Thissectionhastherepairproceduresforthetransmission.
Thetransmissionserialnumberislocatedonthe rightsideofthetransmissioncontrolvalvedirectly belowthefloorplate.SeeFigure1.
A. EARLYLIFTTRUCKMODELSEXCEPT H4.0FT5/FT6;H4.5FTS5,H4.5FT6;H5.0-5.5FT (H80,90,100,110,120FT)(N005,P005) MODELS
B. NEWERLIFTTRUCKMODELS
Figure1.TransmissionSerialNumber Location
NOTE: Thechargepumpcanberemovedfromthe transmissionwhileitisstillinthelifttruckbut, forthesakeofclarity,thefollowingproceduresare shownwiththetransmissionremovedfromthelift truck.
Removefourmountingcapscrews,washers,transmissionchargepump,andgasketfromthetorque converterhousing.Discardthegasket.SeeFigure2.
Inspectthesplinesontheshaftofthetransmission chargepumpfordamageorwornareasthatcould affecttheoperationofthepump.Ifthesplinesare damaged,replacethetransmissionchargepump.
Installnewgasket,transmissionchargepump,four mountingcapscrews,andwashersinthetorque converterhousing.Tightencapscrewsto19N•m (168lbfin).
NOTE: THETRANSMISSIONISSHOWNREMOVED FROMTHELIFTTRUCKFORCLARITY.
A. EARLYLIFTTRUCKMODELSEXCEPT H4.0FT5/FT6;H4.5FTS5,H4.5FT6;H5.0-5.5FT (H80,90,100,110,120FT)(N005,P005) MODELS
B. NEWERLIFTTRUCKMODELS
1.CAPSCREW
2.CHARGEPUMP
3.GASKET
4.TORQUECONVERTERHOUSING
Figure2.TransmissionChargePump
Makesuretheengineandtransmissionare heldinpositionsothattheywillnotfalland causeaninjuryanddamagetotheequipment.
Becarefulthatyoudonotdamagepartsof thetorqueconverterortransmissionwhen thetransmissionisseparatedfromtheengine. Keepthetransmissionandengineinalignmentuntiltheyarecompletelyseparatedso partsofthetransmissionarenotdamaged. Useacraneorliftingdevicetoseparatethe transmissionfromtheengine.
1. Removetheengineandtransmissionasaunit fromthelifttruck.Seethesection Frame 100 SRM1243forS4.0,4.5,5.5FT,S5.5FTS,(S80, 100,120FT;S80,100FTBCS;S120FTS;S120FTPRS)(G004)andH4.0FT5/FT6;H4.5FTS5, H4.5FT6;H5.0-5.5FT(H80,90,100,110,120FT) (N005,P005)lifttrucks,and Frame 100SRM 1120forS30FT,S35FT,S40FTS(E010);H1.6FT, H1.8FT,2.0FTS(H30FT,H35FT,H40FTS) (F001);S2.0-3.5FT(S40-70FT,S55FTS)(F187); H2.0-3.5FT(H40-70FT)(L177)lifttrucks.
Usecarewhendisconnectingthewiringharnessconnectorsfromelectricalconnectorson thetransmissionandcontrolvalve.Theconnectorsonthetransmissionandcontrolvalve areeasilydamaged.
NOTE: Whendisconnectingwiringharnessconnectorsduringdisassembly,tageachconnectortoaidin connectingthewiringharnessduringreassembly.
2. Puttheengineandtransmissiononsolidblocks onaworksurface.Disconnecttheconnectorsof thetransmissionwiringharnessfromthecontrol valveandtransmission.Removethetransmissionwiringharnessfromthetransmission.See Figure3.
Makesurethattheengine/transmissionassemblyisstablebeforeattemptingtorotatetheengine.
Useaflashlighttoseetheboltsastheyarerotatedintoviewthroughtheaccesshole.Donot useyourfingerstocheckforalignmentofthe boltswiththeaccesshole.
3. Moveeachboltintoviewthroughtheaccesshole oftheflywheelhousingbyrotatingthecrankshaft.Removethefourcapscrewsthatattachthe flywheeltothetorqueconverter.SeeFigure4.
4. Removetheaccesscoverfromthetorqueconverterhousing.Installaliftingeyeboltintothe rearaccesscoverbolthole,andconnectalifting devicetotheeyebolt.Removethe10capscrews thatholdthetorqueconverterhousingtotheflywheelhousingontheengine.Carefullyseparate thetransmissionfromtheengine.
NOTE: Thetorqueconvertercannotberepairedand mustbereplacedasaunit,ifdamaged.
5. Carefullyremovethetorqueconverterfromthe statorsupport.SeeFigure5.
6. Removetheplug,suctionscreenspring,andsuctionscreenfromthetorqueconverterhousing, anddraintheoilfromthetransmission.
7. Removethetransmissionchargepumpand transmissionoilfilterfromthetorqueconverter housing.
NOTE: Step8,Step9,andthe NOTE belowapplytoearlylifttruckmodelsexceptH4.0FT5/FT6; H4.5FTS5,H4.5FT6;H5.0-5.5FT(H80,90,100,110, 120FT)(N005,P005)models.
8. Removethedipstickfromthedipsticktube, anddisconnecttheventtubeassemblyfromthe transmissionhousing.
NOTE: Thedipsticktubemustberemovedbeforethe torqueconverterhousingcanberemovedfromthe frontcoverhousing.
9. Removethedipsticktubefromthetorqueconverterhousing.
A. GM2.4LENGINE
B. MAZDAENGINE
C. YANMARENGINE
D. GM4.3LENGINE
E. ILLUSTRATESNEWDIPSTICKANDBREATHER LOCATIONANDNEWFITTINGDESIGNUSED
ONENGINEANDTRANSMISSIONSSHOWN INILLUSTRATIONSATHROUGHD,EXCEPT WHENDISUSEDONH4.0FT5/FT6;H4.5FTS5, H4.5FT6;H5.0-5.5FT(H80,90,100,110,120FT) (N005,P005)LIFTTRUCKMODELS
F. CUMMINS4.5LDIESELENGINE
1.ACCESSHOLE2.FLYWHEELHOUSING
A.
MODELS
10. Ifdamaged,removethesmallaccesscoverfrom thetorqueconverterhousing.
NOTE: PerformStep11onlyifrepairoftheofthe transmissionchaindriveisrequired.Ifthetransmissionclutchpacksareinneedoffurtherrepair, seeClutchPacksRepair.
11. Remove12capscrewsfromthetransmission housingandfourmountingcapscrewsfromthe frontofthetorqueconverterhousing.Using asmallprybarinthedesignatedprypoints, removethetorqueconverterhousingfromthe frontcoverhousing.DiscardtheO-ringsand gasket.SeeFigure6andFigure7.
1. InstallnewO-ringsandgasketandusingfour capscrews,installthetorqueconverterhousing onthefrontcoverhousingand12capscrewson thetransmissionhousing.Tightencapscrewsto 38N•m(28lbfft).SeeFigure7.
2. Ifremoved,installthesmallaccesscoveronthe torqueconverterhousing.Tightencapscrewsto 7.9N•m(69lbfin).SeeFigure8.
NOTE: TheinformationinStep3andStep4applies onlytoearlylifttruckmodelsexceptforH4.0FT5/ FT6;H4.5FTS5,H4.5FT6;H5.0-5.5FT(H80,90,100, 110,120FT)(N005,P005)models.
3. Cleanthesurfaceofthedipsticktubeanddipstickholeinthetorqueconverterhousing.Apply adhesive(HysterP/N264159)totheentiresurfaceoftheholeinthehousing.Insertthedipstick tubeuntilthecollarbottomsonthehousingand orientthetabagainstthehousingflange.
4. Installthedipstickintothedipsticktube,and connecttheventtubeassemblytothetransmissionhousing.
5. Installanewtransmissionoilfilteronthetorque converterhousing.
6. Installthetransmissionchargepumponthe torqueconverterhousing.Tightencapscrewsto 19N•m(168lbfin).
7. Installthesuctionscreen,suctionscreenspring, andplugintothetorqueconverterhousing.
A. EARLYLIFTTRUCKMODELSEXCEPT H4.0FT5/FT6;H4.5FTS5,H4.5FT6;H5.0-5.5FT (H80,90,100,110,120FT)(N005,P005) MODELS
B. NEWERLIFTTRUCKMODELS
8. Installthetorqueconverterontotheinputshaft andstatorsupportofthetransmission.Make surethesplinesarealignedandtheconverter engagesfully.
9. Lubricatethepilothubonthetorqueconverter withantiseizecompound.SeeFigure8.
10. Ifremoved,installaliftingeyeboltintotherear accesscoverbolthole,andconnectaliftingdevicetotheeyebolt.Alignthetorqueconverter housingwiththeflywheelhousing.Makesure thepilothubonthetorqueconverterengagesthe flywheel.
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Becarefulthatyoudonotdamagepartsof thetorqueconverterortransmissionwhen thetransmissionisjoinedtotheengine.Keep thetransmissionandengineinalignmentuntiltheyarecompletelyjoinedsopartsofthe transmissionarenotdamaged.Useacraneor liftingdevicetojointhetransmissiontothe engine.
11. Installthetransmissiontotheengine.Install
housingtotheflywheelhousing.Tightenthe capscrewsto38N•m(28lbfft).SeeFigure9.
Usecarewhenconnectingthewiringharness connectorstoelectricalconnectorsonthe transmissionandcontrolvalve.Theconnectorsonthetransmissionandcontrolvalveare easilydamaged.
12. Installthetransmissionwiringharnessonthe transmission.Connecttheconnectorsofthe transmissionwiringharnesstothecontrolvalve andtransmission.SeeFigure9.
11.CAPSCREW
12.WASHER
13.SMALLACCESSCOVER
14.TORQUECONVERTER
13. Rotatetheenginecrankshafttopositionthe flywheelmountingholesinlinewiththetorque convertermountingholes.Installthecapscrews thatholdthetorqueconvertertotheflywheel, aftercoatingthethreadswithLoctite™242,
15.TRANSMISSIONCHARGEPUMP
16.STATORSUPPORT
17.PILOTHUB
throughtheaccessholeoftheflywheelhousing. SeeFigure10.Tightenthecapscrewsto56N•m (41lbfft).Removetheliftingeyebolt,andinstall theaccesscoveronthetorqueconverterhousing.
A. GM2.4LENGINE
B. MAZDAENGINE
C. YANMARENGINE
D. GM4.3LENGINE
E. ILLUSTRATESNEWDIPSTICKANDBREATHER LOCATIONANDNEWFITTINGDESIGNUSED
ONENGINEANDTRANSMISSIONSSHOWN INILLUSTRATIONSATHROUGHD,EXCEPT WHENDISUSEDONH4.0FT5/FT6;H4.5FTS5, H4.5FT6;H5.0-5.5FT(H80,90,100,110,120FT) (N005,P005)LIFTTRUCKMODELS
F. CUMMINS4.5LDIESELENGINE
1.ACCESSHOLE2.FLYWHEELHOUS ING
Makesuretheengineandtransmissionare heldinpositionsothattheywillnotfalland causeaninjuryanddamagetotheequipment.
14. Installtheengineandtransmissionasaunitinto thelifttruck.Seethesection Frame 100SRM 1243forS4.0,4.5,5.5FT,S5.5FTS,(S80,100, 120FT;S80,100FTBCS;S120FTS;S120FTPRS) (G004)andH4.0FT5/FT6;H4.5FTS5,H4.5FT6; H5.0-5.5FT(H80,90,100,110,120FT)(N005, P005)lifttrucks,and Frame 100SRM1120for S30FT,S35FT,S40FTS(E010);H1.6FT,H1.8FT, 2.0FTS(H30FT,H35FT,H40FTS)(F001);S2.03.5FT(S40-70FT,S55FTS)(F187);H2.0-3.5FT (H40-70FT)(L177)lifttrucks.
15. Fillthetransmissiontothecorrectlevelusing thecorrecttransmissionfluidandprocedure giveninthesection PeriodicMaintenance
8000SRM1150forS2.0-3.5FT(S40-70FT, S55FTS)(F187);H2.0-3.5FT(H40-70FT) (L177)lifttrucks, PeriodicMaintenance
8000SRM1207forS30FT,S35FT,S40FTS (E010);H1.6FT,H1.8FT,2.0FTS(H30FT, H35FT,H40FTS)(F001)lifttrucks,and PeriodicMaintenance 8000SRM1248forS4.0, 4.5,5.5FT,S5.5FTS,(S80,100,120FT;S80, 100FTBCS;S120FTS;S120FTPRS)(G004)and H4.0FT5/FT6;H4.5FTS5,H4.5FT6;H5.0-5.5FT (H80,90,100,110,120FT)(N005,P005)lift trucks.
WARNING
Makesuretheengineandtransmissionare heldinpositionsothattheywillnotfalland causeaninjuryanddamagetotheequipment.
Keepthetransmissionandengineinalignment untiltheyarecompletelyseparatedsopartsof thetransmissionarenotdamaged.Useacrane orliftingdevicetoseparatethetransmission fromtheengine.
1. Removetheengineandtransmissionasaunit fromthelifttruck.Seethesection Frame 100 SRM1243forS4.0,4.5,5.5FT,S5.5FTS,(S80, 100,120FT;S80,100FTBCS;S120FTS;S120FTPRS)(G004)andH4.0FT5/FT6;H4.5FTS5, H4.5FT6;H5.0-5.5FT(H80,90,100,110,120FT) (N005,P005)lifttrucks,and Frame 100SRM 1120forS30FT,S35FT,S40FTS(E010);H1.6FT,
H1.8FT,2.0FTS(H30FT,H35FT,H40FTS) (F001);S2.0-3.5FT(S40-70FT,S55FTS)(F187); H2.0-3.5FT(H40-70FT)(L177)lifttrucks.
Topreventpossibledamagetothetransmissionassemblywhenplacingtheassemblyona worksurface,placeblocksunderthebackside ofthetransmissionhousingforadditionalsupport.
Usecarewhendisconnectingthewiringharnessconnectorsfromelectricalconnectorson thetransmissionandcontrolvalve.Theconnectorsonthetransmissionandcontrolvalve areeasilydamaged.
NOTE: Whendisconnectingwiringharnessconnectorsduringdisassembly,tageachconnectortoaidin connectingthewiringharnessduringreassembly.
2. Puttheengineandtransmissiononsolidblocks onaworksurface.Disconnecttheconnectorsof thetransmissionwiringharnessfromthecontrol
valveandtransmission.Removethetransmissionwiringharnessfromthetransmission.See Figure11.
1.GM2.4LENGINE
2.CAPSCREW
3.TRANSMISSIONWIRINGHARNESS
4.TRANSMISSION
5.CAPSCREW
6.ACCESSCOVER
7.CONTROLVALVE