Hyster F003 (H2.50J Europe) Forklift Service Repair Manual

SERVICE REPAIR H2.00J H2.50J H3.00JS (Europe) [F003]

PART NO. 1510478

8000 SRM 988

INTRODUCTION GENERAL This section has the repair procedures and troubleshooting for the single speed powershift transmission. The

description and operation of the transmission and torque converter are found in the SINGLE SPEED POWERSHIFT TRANSMISSION Description and Operation.

FIGURE 1. INSIDE THE TRANSMISSION

REPAIRS Before removing the transmission from the lift truck, make the checks described in Checks and Adjustments.

REMOVAL A. Remove the engine and transmission together as described in the ENGINE sections.

B. Remove the inspection plate at the top of the flywheel housing. Loosen the two capscrews that hold the oil sump tube to the transmission housing. Move the end of the tube toward the center of the housing. See Figure 2.

C. Remove the 11 capscrews and lock washers that hold the transmission to the engine.

D. Use blocks or chains to prevent engine or transmission damage when separating the transmission from the engine.

Do not let the weight of the transmission press on the torque converter or oil sump tube. Slide the transmission from the engine and torque converter. Do not damage oil sump tube.

Remove the gasket.

NOTE Keep all the gaskets and seals that are removed from the transmission. An old gasket is a reference to help select the correct new gasket. Always install new gaskets and seals.

Before removing the torque converter from the engine, put alignment marks on the flywheel and torque converter.

E. Remove the starter motor.

DISASSEMBLY Before disassembling the transmission, carefully clean the transmission housing. Keep the parts in a clean container when they are removed. Keep the parts of a unit together to prevent the loss of parts.

FIGURE 2. OIL SUMP TUBE

FIGURE 3. CHECKING THE GEAR CLEARANCE

FIGURE 4. CHECK THE CONTACT PATTERN BEFORE DISASSEMBLY A. Before disassembling the transmission, check the contact pattern and gear clearance of the ring and pinion. See Steps V to X in the Assembly section for the procedures. If the pattern and clearance are the same as the specifications, the pinion depth shims do not need to be changed. The shims for the stator reaction sleeve and shims for the turbine shaft must be changed if the pinion depth shims are changed.

B. Put identification marks on the side bearing caps and housing. Remove the adjuster retainer capscrews and the bearing cap capscrews. Remove the caps and adjuster screws. Loosen the locknut and remove the thrust screw for the ring gear from the housing. Remove the ring gear and differential assembly from the housing. Keep the bearing cups with the same cones. See Figure 5.

FIGURE 5. MAKE IDENTIFICATION MARKS BEFORE DISASSEMBLY

FIGURE 8. REMOVING THE DIFFERENTIAL ASSEMBLY FIGURE 6. REMOVE THE THRUST PLUG

D. If the pinion depth adjustment is correct, use a dial indicator to check the movement of the stator reaction sleeve.

Loosen 3 turns the 6 capscrews that hold the sleeve to the end cover. Fasten the dial indicator base to the housing. Put the plunger of the dial indicator on the end of the reaction sleeve. See Figure 11. Push the sleeve toward the transmission. Set the dial indicator to zero. Pull the sleeve and measure the travel. The movement must be less than 0.005 inch (0.012 mm). If the movement and the pinion depth are correct, the same shims can be used when assembling the transmission.

FIGURE 7. REMOVING THE BEARING CAPS

C. Put identification marks on each half of the case. Remove the capscrews that hold the differential case together. Remove the spider gears, spider, thrust washers and side gears.

Do not remove the ring gear unless it is damaged. Remove the bearings as shown in Figure 10.

E. If the pinion depth adjustment and the reaction sleeve clearance are correct, use a dial indicator to check the turbine shaft clearance. Move the dial indicator plunger to the end of the turbine shaft. Push the shaft and set the dial indicator to zero.

Pull on the shaft and measure the travel. The clearance must be 0.001 inch (0.025 mm) to 0.021 inch (0.005 mm). If the clearance is correct, the same shims can be used when assembling the transmission.

NOTE If the pinion depth shims or the reaction sleeve shims are changed, the turbine shaft shims must be changed. The turbine shaft clearance must be checked after assembling the transmission.

FIGURE 9. DISASSEMBLY OF THE DIFFERENTIAL

FIGURE 10. REMOVING THE SIDE BEARINGS

FIGURE 11. CHECKING MOVEMENT OF THE STATOR REACTION SLEEVE

G. Loosen evenly the 8 capscrews that hold the end cover to the housing. The cover has spring pressure against it. Remove the cover. See Figure 13.

FIGURE 12. CHECKING MOVEMENT OF THE TURBINE SHAFT FIGURE 14. REMOVING THE PISTON AND SEAL F. Remove the two capscrews from the oil sump tube. Loosen one the hose clamps. Remove the sump tube from the housing.

H. Remove the piston and seal from the end cover. See Figure 14.

FIGURE 13. REMOVE THE END COVER

FIGURE 15. REMOVING THE REACTION SUN GEAR

I. Remove the reaction sun gear. Remove the 8 piston return springs. See Figure 15.

FIGURE 18. REMOVING THE SPECIAL CAPSCREW

FIGURE 16. REMOVING THE TURBINE SHAFT

J. Remove the turbine shaft. Remove the thrust washer and shims from the end of the pinion shaft. See Figures 16 and 17.

FIGURE 19. USE CAPSCREWS TO PULL PRESSURE PLATE

L. Remove the separator plates and friction discs from the reverse clutch. See Figure 20.

FIGURE 17. REMOVING THE THRUST WASHER, SHIMS AND FORWARD CLUTCH

K. Remove the four separator plates and the two friction discs from the forward clutch. Remove the special capscrew and O-ring that holds the pressure plate in position. Put two capscrews in the threaded holes of the pressure plate to remove the pressure plate. See Figures 18 and 19.

FIGURE 20. REMOVE THE REVERSE CLUTCH

M. Apply compressed air to the port shown in Figure 21.

Remove the reverse piston and seal.

FIGURE 21. REMOVING THE REVERSE CLUTCH PISTON

FIGURE 23. REMOVING THE CAPSCREWS O. Disassemble the planetary gear carrier by removing the six place bolts. Remove the carrier housing from the planetary gears.

N. Remove the 6 place bolts that hold the pinion bearing housing to the transmission housing. Press the pinion assembly and pilot bearing from the transmission housing.

Make sure the assembly is not damaged when it separates from the housing. Keep the shims together. See Figure 22.

P. Remove the six thrust washers from the gears. Slide the planetary gears from the shafts. Keep the gears with the same shafts. Remove the three thrust washers and the shafts. See Figure 24.

Q. To replace the needle bearings in the gears, remove the snap rings. Use a press to remove the bearings.

R. Check the clearance between the thrust washer of the pinion bearing housing and the reverse ring gear. The clearance must be 0.015 inch (0.381 mm) to 0.025 inch (0.635 mm). If the pinion bearing preload or pinion bearings are not changed, the same shims can be used for the wear plate of the carrier hub. See Figure 25.

S. Use a spring scale as shown in Figure 26 or a torque wrench to measure the preload of the pinion bearings. The indication must be 5 to 35 inch pounds (0.56 to 5 N.m). Changing the bearing preload shims changes the clearance of the reverse ring gear. If the preload is correct and the same bearings are installed again, the same shims can be installed. See Figure 26.

FIGURE 22. CAPSCREWS FOR THE PINION BEARING HOUSING

T. To disassemble the pinion carrier assembly, bend the lock plate from the pinion nut. Remove the nut with an air impact wrench. See Figure 27.

FIGURE 25. CHECK THE CLEARANCE HERE

FIGURE 26. CHECKING THE PRELOAD OF THE PINION BEARINGS

FIGURE 24. DISASSEMBLING THE PLANETARY GEAR CARRIER

FIGURE 27. REMOVING LOCK PLATE AND NUT

W. Use a brass drift to remove the bearing cones from the pinion bearing housing.

X. Use a press to remove the bearing cone and the pilot bearing from the pinion.

WARNING The inner race must have support when the pinion is pushed from the bearing.

FIGURE 28. REMOVING PLANETARY GEAR HUB

U. Remove the carrier hub, reverse ring gear, O-rings and thrust washer.

V. Use a press to push the pinion shaft from the bearing cone. Remove the seal, bearing cone, spacer and shims. See Figure 29.

FIGURE 30. CAPSCREWS THAT HOLD CONTROL VALVE

Y. Remove the control valve by removing the five capscrews.

Use a plastic hammer to loosen the valve body from the gasket. To disassemble the control valve, see Assembly.

CLEANING Cleaning the Powershift transmission is a very important part of the repair procedure. Before inspecting the bearings, all oil and dirt must be removed. Use solvent to clean all parts of the transmission. Use compressed air to dry the parts and clean the oil passages.

CAUTION Do not use a cloth to clean the parts. Particles from the cloth can cause restrictions in the oil passages of the transmission.

Make sure all of the gasket material is removed. Any piece of gasket material that is not removed can cause a leak.

FIGURE 29. REMOVING THE BEARING CONE FROM THE PINION SHAFT

INSPECTION A. Inspect the ring and pinion gears for wear or damage. The ring and pinion must be replaced as a set if either is damaged.

Check the spider holes in the differential case for wear. Inspect the spider, spider gears, thrust washers and side gears for wear.

G. Put snap ring pliers in the hub of the torque converter.

Expand the tips of the pliers so that they touch the splines of the inner race of the stator clutch. Quickly turn the pliers counterclockwise. The stator must turn with the inner race and continue to turn counterclockwise after the inner race is stopped. When the pliers are quickly turned in the clockwise direction, only the inner race will turn.

H. Inspect the bore for the turbine shaft in the stator reaction sleeve. Check for grooves on the surface for the metal sealing ring.

I. Inspect the planetary gear teeth for wear or damage.

J. Inspect the clutch pressure plate for damage where the separator plates touch. Replace the pressure plate if the pressure plate has grooves or defects.

K. Check all parts with splines for damage to the splines.

L. Make sure the valve spools in the control valve move freely. The spools and bores must not have scratches or grooves. The edges of the spools must be sharp to keep dirt from getting between the spool and the bore. Do not change the shape of the spools.

ASSEMBLY Assembling The Control Valve FIGURE 31. INSPECT THE DIFFERENTIAL CASE FOR WEAR

B. Visually inspect the races, balls, and rollers of all the bearings. Replace the bearing assembly if any defect is found.

C. Inspect all the thrust washers and wear plates. Wear on thrust washers and wear plates causes clearances to change.

D. Check the bushings, needle bearings and shafts for wear or damage.

E. Make sure the piston return springs are all the same length and not bent.

F. Check the torque converter hub for wear or grooves. Inspect the bore of the end cover for wear.

A. Disassemble the control valve only in an area free of dirt.

Before disassembly, carefully clean the outside of the valve body. Remove all gasket material. To keep the parts in the correct positions, remove, clean and install the valves and springs of one bore before removing the next assembly. Do not disassemble the solenoid. Replace all seals and O-rings.

Make sure the spools move freely in the bores and the drain holes are open.

CAUTION Do not get any grease or oil on the brake fluid seal or bore of the inching spool. Use alcohol to clean the inching spool and bore.

FIGURE 32. CONTROL VALVE

FIGURE 33. LUBRICATION OF INCHING BORE

1. FROM MONOTROL PEDAL 2. “2” SPRING CAVITY DRAIN 3. “3” SPRING CAVITY DRAIN 4. “3” REGULATOR SUMP 5. MODULATION SPRING CAVITY DRAIN 6. TO DIRECTION SPOOL 7. DRAIN FOR FORWARD CLUTCH 8. TO REVERSE CLUTCH 9. TO FORWARD CLUTCH 10. DIRECTION SPOOL INLET 11. FROM SOLENOID VALVE 12. TO SOLENOID VALVE 13. SOLENOID SUMP 14. REVERSE CLUTCH DRAIN 15. TO INCHING VALVE

16. DIRECTION SPOOL SPRING DRAIN 17. CONTROL SPRING DRAIN 18. INCHING DRAIN 19. INCHING VALVE INLET 20. MODULATION VALVE INLET 21. MODULATION PILOT PASSAGE 22. BALANCE SPRING DRAIN 23. HOLES FOR CAPSCREWS 24. DRAIN FOR BRAKE FLUID 25. INLET FROM HOUSING 26. “1” REGULATOR 27. “2” REGULATOR 28. TO TORQUE CONVERTER 29. “1” SPRING CAVITY DRAIN

FIGURE 34. CONTROL VALVE PASSAGES

FIGURE 35. INCHING VALVE

Assembling The Differential NOTE The parts must be completely clean and all gasket material must be removed.

B. If the carrier bearings were removed from the differential case, press the bearings in position. The force must be applied to the bearing race. The bearing cups and cones must be installed as a set.

C. If the ring gear was removed from the differential case put the ring gear in water that is 160 to 180 degrees F (71 to 82 degrees C). After 10 minutes, remove the ring gear from the water and put it on the differential case. Do not use a press or hammer to install the ring gear.

D. Apply Loctite 277 and install the 12 bolts, lock washers and nuts and tighten the nuts evenly to 85 to 115 foot pounds (115 to 156 N.m).

CAUTION Make sure no dirt or metal particles are between the ring gear and differential case.

E. Put the spider gears and thrust washers on the spider. Install the assembly into the differential case. See Figure 37.

F. Align the identification marks on the differential case. Use Loctite 277 on the capscrews and tighten the capscrews to 60 to 75 ft lb (82 to 102 N.m).

G. Press the pinion pilot bearing on the end of the pinion gear.

Press only on the inner race. Use a punch on the end of the pinion gear to hold the bearing in position. See Figure 38.

H. Install the tapered roller bearing with the long rollers on the pinion shaft. Press only on the inner race. See Figure 39.

FIGURE 38. PUNCH MARKS TO HOLD PILOT BEARING

FIGURE 36. ASSEMBLING THE DIFFERENTIAL

I. Install the bearing cup in the pinion bearing carrier with the tapered surface as shown in Figure 39.

J. Install the smaller bearing cup in the bearing carrier as shown in Figure 39.

K. Install the bearing preload shims and spacer on the pinion shaft. Lubricate the bearings and put the threaded end of the pinion shaft through the bearing cups. Install the bearing cone, thrust washer, reaction ring gear, carrier hub and nut.

L. Tighten the nut to 150 foot pounds (203 N.m). Use a spring scale as shown in Figure 43 to measure the resistance to turning. Multiply the reading from the spring scale by 2 to get the turning torque in inch pounds. The carrier must be turning when the reading is taken. The turning torque of the carrier must be 5 to 35 inch pounds (0.56 to 5.3 N.m). If the torque is less than the specification, disassemble the carrier and remove shims. If the torque is greater than the specification, add shims. The shims are available in three thicknesses; 0.020 inch (0.5 mm), 0.007 inch (0.18 mm) and 0.005 inch (0.13 mm).

FIGURE 37. ALIGNING THE IDENTIFICATION MARKS

FIGURE 39. PINION BEARING ASSEMBLY

FIGURE 40. INSTALLING THE SPACER

FIGURE 42. INSTALLING THE REACTION RING GEAR

FIGURE 41. INSTALLING THE BEARING CONF

FIGURE 43. CHECKING THE BEARING PRELOAD

M. When the bearing preload is correct, check the clearance of’ the ring gear between the thrust washer and planetary gear hub. The clearance must be 0.015 to 0.025 inch (0.38 l to 0.635 mm). If the clearance is not correct, change the shims under the wear plate on the reaction ring gear. The shims are available in three thicknesses; 0.020 inch (0.5 mm), 0.007 inch (0.18 mm) and 0.005 inch (0. 13 mm). Use Loctite 290 on the threads of the allen screws. Tighten the screws to 86 inch pounds (9.7 N.m).

N. When the clearance is correct, remove the nut, planetary gear hub and reaction ring gear. Put the O-ring on the end of the planetary gear hub. Put sealant around the outside diameter of the seal. Put a small amount of oil on the lip of the seal.

Install the seal as shown in Figure 46.

O. Install the reaction ring gear, planetary gear hub,lock plate

and nut. Tighten the nut to 150 foot pounds (203 N.m). Bend the lock plate around the nut. See Figure 42.

FIGURE 44. CHECKING THE CLEARANCE

1. THRUST PLATE 2. MOUNTING SCREWS

FIGURE 46. INSTALLING THE PINION SEAL

FIGURE 47. LOCK PLATE AND NUT

FIGURE 45. CHANGING THE SHIMS P. If the needle bearings were removed from the planetary gears, use a press to install the bearings. Lubricate the bearings and press against the end of the bearing that has the writing. Do not use a hammer. Install the snap rings into the grooves in the gears.

R. Install the three long and three short planetary gears. Use a light grease to hold the thrust washers in position on the planetary carrier. Put the planetary carrier over the gears.

Install the capscrews and tighten to 20 foot pounds (27 N.m).

Align the shafts and install the thrust plate. Use Loctite 290 and tighten the screws with an allen wrench to 86 inch pounds (0.97 N.m). See Figure 50.

FIGURE 48. INSTALLING THE PLANETARY GEAR SHAFTS AND THRUST WASHERS

Q. Lubricate with hydraulic oil and install the six shafts and the three double thrust washers. The bronze side of the thrust washer must be toward the planetary gears. See Figures 48 and 49.

FIGURE 50. TIGHTENING THE CAPSCREWS

S. Put an O-ring on the pinion bearing carrier and install the shims that were removed. Install the assembly in the transmission housing. Install the capscrews and tighten to 35 foot pounds (46 N.m).

FIGURE 49. INSTALLING THE THRUST WASHERS

FIGURE 51. CAPSCREWS FOR THE PINION BEARING CARRIER

Complete manual From aservicemanualpdf.com Thank you very much for your reading.

Please Click Here Then Get More Information.