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TRANSMISSION
REPAIR (HR 36000)
H36.00-48.00E (H800-1050E) [D117];
H40.00-52.00XM-16CH (H1050, 1150HD-CH) [E117];
RS45-27CH, RS45-30CH, RS45-27IH, RS46-33CH, RS46-30IH,
RS46-36CH, RS46-33IH [A222];
HR45-25, HR45-27, HR45-31, HR45-40S, HR45-36L, HR45-40LS,
HR45-45LSX, HR45H [A227, B227]
• 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 Mainte-
nance section.
• Keep the unit clean and the working area clean and orderly.
• 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.
• 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 ............................................................................................................................................................... 1
Torque Converter Repair ................................................................................................................................... 2
Torque Converter, Remove ............................................................................................................................ 2
Torque Converter, Disassemble .................................................................................................................... 2
Clean and Inspect .......................................................................................................................................... 2
Torque Converter, Assemble ......................................................................................................................... 4
Torque Converter (Turbine) Housing, Disassemble..................................................................................... 5
Relief Valve for Lube Pressure, Disassemble and Assemble....................................................................... 5
Oil Sealing Rings Sleeve, Replace ................................................................................................................ 5
Torque Converter Housing, Assemble .......................................................................................................... 5
Torque Converter, Install .............................................................................................................................. 6
Transmission Repair .......................................................................................................................................... 6
Remove, Transmission Only.......................................................................................................................... 6
Remove, Transmission and Engine Assembly.............................................................................................. 7
Transmission, Disassemble ........................................................................................................................... 8
Output Shaft, Disassemble and Assemble............................................................................................... 9
Fourth-Speed Shaft, Disassemble and Assemble .................................................................................... 10
Third-Speed Shaft, Disassemble and Assemble ...................................................................................... 11
Forward Shaft and Clutch, Disassemble and Assemble ......................................................................... 14
Reverse and Second-Speed Shaft and Clutch, Disassemble and Assemble ........................................... 15
First-Speed Shaft and Clutch, Disassemble and Assemble .................................................................... 17
Input Shaft, Disassemble and Assemble.................................................................................................. 19
Speed Sensor, Install ..................................................................................................................................... 21
Transmission, Clean and Inspect.................................................................................................................. 22
Transmission, Assemble ................................................................................................................................ 22
Control Valve.................................................................................................................................................. 24
Clean and Inspect...................................................................................................................................... 24
Assemble and Install................................................................................................................................. 24
Install, Transmission..................................................................................................................................... 25
Install, Transmission and Engine Assembly................................................................................................ 25
Clean Oil System of Transmission After Major Repair ............................................................................... 26
Automatic Powershift Control (APC 100)......................................................................................................... 26
Functional Description .................................................................................................................................. 26
Fuses .............................................................................................................................................................. 29
Transmission Control Lever.......................................................................................................................... 29
First-Speed Shaft Bearings Adjustment........................................................................................................... 32
Torque Converter Stall Speed Check ................................................................................................................ 35
Transmission Oil Pressures Check ................................................................................................................... 35
Clutch Pressures Check ................................................................................................................................ 35
Torque Converter (Torque Converter Regulator) Oil Pressure Check ........................................................ 35
Troubleshooting.................................................................................................................................................. 37
Diagrams, Schematics, or Arrangements ......................................................................................................... 39
Figure 31. Transmission Hydraulic Diagram.......................................................................................... 40
ii
1300 SRM 635 General
General
This four-speed powershift transmission is an ALWAYS replace all seals, O-rings, metal seal rings,
HR-36000 series transmission manufactured by gaskets, and snap rings with new ones. Lubricate all
Spicer-Clark. seals with clean transmission oil before installation.
Lubricate metal seal rings with multipurpose grease
This section has the repair procedures for the #2 before installation. Use care with seals especially
torque converter, transmission, control valve, and during installation to prevent damage.
the oil pump for the transmission. See the section
Four-Speed Powershift Transmission, Descrip- If possible, use magnaflux to check all gears and
tion and Operation (HR 36000) 1300 SRM 634 for shafts. Check gear teeth for wear, pitting, chipping,
information on the operation of this transmission. nicks, cracks, or scoring. If gears show spots where
The transmission assembly is shown in Figure 1. hardened surface has worn through, replace gear.
Make sure shafts are not bent or the splines twisted.
1
Torque Converter Repair 1300 SRM 635
If it is necessary to disassemble the torque converter, 8. Remove screws and washers that fasten hub to
do so as follows and as shown in Figure 2: impeller. Remove backing ring. Remove impeller
from hub. Remove O-ring between hub and im-
1. Remove capscrews and lockwashers that fasten peller.
drive plates and bearing cover to impeller cover.
Remove backing ring, drive plates, bearing cover, 9. Straighten locking tabs for hub bolts. Remove
and O-ring. turbine-to-hub bolts and washers. Remove tur-
bine hub.
2. Remove two rings and washer spacer that fas-
tens the turbine hub. One ring is thicker than If necessary, disassemble turbine and impeller cover.
the hub locating ring. Install blocks under the edges of the impeller cover to
suspend the turbine and hub. Remove bearing snap
NOTE: Use a drain pan for the oil in the converter ring and spacer. Use a drift and hammer to remove
section that did not drain during initial drain of oil. turbine and hub from impeller cover bearing.
3. Remove screws and washers that fasten impeller
CLEAN AND INSPECT
cover. Use a screwdriver at the slots to remove
impeller cover, turbine, and turbine hub. Re-
move large O-ring for the cover. WARNING
Cleaning solvents can be flammable and toxic
4. Remove locating snap ring from under turbine and can cause skin irritation. When using
hub. This ring is thinner than the retainer ring cleaning solvents, always follow the solvent
of Step 2. Remove snap ring that fastens stator manufacturer’s recommended safety precau-
to stator support. The stator support is fastened tions.
to the stator with a dowel. Do not remove spacer
if stator or spacer will not be replaced. Clean the parts of the torque converter in solvent.
Dry parts with compressed air. Inspect splines and
5. Remove retainer for oil baffle (Figure 3). Use a gear teeth for damage. Inspect shafts, bearings,
special removal tool to remove impeller and oil and bearing surfaces for scratches, wear, or damage.
baffle. The special removal tool is very similar to Clean holes that have threads and capscrews where
a gear puller, but is for larger diameter parts. a thread-locking compound is used.
6. Remove screws and washers that fasten stator
support to converter housing. Rotate stator
2
1300 SRM 635 Torque Converter Repair
3
Torque Converter Repair 1300 SRM 635
TORQUE CONVERTER, ASSEMBLE 2. Align impeller cover over turbine and hub. In-
stall bearing for impeller cover in cover and over
If the turbine and impeller cover were not disassem- turbine hub. Install new O-ring. Install spacer
bled, go to Step 3. on turbine hub. Install bearing rings.
If disassembled, assemble turbine and impeller cover 3. Make sure the surface of impeller hub and holes
as follows (see Figure 2): for screws are clean and dry. Put new O-ring on
impeller hub. If removed, use a drift or press the
1. Align holes in turbine and turbine hub and in-
same size as the bearing and install hub bearing
stall lock tabs, hub bolts, and washers. Tighten
and snap ring in hub.
hub bolts to 122 to 134 N•m (90 to 99 lbf ft). Bend
a corner of lock tab over bolt heads.
4
1300 SRM 635 Torque Converter Repair
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 1. HOUSING 5. PLUNGER
must be removed with a tap and cleaned with 2. WASHER 6. VALVE SEAT
solvent. Make sure the hole is dry before in- 3. SPRING RETAINER
stalling a new screw. 4. SEAT 7. RETAINING RING
5. Put a thin coat of Loctite© 638 on the outer di- Figure 4. Relief Valve Assembly
ameter of the oil seal of the oil baffle (Figure 3).
Press oil seal in oil baffle with lip of seal down. OIL SEALING RINGS SLEEVE, REPLACE
6. Carefully install oil baffle on impeller without There is a sleeve at the front end of the forward,
damaging oil seal. Install a new sealing ring for reverse, and fourth-gear clutch shafts. Remove the
oil baffle. Install hub gear on impeller hub and sleeves ONLY if they are to be replaced.
install snap ring. 1. Remove locating ring for front bearing of clutch
shaft.
TORQUE CONVERTER (TURBINE)
HOUSING, DISASSEMBLE 2. Remove retainer plate screw, washer, and plate.
2. Put a mark on each pump gear for correct loca- 5. Put sleeve lock in position. Install capscrew and
tion during installation. Remove bearing sup- washer. Tighten capscrew.
port screws and lockwashers for the drive (cen-
ter) gear. Remove drive gear and bearing assem- 6. Install locating ring for front bearing of clutch
bly. Remove other two pump gear and bearing shaft in ring groove.
assemblies using the same procedure.
TORQUE CONVERTER HOUSING,
RELIEF VALVE FOR LUBE PRESSURE, ASSEMBLE
DISASSEMBLE AND ASSEMBLE Assemble converter housing assembly as follows and
If the unit has this relief valve, disassemble, clean, or as shown in Figure 3:
replace and assemble the valve as shown in Figure 4.
1. Install two pump drive gears as marked during
disassembly. Install transmission pump gear at
center location. Tighten all mount capscrews.
5
Transmission Repair 1300 SRM 635
2. Install input shaft and gear. Use a hammer with with a soft face to tap shaft of the fourth-speed
a soft face to tap shaft so bearing snap ring can clutch until locating ring is completely in groove
be installed. Install snap ring and continue to tap of converter housing.
shaft so snap ring is against shoulder in housing.
5. Install the front bearing of the forward clutch.
3. Open locating ring for the front bearing of the
reverse clutch. See Figure 15. Use a hammer TORQUE CONVERTER, INSTALL
with a soft face to tap shaft of the reverse and
second clutch until locating ring is completely in The torque converter is assembled in the torque con-
groove of converter housing. verter housing and is installed with the transmis-
sion. See Install, Transmission.
4. Open locating ring for the front bearing of the
fourth-speed clutch. See Figure 7. Use a hammer
Transmission Repair
REMOVE, TRANSMISSION ONLY 13. Place tags on lines for identification.
NOTE: The transmission can be removed from under 14. Remove the drain plug from the transmission
the lift truck or as a complete assembly with the en- sump.
gine. If an inspection pit is not available, the truck
must be raised 500 mm (19.7 in.) from the ground to 15. Drain the oil.
provide easier access and removal.
16. Put plugs and caps on open fittings.
1. Place truck on level surface.
17. Disconnect the hoses at the hydraulic pumps.
2. Shut down engine.
18. Put plugs and caps on open fittings.
3. Apply parking brake.
NOTE: The hydraulic pumps are fastened to the
4. Operate all hydraulics to release pressure in the transmission with 4 capscrews each.
system.
The drive shaft of the hydraulic pump is engaged in
NOTE: When removing battery cables, remove splines in the drive gear.
ground cable first.
The drive shaft of the hydraulic pump will slide from
5. Disconnect the cables at the battery. the drive gear when the hydraulic pump is removed.
6. Remove floor plates and covers to provide access 19. Remove the hydraulic pumps.
to the hydraulic pump and transmission.
20. Disconnect and remove the dipstick assembly.
7. Close shutoff valves on hydraulic tank.
21. Install blocks and a jack under the flywheel end
8. Disconnect the drive shaft at the differential. of the engine as a support.
9. Remove the drive shaft between the transmis- 22. Disconnect exhaust system to avoid possible
sion and the differential. damage.
6
1300 SRM 635 Transmission Repair
1. TRANSMISSION 3. FRAME MOUNT 9. Remove the drive shaft between the transmis-
HOUSING 4. FRAME BRACKET sion and the differential.
2. TRANSMISSION 5. ISOLATOR
MOUNT 10. Disconnect the wiring harness on top of the
transmission.
Figure 5. Transmission Mount
11. Disconnect the wires at the solenoids on the
25. Remove the 8 bolts securing the drive plates to
transmission control valve.
the torque converter.
12. Disconnect the wires at the pressure and temper-
26. Remove all fasteners between engine flywheel
ature sending unit on the transmission.
housing and torque converter housing.
13. Place tags on lines for identification.
27. Verify all the connections have been removed.
14. Remove the drain plug from the transmission
28. Carefully slide back the transmission from the
sump.
frame approximately 40 mm (1.60 in.) to permit
the transmission to be lowered. 15. Drain the oil.
REMOVE, TRANSMISSION AND ENGINE The drive shaft of the hydraulic pump is engaged in
ASSEMBLY splines in the drive gear.
NOTE: The transmission can be removed from under The drive shaft of the hydraulic pump will slide from
the lift truck or as a complete assembly with the en- the drive gear when the hydraulic pump is removed.
gine. If an inspection pit is not available, the truck 19. Remove the hydraulic pumps.
7
Transmission Repair 1300 SRM 635
20. Disconnect and remove the dipstick assembly. 35. Remove the capscrews that hold the two rear en-
gine mount brackets to the frame.
21. Install blocks and a jack under the flywheel end
of the engine as a support. NOTE: Verify all the connections to the engine or
transmission have been removed.
22. Disconnect exhaust system to avoid possible
damage. 36. Carefully lift the engine and transmission as-
sembly from the frame.
23. Remove engine hood and ballast cover.
TRANSMISSION, DISASSEMBLE
24. Disconnect the air cleaner intake elbow.
Make sure to keep the parts for each clutch together
25. Drain coolant from the cooling system.
during disassembly. Make a note of the order of the
26. Disconnect cooling lines. friction discs and separator plates of each clutch.
Also make a note of which way each bearing seal
27. Remove the radiator and transmission oil cooler. is facing for correct installation. Disassemble the
transmission as follows:
28. Remove the tubing between the engine and air
cleaner. 1. Remove torque converter assembly from trans-
mission. If necessary, disassemble torque con-
29. Disconnect fuel lines at the fuel filter. verter as described in Torque Converter, Disas-
semble.
30. Disconnect the throttle linkage.
2. Remove solenoid dust cover from transmission
31. Disconnect wires and wiring harnesses at the en-
control valve. Remove screws and lockwashers
gine.
that fasten control valve cover. Remove cover as-
32. Disconnect the heater hoses at the engine. sembly of control valve, seal plate, and inner and
outer gaskets. Remove control valve housing and
NOTE: Verify that the lifting device has a capacity of gasket.
at least 1360 kg (3000 lb).
3. Remove screws that fasten stator support. Ro-
33. Connect a lifting device to the engine. tate stator support so curved "cutout" section is
aligned with pump drive gear to allow removal.
34. Remove the capscrews that hold the engine See Figure 3. Remove stator support.
mount at the fan end of the engine. See Figure 6.
4. Use a crane and sling to support torque con-
verter housing. Remove capscrews that fasten
torque converter housing to transmission case.
Remove torque converter housing with the
reverse/second- and fourth-speed clutch assem-
blies attached.
8
1300 SRM 635 Transmission Repair
spacer. Remove bearing cap nuts and lockwash- 18. Remove forward clutch assembly. See Figure 13.
ers for rear bearing of output shaft. Remove Remove outer race of the rear bearing of the in-
bearing cap and O-ring. See Figure 7. put shaft. Remove bearing cup and oil baffle
spacer of the first-speed shaft.
8. Remove bearing cap nuts and lockwashers for
bearing of the third-speed shaft. Remove bearing Output Shaft, Disassemble and Assemble
cap, O-ring, rings, and washer. See Figure 10.
NOTE: The following procedures describe the disas-
9. Remove bearing cap nuts and lockwashers for the sembly of each of the shaft assemblies and clutches.
bearing of the first-speed (low) shaft. Remove These assemblies have been removed from the trans-
bearing cap, shims, O-ring, and ring. See Fig- mission as assemblies in the previous procedures.
ure 17. Keep cap and shims together. If cap, Disassemble only the shaft or clutch assembly nec-
clutch, front or rear bearings, transmission case, essary to make repairs.
or rear cover are not replaced, the same shims
will be used during assembly.
CAUTION
10. Remove clutch pressure and lube tubes and Inspect all bearings for damage and wear.
O-rings at the holes under bearing cap for the Bearings are normally replaced during a ma-
first-speed shaft bearing. jor disassembly and assembly such as this.
11. Remove locating rings for the rear bearings of the Inspect clutch plates for wear of friction mate-
third-speed and output shafts. rial and damage to the separator plates.
12. Remove nuts, screws, and lockwashers that fas- Make sure to keep all parts of each clutch as-
ten the rear cover of the transmission. Remove sembly together. Some of these parts look the
oil screen plug and oil screen. Tap on the end of same, but are not. Using the wrong part can
the output shaft and clutch shafts while prying cause incorrect operation or damage.
cover off to remove cover. Using aligning studs
can help in the removal. Remove cover gasket. Always use new seals, seal rings, and snap
rings during assembly. Apply a thin coat of
13. Remove retaining ring for the fourth-speed hub. multipurpose grease #2 to all seals before in-
Remove hub. Remove three retaining rings for stallation. Fill all seal grooves with this same
the second-speed hub. Remove hub. grease.
14. Use a bearing puller to remove the rear bearing The following procedure describes the disassembly
of the output shaft. Remove first-speed clutch and assembly of the output shaft. See Figure 7:
and output shaft simultaneously. Remove front
bearing for output shaft. 1. Remove inner race of the front bearing of the out-
put shaft.
15. Remove clutch assembly of the third-speed
clutch. 2. Remove front retaining ring for the output gear.
Remove spacers and gear from shaft. If neces-
16. Remove oil baffle screws, lockwashers, and oil sary, remove rear retaining ring.
baffle from cover. Remove bolts and lockwashers
of the suction tube. Remove suction tube and 3. If removed, install rear retaining ring on output
O-ring. shaft. Install spacers and gear with long hub
toward rear. Install front retaining ring.
17. Have another person release the bearing snap
ring for the rear bearing of the forward shaft. 4. Install retainer and press front bearing on out-
Use a hammer that has a soft face to tap the end put shaft with race shoulder facing gear. Install
of the shaft for removal. bearing and outer race on inner race.
9
Transmission Repair 1300 SRM 635
Fourth-Speed Shaft, Disassemble and remove bearing using a bearing puller. Remove
Assemble other ring.
The following procedure describes the disassembly 2. Remove snap ring for the backing plate of the
and assembly of the fourth-speed shaft: See Figure 7 clutch disc and remove backing plate. Remove
and Figure 8. all friction and separator discs.
1. Remove oil sealing rings from the fourth-clutch 3. Remove seal. Compress wave spring and remove
shaft. Remove snap ring for front bearing and retaining ring from its groove. Release wave
10
1300 SRM 635 Transmission Repair
spring and remove snap ring and retainer for the from its groove. Release wave spring and re-
spring. Remove wave spring and thrust washer. move snap ring and retainer for the spring.
Turn assembly over and tap shaft on a block of Remove wave spring.
wood to remove seals and piston.
11
Transmission Repair 1300 SRM 635
12
1300 SRM 635 Transmission Repair
13
Transmission Repair 1300 SRM 635
Forward Shaft and Clutch, Disassemble disc must be a friction disc. This is the sequence
and Assemble of installation when the clutch has an iron pis-
ton.
The following procedure describes the disassembly
and assembly of the forward shaft and clutch (see 10. Install detent spring and ball in backing plate.
Figure 12 and Figure 13): See Figure 11. Install backing plate in clutch
drum making sure not to lose the spring or ball.
1. Remove piston rings from forward clutch shaft. Compress clutch discs and disc springs and in-
Remove retainer ring for inner race of front bear- stall retainer ring for backing plate.
ing. Use pry bars to remove bearing inner race.
Remove retainer ring for outer bearing.
8. Install inner and outer seal rings on piston. Lock 13. Install rings in outer bearing with shield toward
ring joint and apply grease to stabilize it in ring gear. Install inner race of front bearing. The
groove. Carefully position piston in drum with- large diameter must be toward gear. Install re-
out damaging seal rings. tainer for front bearing.
9. Install one friction disc (teeth on inner diame- 14. Put grease in groove for piston rings. Install pis-
ter). Install one separator disc, then alternately ton rings in grooves. Align piston rings at center
install the other 10 friction discs and the other of groove.
nine separator plates. The first and last clutch
14
1300 SRM 635 Transmission Repair
15
Transmission Repair 1300 SRM 635
1. RETAINER 8. SEAL
2. SPRING 9. PISTON
3. RING 10. SEPARATOR DISC (TEETH OUTSIDE)
4. BEARING 11. FRICTION DISC (TEETH INSIDE)
5. CLUTCH HUB AND GEAR 12. BACKING PLATE
6. PISTON RING 13. SNAP RING
7. CLUTCH DRUM AND GEAR 14. TRANSMISSION HOUSING
9. Install detent spring and ball in backing plate. 14. Compress wave spring and remove retaining ring
See Figure 11. Install backing plate in clutch from its groove. Release wave spring and remove
drum making sure not to lose the spring or ball. snap ring and retainer for spring. Remove wave
Compress clutch discs and disc springs and in- spring and thrust washer. Remove second clutch
stall retainer ring for backing plate. piston.
10. Carefully install hub and gear in drum. Make 15. Make sure the bleed valve is clean in the second-
sure hub splines engage splines of all friction gear piston removed in Step 14. Install inner and
discs. To avoid damage, do not force hub through outer seal rings on piston. Lock ring joint and
the discs. apply grease to stabilize it in ring groove. Care-
fully position second-gear piston in drum without
11. Install outer bearing with shield toward gear. In- damaging seal rings.
stall retainer ring for outer bearing. Install front
bearing. The groove in the bearing must be to- 16. Put thrust washer, wave spring, wave spring re-
ward gear. Install retainer ring for front bearing. tainer, and snap ring for retainer on shaft. Com-
press wave spring and install retainer ring for
12. Put grease in groove for sealing rings. Install spring into the groove of the shaft. Make sure
sealing rings in grooves. Align sealing rings at retainer ring is completely in groove.
center of groove.
16
1300 SRM 635 Transmission Repair
17
Transmission Repair 1300 SRM 635
9. Put retainer for wave spring, wave spring, wave drum. The last disc is a friction disc. Install
spring retainer, and snap ring for retainer on backing plate and snap ring in drum.
shaft. Compress wave spring and install retainer
ring for spring into the groove of shaft. Make 11. Install gear spacer and inner bearing. The bear-
sure retainer ring is completely in groove. ing does not have an oil shield. Use a press to in-
stall bearing. Carefully install hub gear. Make
10. Install a separator disc (teeth on outside) in sure hub splines engage splines of all friction
clutch drum. Alternately install the 10 friction discs. To avoid damage, do not force the hub
discs and the other nine separator discs in the through the discs.
18
1300 SRM 635 Transmission Repair
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.
19
Transmission Repair 1300 SRM 635
20
1300 SRM 635 Transmission Repair
SPEED SENSOR, INSTALL shims under the head of the bushing. Use Loctite®
number 270 or number 262 on both the bushing and
Temporarily install bushings for speed sensors. Use housing threads. Install shims and tighten bushings
a depth micrometer to measure the depth at each to 61 to 68 N•m (45 to 50 lbf ft). After the Loctite®
speed sensor bushing. Add shims to get the correct has set, install speed sensors and tighten them to
dimensions as shown in Figure 18. Clean threads of 54 N•m (40 lbf ft).
bushing and housing using Loctite© cleaner. Install
21
Transmission Repair 1300 SRM 635
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 precau-
tions.
6. Install the first-speed clutch and output shaft in 1 1/4" - 18 271 - 339 200 - 250
transmission housing. Make sure they are fully 1 1/2" - 18 407 - 474 300 - 350
in position in the housing. Install rear bearing
1 1/4" - 12 543 - 610 400 - 450
on output shaft. The groove in the bearing for
the snap ring must be toward the rear.
22
1300 SRM 635 Transmission Repair
11. Install locating ring for rear bearing of the third- 16. Install pilot bearing for the second and third
speed shaft. Install new O-ring on bearing cap. clutches on the shafts. Use grease to keep bear-
Install bearing cap, lockwashers, and nuts on ings in position.
studs. Tighten nuts.
17. Leave the passage for the first-speed clutch
12. Install screen assembly for oil sump and in- open for internal lube tube installation. Install
stall plug. Tighten plug to 13 to 20 N•m (10 to plug for external lube tube installation. See
15 lbf ft). Figure 21. Tighten plug to 9.5 to 13.5 N•m (7 to
10 lbf ft).
13. Make sure the shim pack is correct for the bear-
ings of the first-speed clutch as described in
First-Speed Shaft Bearings Adjustment. In-
stall 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.
1. CONVERTER HOUSING
2. PASSAGE OPEN FOR INTERNAL LUBE
INSTALLATION
23
Transmission Repair 1300 SRM 635
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 precau-
tions.
24
1300 SRM 635 Transmission Repair
4. Install new O-ring on housing for pressure regu- INSTALL, TRANSMISSION AND ENGINE
lator valve. Install regulator valve and charging ASSEMBLY
pump on converter housing. Install lockwash-
ers and screws. Tighten screws. Install suc- NOTE: Verify that the lifting device has a capacity of
tion tube, O-ring, adapter fitting, adapter flange, at least 1360 kg (3000 lb).
flange screws, and lockwashers. Tighten screws.
1. Connect a lifting device to the engine.
INSTALL, TRANSMISSION
2. Carefully lower the engine and transmission into
1. Install the mounts on transmission housing. See the frame.
Figure 5. Connect a lifting device with a mini-
3. Install the capscrews that hold the 2 rear engine
mum capacity of 725 kg (1600 lb) to the lifting
mount brackets to the frame.
eyes on the transmission.
4. Install the capscrews that hold the engine mount
2. Install two 89 mm (3.5 in.) long guide studs in the
at the fan end of the engine. See Figure 6.
engine flywheel housing. Rotate engine flywheel
to align a mounting hole for the drive plates with 5. Connect the heater hoses at the engine.
the access hole of flywheel housing. Check end
play of flywheel. 6. Connect wires and wiring harnesses at the en-
gine.
3. Install a 102 mm (4 in.) locating stud in a drive
plate nut. Align locating stud of drive plate with 7. Connect the throttle linkage.
flywheel screw hole at the access hole.
8. Connect the fuel lines at the fuel filter.
4. Use the lifting device to put transmission as-
sembly into the approximate position. Align 9. Install the tubing between the engine and air
drive plates on flywheel and converter housing cleaner.
with flywheel housing. Install housing screws to
10. Install the radiator and transmission oil cooler.
fasten converter and flywheel housings together.
Remove housing studs and install all housing 11. Connect cooling lines.
screws. Tighten all screws.
12. Fill cooling system with coolant.
5. Install nuts and bolts for transmission mounts.
Tighten nut for transmission mount to 120 N•m 13. Connect the air cleaner intake elbow.
(90 lbf ft).
14. Install engine hood and ballast cover.
6. Remove locating stud in drive plates. Install
screw to fasten drive plates to flywheel. A screw- 15. Connect exhaust system.
driver or pry bar can be used to hold the drive
16. Connect and install dipstick assembly.
plates against the flywheel to install the screw.
Rotate flywheel and install each drive plate NOTE: The drive shaft of the hydraulic pump will
screw in turn. After all screws are installed, slide into the drive gear before the hydraulic pumps
tighten all M10 screws to 61 N•m (48 lbf ft). are installed.
Check that flywheel end play is within 0.03 mm
(0.001 in.) of the end play of Step 2. 17. Install the drive shaft of the hydraulic pump.
7. Connect drive shafts to transmission. Make sure NOTE: The hydraulic pumps are fastened to the
to align the marks. Tighten capscrews for input transmission with 4 capscrews.
yoke to 68 N•m (50 lbf ft). Tighten capscrews for
output yoke to 163 N•m (120 lbf ft). 18. Install hydraulic pumps.
8. Connect oil lines and dipstick tube at transmis- 19. Remove plugs and caps on open fittings.
sion. Connect wiring harness at transmission.
20. Connect the hoses at the hydraulic pumps.
25
Automatic Powershift Control (APC 100) 1300 SRM 635
22. Replace the drain plug from the transmission Clean the system as follows:
sump.
1. Drain the entire system completely.
23. Replace the transmission oil.
2. Disconnect and clean all oil lines for the trans-
24. Connect the wires at the pressure and tempera- mission. If possible, remove oil lines completely
ture sending unit on the transmission. to clean them.
25. Connect the wires at the solenoids on the trans- 3. Remove filter elements and clean filter can. In-
mission control valve. stall new filter elements.
26. Connect the wiring harness on top of the trans- 4. Use oil and compressed air with flow opposite the
mission. normal direction to flush the oil cooler. Do NOT
use flushing compounds.
27. Replace the drive shaft between the transmission
and the differential. 5. Assemble all components and oil lines. Fill trans-
mission with the correct oil to the LOW mark
28. Connect the drive shaft at the differential. (dipstick or lower fill plug). Install new gaskets
and hydraulic pumps for the hydraulic systems of
29. Open shut-off valves on the hydraulic tank.
the lift truck to the flange on the transmission.
30. Replace floor plates and covers. Connect hydraulic lines as necessary. See the
Hydraulic System. Fill hydraulic tank of lift
NOTE: When replacing battery cables, replace the truck with correct amount and type of hydraulic
ground cable last. oil.
31. Connect the cables to the battery. 6. Operate engine at idle speed for two minutes
to fill all hydraulic lines and filters. Check
32. Start engine. for leaks. Check oil level of transmission with
engine operating. Add oil as necessary to the
33. Operate hydraulic functions and check for leaks.
LOW mark. If necessary, install the fill and level
plugs.
CLEAN OIL SYSTEM OF TRANSMISSION
AFTER MAJOR REPAIR 7. Operate engine at stall until oil is 82 to 93 C (180
to 200 F) and check for leaks. See Torque Con-
NOTE: The complete oil system of the transmission verter Stall Speed Check.
must be cleaned after every major repair. This clean-
ing is necessary to make sure the transmission oper-
ates correctly.
26
1300 SRM 635 Automatic Powershift Control (APC 100)
that would cause excess speed while driving due to 2. Switch Descriptions
a turbine failure.
• Automatic Shifting a. Idle/Not Idle (pin no. 23). Switch open -
An automatic shift to a higher gear is made when throttle pedal is depressed. Switch closed -
the throttle pedal is pressed, the turbine speed ex- engine is idling, throttle pedal released.
ceeds a minimum speed, and the speed ration has
b. Automatic/Manual (pin no. 9). Switch open
reached a certain value. No upshifts are allowed in
- APC 100 is shifting automatically. Switch
the braking mode (throttle pedal released).
closed - APC 100 in manual mode, operator
An automatic shift to a lower gear is made when
decides when to shift. Downshifts or direc-
the tractive effort in the lower gear exceeds the
tion changes at high speeds are inhibited.
tractive effort in the higher gear.
• Declutch c. Declutch Request (pin no. 8). Switch open -
The transmission shifts to neutral under certain no declutch is applied. Switch closed - when
conditions for load handling procedures. declutch is requested, the control unit will
shift the transmission to NEUTRAL when
The following paragraphs describe the pin connec-
vehicle speeds are less than a preset value,
tions at the APC 100 control unit.
depending on the unit. When the request is
1. Diagnostic LEDs (See Figure 23) dropped, the direction is engaged again.
a. RED LED - ON when internal failure pre- d. Parking Brake request (pin no. 27). Switch
vents correct operation. open - parking brake is not applied. Switch
closed - when parking brake is applied, con-
b. GREEN LED - Light reflects the position of trol unit will shift the transmission to NEU-
the idle/not idle switch (pin no. 23). When TRAL.
the throttle is at idle, the light is OFF. The
light is ON when the throttle is pressed. e. Second Gear Start Request (pin no. 7). 24
volts applied - transmission starts in first
c. YELLOW LED - ON when turbine rpm=0 gear when transmission control lever is set
(truck not moving) or when engine rpm=0 for second gear or lower. No voltage applied
(engine stopped). - transmission starts in second gear when
transmission control lever is set for fourth
gear.
27
Automatic Powershift Control (APC 100) 1300 SRM 635
28
1300 SRM 635 Automatic Powershift Control (APC 100)
29
Automatic Powershift Control (APC 100) 1300 SRM 635
NOTE: *CLARK GEAR SELECTOR SHOWN. HOBBS GEAR SELECTOR SHOWN IN FIGURE 27.
30
1300 SRM 635 Automatic Powershift Control (APC 100)
31
First-Speed Shaft Bearings Adjustment 1300 SRM 635
32
1300 SRM 635 First-Speed Shaft Bearings Adjustment
to record the average measurement at each step. this dimension for the final shim gap dimension
See Table 4. (total shim thickness). See the example chart
(Figure 29). In the example, the line crosses
Table 4. Example Torque Values at the zero line at 23.42 mm (0.922 in.). The av-
Dimensions Shown erage thickness of the bearing cap is 22.14 mm
(0.872 in.). Subtracting the thickness from the
Torque Value Gap Dimension zero point value equals 1.28 mm (0.050 in.) for
N•m lbf in mm in. the shim gap with no preload or end play. Add
0.15 ±0.02 mm (0.006 ±0.001 in.) to this dimen-
1.1 10 23.39 0.921 sion for the final shim gap dimension (total shim
2.3 20 23.32 0.918 thickness) of 1.41 to 1.45 mm (0.055 to 0.057 in.).
3.4 30 23.27 0.916 NOTE: There is a blank graph included for plotting
4.5 40 23.22 0.914 the actual measured values. If you need more, copy
the graphs before using them. See Figure 30.
5.6 50 23.16 0.912
9. Select shims for the total shim thickness found in
6.8 60 23.14 0.911
Step 8. Measure the thickness of the shim pack
7.9 70 23.06 0.908 to make sure it is correct.
9.1 80 22.99 0.905 10. Remove bearing cap. Install a new oil sealing
10.2 90 22.96 0.904 ring and new O-rings on clutch pressure sleeve
and bearing cap. Install pressure sleeve. In-
11.3 100 22.91 0.902 stall the correct shim pack and bearing cap on
studs. Install lockwashers and nuts. Alternately
8. Draw a straight line through the points on the tighten nuts to 55.6 to 61.0 N•m (41 to 45 lbf ft).
chart as shown in Figure 29. The value where the Rotate output shaft to make sure bearings are
line crosses the zero line minus the average value seated and check the torque of the nuts again.
recorded for the thickness of the bearing cap of
Step 2 is the no-end-play, no-preload shim dimen- 11. Install lubrication line from bearing cap to check
sion. Add 0.15 ±0.02 mm (0.006 ±0.001 in.) to port for lubricating pressure in front housing.
33
First-Speed Shaft Bearings Adjustment 1300 SRM 635
34
1300 SRM 635 Transmission Oil Pressures Check
Attach pressure gauges to the check ports. Check 4. If a clutch pressure is not within the specifica-
that the oil level in the transmission is correct. Op- tions of Step 2, repair that clutch.
erate the transmission in all ranges and directions
until the oil in the transmission is 83 to 94 C (180 to TORQUE CONVERTER (TORQUE
200 F). Connect a tachometer to the engine. Be sure CONVERTER REGULATOR) OIL
to use the hydraulic schematic shown in Figure 31. 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
2. Run the engine at idle (400 to 600 rpm) and 83 up, and the park brake is set. The correct oil
to 94 C (180 to 200 F) transmission oil tempera- pressure is 172 kPa (25 psi) min. @ 2000 rpm
ture, with brake pedals up and park brake set. and 483 kPa (70 psi) @ governed speed.
All clutch pressures must be within 34.5 kPa
(5 psi) of each other.
35
Transmission Oil Pressures Check 1300 SRM 635
1. Port S
2. Port R
36
1300 SRM 635 Troubleshooting
Troubleshooting
Transmission oil tempera- Type of oil is not correct or oil level is Check oil type and level.
ture is too hot. not correct.
Oil cooler or oil lines have a restric- Check and clean oil lines and oil
tion. cooler.
Clutches do not engage completely. Check oil pressure and repair as nec-
essary.
Torque converter does not operate Check stall speed and repair as nec-
correctly. essary.
One or more clutches do not Oil level is not correct or oil is the Check oil type and level.
engage or engage slowly. wrong type.
Transmission has internal oil leaks. Check oil pressure to locate problem.
Replace damaged parts.
External oil line(s) is damaged, has Check and repair oil lines.
a restriction, or is disconnected.
Main oil pressure is low. There is a restriction in the oil filter. Install new oil filter.
Oil level is not correct or oil is the Check oil type and level.
wrong type.
37
Troubleshooting 1300 SRM 635
Main oil pressure is low. Oil pump is worn or damaged. Repair oil pump.
(Cont.)
There is a leak between the oil pump Check for and repair internal leaks.
and the regulator.
Torque converter is too hot, Oil pressure is not correct. Check oil pressure to locate problem.
or performance is not to spec- Replace damaged parts.
ifications.
Torque converter makes too Bearings are damaged. Replace damaged parts.
much noise.
Oil pressure in the torque There is a restriction in the torque Check passages for restrictions.
converter circuit is high. converter circuit.
None of the display LEDs are There is no power to the controller. Check and repair wiring as neces-
on when key switch is ON. sary.
The red light is on continu- There is no power to the controller. Check and repair wiring as neces-
ously. sary.
38
1300 SRM 635 Diagrams, Schematics, or Arrangements
The transmission remains in The transmission controller is dam- Override the controller and drive the
a certain gear. aged. vehicle manually.
39
Diagrams, Schematics, or Arrangements 1300 SRM 635
40
1300 SRM 635 Diagrams, Schematics, or Arrangements
41
NOTES
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