5.
Remove the needle bearing and snap ring from the clutch shaft.
1.NEEDLE BEARING
2.CLUTCH SHAFT
3.SNAP RING
4.GEAR
STEP 6.
Remove the piston ring. Using a bearing puller, remove the tapered roller bearing from the clutch shaft.
1.PISTON RING
2.TAPERED ROLLER BEARING
3.CLUTCH SHAFT
STEP 7.
Remove the retaining ring from the clutch pack carrier.
1.RETAINING RING
2.CLUTCH PACK CARRIER
STEP 8.
Remove the end shim and disc set from the clutch pack carrier.
1.END SHIM
2.DISC SET
3.CLUTCH PACK CARRIER
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WARNING
The spring has a force of 1700 ±147 N (382 ±33 lbf).
STEP 9.
Using a spring compression tool, Hyster P/N 4612858, compress the spring and remove the "L" ring.
1.COMPRESSION TOOL
2.COMPRESSION SPRING
3."L" RING
STEP 10.
Slowly release the compression spring and remove the guide ring, compression spring and washer, from the clutch pack carrier.
1.GUIDE RING
2.COMPRESSION SPRING
3.CLUTCH PACK CARRIER
4.WASHER
NOTE: Use compressed air to aid in the removal of the piston.
STEP 11.
Remove piston from clutch pack carrier.
1.PISTON 2.CLUTCH PACK CARRIER
STEP 12.
Remove and discard inner and outer O-rings from the piston.
1.INNER O-RING
2.OUTER O-RING
3.PISTON
First Speed Clutch, Disassemble
STEP 1.
Remove the threaded stud and piston ring. Using a bearing puller, remove the tapered roller bearing from the clutch shaft.
1.THREADED STUD
2.PISTON RING
3.TAPERED ROLLER BEARING
4.CLUTCH SHAFT
STEP 2.
Remove the retaining ring and axial bearing assembly from the clutch shaft.
1.RETAINING RING
2.AXIAL BEARING ASSEMBLY (3 PIECES)
3.CLUTCH SHAFT
STEP 3.
Remove the idler gear, two needle bearings, and axial bearing assembly from the clutch shaft.
1.IDLER GEAR
2.NEEDLE BEARING
3.AXIAL BEARING ASSEMBLY (3 PIECES)
4.CLUTCH SHAFT
STEP 4.
Remove the clutch pack carrier from the clutch shaft.
1.CLUTCH PACK CARRIER
2.CLUTCH SHAFT
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STEP 5.
Remove the piston ring. Using a bearing puller, remove the tapered roller bearing from the clutch shaft.
1.PISTON RING
2.TAPERED ROLLER BEARING
3.CLUTCH SHAFT
STEP 6.
Remove the retaining ring from the clutch pack carrier.
1.RETAINING RING
2.CLUTCH PACK CARRIER
STEP 7.
Remove the end shim and disc set from the clutch pack carrier.
1.END SHIM
2.DISC SET
3.CLUTCH PACK CARRIER
WARNING
The spring has a force of 580 ±72 N (130 ±16 lbf).
STEP 8.
Using a spring compression tool, Hyster P/N 4612858, compress the spring and remove the snap ring.
1.COMPRESSION TOOL
2.COMPRESSION SPRING
3.SNAP RING
STEP 9.
Slowly release the compression spring and remove the guide ring, compression spring, and guide ring from the clutch pack carrier.
1.GUIDE RING
2.COMPRESSION SPRING
3.CLUTCH PACK CARRIER
NOTE: Use compressed air to aid in the removal of the piston.
STEP 10. Remove piston from clutch pack carrier.
STEP 11.
Remove and discard inner and outer O-rings from the piston.
1.INNER O-RING
2.OUTER O-RING
3.PISTON
STEP 1.
Remove the threaded stud and piston ring. Using a bearing puller, remove the tapered roller bearing from the clutch shaft.
1.THREADED STUD
2.PISTON RING
3.TAPERED ROLLER BEARING
4.CLUTCH SHAFT
STEP 2.
Remove the retaining ring and axial bearing assembly from the clutch shaft.
1.RETAINING RING
2.AXIAL BEARING ASSEMBLY (3 PIECES)
3.CLUTCH SHAFT
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STEP 3.
Remove the idler gear, two needle bearings, and axial bearing assembly from the clutch shaft.
1.IDLER GEAR
2.NEEDLE BEARING
3.AXIAL BEARING ASSEMBLY (3 PIECES)
4.CLUTCH SHAFT
STEP 4.
Remove the clutch pack carrier from the clutch shaft.
2.CLUTCH SHAFT
STEP 5.
Remove the piston ring. Using a bearing puller, remove the tapered roller bearing from the clutch shaft.
1.PISTON RING
2.TAPERED ROLLER BEARING
3.CLUTCH SHAFT
STEP 6.
Remove the retaining ring from the clutch pack carrier.
1.RETAINING RING
2.CLUTCH PACK CARRIER
STEP 7.
Remove the end shim and disc set from the clutch pack carrier.
1.END SHIM
2.DISC SET
3.CLUTCH PACK CARRIER
WARNING
The spring has a force of 430 ±25 N (97 ±6 lbf).
STEP 8.
Using a spring compression tool, Hyster P/N 4612858, compress the spring and remove the snap ring.
1.COMPRESSION TOOL
2.COMPRESSION SPRING
3.SNAP RING
STEP 9.
Slowly release the compression spring and remove the guide ring, compression spring, and guide ring from the clutch pack carrier.
1.GUIDE RING
2.COMPRESSION SPRING
3.CLUTCH PACK CARRIER
NOTE: Use compressed air to aid in the removal of the piston.
STEP 10.
Remove piston from clutch pack carrier.
1.PISTON
2.CLUTCH PACK CARRIER
STEP 11.
Remove and discard inner and outer O-rings from the piston.
1.INNER O-RING
2.OUTER O-RING
3.PISTON
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Third Speed Clutch, Disassemble
STEP 1.
Remove the piston ring. Using a bearing puller, remove the tapered roller bearing from the clutch shaft.
1.PISTON RING
2.TAPERED ROLLER BEARING
3.CLUTCH SHAFT
STEP 2.
Remove the axial bearing assembly, idler gear, and two needle bearings from the clutch shaft.
1.AXIAL BEARING ASSEMBLY (3 PIECES)
2.IDLER GEAR
3.NEEDLE BEARING
4.CLUTCH SHAFT
STEP 3.
Remove the clutch pack carrier from the clutch shaft.
1.CLUTCH PACK CARRIER
2.CLUTCH SHAFT
STEP 4.
Remove the piston rings. Using a bearing puller, remove the tapered roller bearing from the clutch shaft.
1.PISTON RING
2.TAPERED ROLLER BEARING
3.CLUTCH SHAFT
STEP 5.
Remove the retaining ring from the clutch pack carrier.
1.RETAINING RING
2.CLUTCH PACK CARRIER
STEP 6.
Remove the end shim and disc set from the clutch pack carrier.
1.END SHIM
2.DISC SET
3.CLUTCH PACK CARRIER
WARNING
The spring has a force of 430 ±25 N (97 ±6 lbf).
STEP 7.
Using a spring compression tool, Hyster P/N 4612858, compress the spring and remove the snap ring.
1.COMPRESSION TOOL
2.COMPRESSION SPRING
3.SNAP RING
STEP 8.
Slowly release the compression spring and remove the guide ring, compression spring, and guide ring from the clutch pack carrier.
1.GUIDE RING
2.COMPRESSION SPRING
3.CLUTCH PACK CARRIER
NOTE: Use compressed air to aid in the removal of the piston.
STEP 9.
Remove piston from clutch pack carrier.
1.PISTON
2.CLUTCH PACK CARRIER
STEP 10.
Remove and discard the inner and outer O-rings from the piston.
1.INNER O-RING
2.OUTER O-RING
3.PISTON
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Input Shaft, Disassemble
STEP 1.
Remove piston ring. Using a bearing puller, remove two tapered roller bearings from the input shaft.
1.PISTON RING
2.TAPERED ROLLER BEARING
3.INPUT SHAFT
WARNING
To prevent serious eye injury, always wear safe eye protection when performing vehicle maintenance or service.
WARNING
To avoid personal injury when cleaning parts, work in a well-ventilated area, wear protective clothing (face shield or safety glasses and protective gloves), and follow chemical manufacturer's recommendations for safe usage.
Solvent cleaners can be flammable, poisonous, and cause burns. Examples of solvent cleaners are carbon tetrachloride, emulsion-type cleaners, and petroleum-based cleaners. To avoid serious personal injury when using solvent cleaners, carefully follow manufacturer's instructions and these procedures:
•Wear safe eye protection.
•Wear clothing that protects skin.
•Work in a well-ventilated area.
• Do not use gasoline or solvents that contain gasoline. Gasoline can explode.
• Use hot solution tanks or alkaline solutions correctly. Carefully follow manufacturer's instructions.
Clean all parts thoroughly using solvent type cleaning fluid. It is recommended that parts be immersed in cleaning fluid and moved up and down slowly until all old lubricant and foreign material is dissolved and parts are thoroughly cleaned.
The importance of careful and thorough inspection of all parts cannot be overstressed. Replacement of all parts showing indication of wear or stress will eliminate costly and avoidable failures at a later date.
Clean interior and exterior of housings, bearing caps, etc., thoroughly. Cast parts may be cleaned in hot solution tanks with mild alkali solution providing these parts do not have ground or polished surfaces. Parts should remain in solution long enough to be thoroughly cleaned and heated. This will aid the evaporation of the cleaning solution and rinse water. Parts cleaned in solution tanks must be thoroughly rinsed with clean water to remove all traces of alkali. Cast parts may also be cleaned with steam cleaner.
Inspect housings, covers and bearing caps to ensure that they are thoroughly clean and that mating surfaces, bearing bores, etc., are free from nicks or burrs. Check all parts carefully for evidence of cracks or conditions which would cause subsequent oil leaks or failures.
Replacement of spring load oil seals, O-rings, metal sealing rings, gaskets, and snap rings is more economical when the unit is disassembled than premature overhaul to replace these parts at a future time. Further loss of lubricant through a worn seal may result in failure of other more expensive parts of the assembly. Sealing members should be handled carefully, particularly when being installed. Cutting, scratching, or curling under of lips of seals seriously impairs its efficiency. When assembling new metal type piston rings, these should be lubricated with a coat of Vaseline to stabilize rings in their grooves for ease of assembly of mating members. Lubricate all O-rings with recommended type Automatic Transmission Fluid before assembly. Prior to installation of rubber seals, lightly coat the outer surface with mineral spirits, and coat the inner surface with multipurpose grease.
Compressed air can move particles so that they cause injury to the user or to other personnel. Make sure that the path of the compressed air is away from all personnel. Wear protective goggles or a face shield to prevent injury to the eyes.
NOTE: Do not spin the bearings when drying.
Remove bearings from cleaning fluid and strike flat against a block of wood to dislodge solidified particles of lubricant. Immerse again in cleaning fluid to flush out particles. Repeat above operation until bearings are thoroughly clean. Dry bearings using moisture-free compressed air. Be careful to direct air stream across bearing to avoid spinning. Bearings may be rotated slowly by hand to facilitate drying process.
NOTE: Do not replace a bearing cone or cup individually without replacing the mating cup or cone at the same time.
Carefully inspect all rollers, cages and cups for wear, chipping, or nicks to determine fitness of bearings for further use. After inspection, dip bearings in recommended Automatic Transmission Fluid and wrap in clean lint-free cloth or paper to protect them until installed.
If Magna-Flux process is available, use process to check parts. Examine teeth on all gears carefully for wear, pitting, chipping, nicks, cracks, or scores. If gear teeth show spots where case hardening is worn through or cracked, replace with new gear. Small nicks may be removed with suitable hone. Inspect shafts and quills to make certain they are not sprung, bent, or spline-twisted, and that shafts are true.
Input Shaft, Assemble
STEP 1.
Using a press, install two tapered roller bearings on the input shaft until they bottom out, and install the piston ring on the input shaft.
1.PISTON RING
2.TAPERED ROLLER BEARING
3.INPUT SHAFT
Third Speed Clutch, Assemble
CAUTION
Make sure that the O-rings are not deformed during installation, and DO NOT roll the O-rings onto the piston.
NOTE: Prior to installing O-rings, coat with transmission oil to make installation easier.
STEP 1.
Install new inner and outer O-rings on the piston.
1.INNER O-RING
2.OUTER O-RING
3.PISTON
NOTE: Check piston relief valve functionality prior to installation of the piston.
STEP 2.
Using the spring compression tool, Hyster P/N 4612858, install the piston into the clutch pack carrier, as noted during disassembly, until it bottoms out.
1.PISTON
2.CLUTCH PACK CARRIER
STEP 3.
Install the guide ring, compression spring, and guide ring into the clutch pack carrier.
1.GUIDE RING
2.COMPRESSION SPRING
3.CLUTCH PACK CARRIER
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STEP 4.
Using the spring compression tool, Hyster P/N 4612858, depress the spring assembly and install the snap ring into the annular groove. Remove the spring compression tool from the clutch pack carrier.
1.COMPRESSION TOOL
2.COMPRESSION SPRING
3.SNAP RING
STEP 5.
Install the friction disk, uncoated side down toward the piston, into the clutch pack carrier. See Figure 10.
NOTE: Prior to installation, the inner and friction discs must be coated with clean automatic transmission fluid.
STEP 6.
Install the inner discs and friction discs into the clutch pack carrier as shown in Figure 10.
STEP 7.
Install the friction disc, uncoated side up, into the clutch pack carrier. See Figure 10.
STEP 8.
Install the end shim and retaining ring into the clutch pack carrier.
1.END SHIM
2.RETAINING RING
3.CLUTCH PACK CARRIER
STEP 9.
Install a dial indicator as shown, and depress the end shim with a force of 100 N (23 lbf), set the dial indicator to zero.
1.DIAL INDICATOR
2.END SHIM
STEP 10.
Press the end shim against the retainer and determine the clearance between the end shim and the retainer. The disk clearance is to be 2.0 to 2.3 mm (0.079 to 0.090 in.). If the clearance is not within the limits specified a new retainer must be installed. See the Parts Manual for the next size retainer.
1.DIAL INDICATOR
2.END SHIM
STEP 11.
Using a press, install the tapered roller bearing on the clutch shaft until it bottoms out, and install the two piston rings.
1.CLUTCH SHAFT
2.TAPERED ROLLER BEARING
3.PISTON RINGS
STEP 12.
Turn the clutch pack carrier over so that the bottom of the carrier is facing up, and using a heat gun, heat the inner diameter to 120°C (248°F).
WARNING
Hot parts. Wear protective clothing and gloves to prevent burns
STEP 13.
Install the clutch pack carrier on the clutch shaft until it bottoms out.
STEP 14.
Install the running disc chamfer side up, axial bearing, and axial washer on the clutch shaft.
1.AXIAL BEARING
2.RUNNING DISC
3.AXIAL WASHER
NOTE: Manually align the inner teeth of the disks prior to performing STEP 15.
STEP 15.
Install the two needle bearings and idler gear on the clutch shaft, rotating the idler gear left and right small amounts to achieve final alignment with the clutch pack.
1.AXIAL BEARING ASSEMBLY
2.NEEDLE BEARING
3.IDLER GEAR
4.CLUTCH SHAFT
STEP 16.
Install the axial washer, axial bearing, and running disc chamfer side down on the clutch shaft.
1.AXIAL WASHER
2.AXIAL BEARING
3.RUNNING DISC
STEP 17.
Using a press, install the tapered roller bearing on the clutch shaft until it bottoms out, and install the piston ring.
1.PISTON RING
2.TAPERED ROLLER BEARING
3.CLUTCH SHAFT
STEP 18.
Check the opening of the clutch by applying compressed air at the bore. See arrow in the figure. The opening of the clutch must be clearly audible.
CAUTION
Make sure that the O-rings are not deformed during installation, and DO NOT roll the O-rings onto the piston.
NOTE: Prior to installing O-rings, coat with transmission oil to make installation easier.
STEP 1.
Install new inner and outer O-rings on the piston.
1.INNER O-RING
2.OUTER O-RING
3.PISTON
NOTE: Check piston relief valve functionality prior to installation of the piston.
STEP 2.
Using the spring compression tool, Hyster P/N 4612858, install the piston into the clutch pack carrier, as noted during disassembly, until it bottoms out.
1.PISTON
2.CLUTCH PACK CARRIER
STEP 3.
Install the guide ring, compression spring, and guide ring into the clutch pack carrier.
1.GUIDE RING
2.COMPRESSION SPRING
3.CLUTCH PACK CARRIER
STEP 4.
Using the spring compression tool, Hyster P/N 4612858 and a press, depress the spring assembly and install the snap ring into the annular groove. Remove the spring compression tool from the clutch pack carrier.
1.COMPRESSION TOOL
2.COMPRESSION SPRING
3.SNAP RING
STEP 5.
Install the friction disk, uncoated side down toward the piston, into the clutch pack carrier. See Figure 9.
NOTE: Prior to installation, the inner and outer friction discs must be coated with clean automatic transmission fluid.
STEP 6.
Install the inner discs and friction discs into the clutch pack carrier as shown in Figure 9.
STEP 7.
Install the friction disk, uncoated side up, into the clutch pack carrier. See Figure 9.
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