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    1300256

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    cristian faundes

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    of 52
    SINGLE-SPEED POWERSHIFT TRANSMISSION (HYSTER T41, T42, T43) REPAIRS S/H1.25-3.00XL (S/H25—60XL) SAFETY PRECAUTIONS MAINTENANCE AND REPAIR ‘When lifting parts or assemblies, make sure that all slings, chains or cables are correctly fastened and that the load being lifted is balanced. Make sure that the crane, cables and chains have the capacity to support the weight of the load. Do not lft heavy parts by hand. Use a lifting mechanism. ‘Wear safety glasses. DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lft trucks. Disconnect the battery ground cable on intemal 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 and working area clean and in order. 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 ori equipment manufacturer. Make sure that all nuts, bolts, snap rings and other fastening devices are removed before using force to remove parts. Always fasten a DO NOT OPERATE sign to the controls of the unit when ‘making repairs or if the unit needs repairs. ‘Make sure you follow the DANGER, WARNING and CAUTION notes in the instructions. Gasoline, Liquid Petroleum Gas (LPG), and Diesel are flammable fuels. Make sure that you 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 has ventilation. CONTENTS INTRODUCTION ...... GENERAL ..... REPAIRS . ‘Torque Converter, Removal ‘Torque Converter, Installation . Front Cover And Transmission Pump, | Removal and Disassembly Front Cover And Transmission Pump, Assembly and Installation . . Clutch Assemblies, Removal and Disassembly . Clutch Assemblies, Inspection Clutch Assemblies, Assembly and Installation .... Differential, Removal and Disassembly Differential, Inspection Differential, Assembly And Installation . CONTROL VALVE ...... Control Valve, Removal and 4 Disassembly Control Valve, Inspection . Control Valve, Assembly and Installation MONOTROL Pedal, Removal and Disassembly MONOTROL Pedal, ‘Assembly and Installation . CHECKS AND ADJUSTMENTS ........- Stall Test .. 28 30 30 Adjustment Of The Direction Control Linkage [S/H1.25—1.75XL (S/H25-35XL) and Earlier Production Models S/H2,00-3.00XL (S/H40-60XL)} ...... 31 ‘Adjustment Of The Brake Pedal And Inching Pedal (Serial Number Codes A177, A187, B10, and Cl) 32 ‘Adjustment Of The Direction Contol Linkage (Serial Number Codes B177, C177, B187, and C187) ‘Test ‘The Direction Control Linkage (Serial Number Codes B177, C177, B187, and C187) ‘Adjustment Of The Inching/Brake Pedal (Serial Number Codes B177, C177, B187, and C187) . [Adjustment Of The Neutral Stat Switch, MONOTROL Pedal (Serial Number Codes BI77, C177, BI87 and C187) 4 ‘Test The Neutral Start Switch, MONOTROL Pedal (Serial Number Codes B177, C177, 35 36 37 BI87 and C187)... 42 Check The Oil Pressures ........00002 42 Check The Relief Valve forthe Transmission Pump . 42 Check The Clutch Pressure . 42 Check The Torque Converter Regulator . 43 Check The Oil Pressure from the Oil Cooler . . a Check The Modulator Pressure . 44 TROUBLESHOOTING ......--+++ “4 ‘TROUBLESHOOTING, PRESSURE TESTS 46 Model ‘This section is for the following models: $1.25-1.75XL ($25-35XL) HL25-1.75XL (H25-35XL) '$2.00-3.00XL (S40-60XL) H2.00-3.00XL (H40-60XL) H2.00-3.00XL (H40-60XL) ‘Serial Code BIO, Later Production CI, Later Production A187, B187, C187, All ‘A177, Later Production BI77, C177, All @HYSTER COMPANY 1990 “THE QUALITY KEEPERS" HYSTER APPROVED PARTS INTRODUCTION GENERAL ‘This transmission design is used in the following lift trucks: ‘TA1: S/HI_.25-1.75XL (S/H25~35XL) T42: $2.00-3.00XL ($40-60XL) ‘743: H2.00-3.00XL (H40-60XL) ‘The operation and intemal parts of the three transmis- sions are the same. The differentials for the three trans- missions are different, but the repair procedures are sim- ilar. ‘Some lift trucks, $/H1.25-1.75XL (S/H25-35XL) and H12,00-3.00XL (H40-60XL), manufactured before 1985 have a different powershift transmission. This powershift transmission is easily identified because it hhas an oil filter on the left side of the transmission case. HOUSING, TORQUE CONVERTER ‘TRANSMISSION PUMP HOUSING, FORWARD CLUTCH |. FRONT COVER 5, FORWARD HUB AND GEAR, 6. CONTROL VALVE 7. OUTPUT GEAR 8. RING GEAR See the section, SINGLE-SPEED POWERSHIFT ‘TRANSMISSION, 1300 SRM 75 for information on this earlier production transmission, The T4143 series of powershift transmissions have an oil filter on top of the transmission control valve as shown in FIGURE 1. ‘This section has the repair procedures for the following parts of the transmission: the oil pump, clutch assem- bilies, control valve and the differential. The torque con- verter cannot be repaired. ‘The engine and transmission are normally removed as a unit for repairs. The engine can be removed separately for repairs. See the section, THE FRAME, 100 SRM 254 for the procedures to remove and install the engine and transmission, See the section, SINGLE-SPEED POWERSHIFT TRANSMISSION (DESCRIP- TION AND OPERATION), 1300 SRM 255 for addi- tional information on the operation of this transmission. 1. PINION ‘TRANSMISSION HOUSING REVERSE HUB AND GEAR REVERSE CLUTCH DIFFERENTIAL HOUSING FIGURE 1. TRANSMISSION HOUSING, TORQUE CONVERTER . IMPELLER, TURBINE STATOR STATOR CLUTCH . TRANSMISSION PUMP ”. FORWARD CLUTCH HOUSING . FORWARD CLUTCH |. HUB AND GEAR, FORWARD " SENonsens 40 32 NOTE: REVERSE res | 7 "8 CLUTCH IS SHOWN = OUT OF ITS NORMAL, 3 ! POSITION. 10. CONTROL VALVE : 11. FILTER Ui Jee S 42, OUTPUT GEAR Se 13. PINION ASSEMBLY Ce 14. RING GEAR 18. DIFFERENTIAL HOUSING 16. TRANSMISSION HOUSING 17. HUB AND GEAR, REVERSE 18. CLUTCH, REVERSE 19. CLUTCH HOUSING, REVERSE 20. FRONT COVER: 21. SCREEN 20 19 18 «417 '$2.00-3,00XL (S40-60XL) model shown FIGURE 2. TRANSMISSION REPAIRS Put the engine and transmission on blocks on a work sur- face. Remove the capscrews that hold the torque conver- ter housing to the engine. A WARNING Make sure the engine and transmission ae held so that they will not fall and cause an injury and dam- age to the equipment. A cauTION Be careful that you do not damage parts of the torque converter or transmission when the transmission is, separated from the engine, Keep the transmission and engine in alignment until they are completely separated so that parts of the transmission are not, damaged. Use a crane or lifting device to separate the transmission from the engine. Torque Converter, Removal (See FIGURE 3.) Remove the capscrews that hold the drive plate to the flywheel and remove the torque converter. Remove the capscrews and remove the drive plate from the torque converter. Torque Converter, Installation 1. Lubricate the pilot hole in the flywheel and the pilot hhub on the torque converter with anti-seize compound, 2. Tighten the capscrews that hold the torque converter to the drive plate to 45 N.m (33 Ibf ft). 3, Install the torque converter on the transmission, Make sure the two tabs on the hub of the torque converter are correctly engaged with the oil pump. A CAUTION The oil pump for the transmission can be damaged if the torque converter hub is not correctly engaged with the oil pump. When the flywheel housing and torque converter housing are joined, check the clear- ance between the drive plate for the torque converter and the flywheel before any bolts are installed. If the pilot hub on the torque converter is correctly en- gaged, there willbe approximately 2 0 7 mm (0.08 to 0.25 in) clearance between the drive plate for the torque converter and the flywheel. If the drive plate is against the flywheel and there is still a space be- tween the two housings, do not continue the installa- tion until the problem is corrected. TORQUE CONVERTER FLYWHEEL, |. PILOT HUB DRIVE PLATE HOUSING, TORQUE CONVERTER ‘TABS FOR TRANSMISSION PUMP ‘THERE MUST BE A CLEARANCE OF 2 to 7 mm (0.08 to 0.25 in) AT A BEFORE THE CAPSCREWS ARE INSTALLED TO. FASTEN THE HOUSINGS TOGETHER AT B. FIGURE 3. TORQUE CONVERTER, MOUNTING 4, Install the transmission on the engine. Check the clearance between the drive plate for the torque conver- ter and the flywheel. Install the capscrews that hold the torque converter housing to the flywheel housing. ‘Tighten the capscrews to 38 N.m (28 Ibf ft. 5. Slide the torque converter to the flywheel and align the holes for the bolts. Install the capscrews that hold the drive plate to the flywheel. Tighten the capscrews to 45 'N.m (33 Ibf fi) Install the cover on the torque converter housing. Front Cover And Transmission Pump, Removal and Disassembly (See FIGURE 5.) NOTE: It is not necessary to remove the torque conver- ter housing to remove transmission pump from the transmission. If the transmission pump is removed be- cause the transmission must be disassembled for re~ pairs, then remove the torque converter housing before removing the transmission pump. 1. The input shaft is part of the FORWARD clutch, The transmission pump must slide over the input shaft when it is removed. The transmission pump fits into a pilot bore. Sometimes a soft hammer or a hammer and wood drift must be used to loosen the transmission pump. Re- move the transmission pump from the front cover. 2, Remove the two screws that hold the pump rotor in the pump body. Disassemble the transmission pump by re- moving the pump rotor and stator support from the pump body. 3, Remove the plugs and regulator valves from the front cover. Make notes so that the parts can be assembled again in the correct position, 4:The front cover is held in alignment with the transmis- sion housing with dowel pins. Use a soft hammer to loosen the front cover from the transmission housing. Do not use a pry bar between the sealing surfaces or you will cause oil leaks. Remove the front cover from the transmission housing. Front Cover And Transmission Pump, Assembly and Installation 1. Install the relief valves and plugs in the front cover. Make sure the parts are installed in the correct ports. Make sure the ball bearings are installed correctly on the clutch shafts. 2. Install the front cover using a new gasket and a gasket sealant, Install the M10 x 1.5 capserews and tighten them to 38 N.m (28 Ibf ft). 3. Install the torque converter housing. ‘Tighten the M10 x 1.5 capscrews to 38 N.m (28 Ibf ft). 4, Use a sealant on the outside diameter of the seal, then install a new oil seal in the transmission pump for the stator support. Install an O-ring on the circumference of the pump body. Install the stator support and the rotor for the transmission pump. 5. Install the transmission pump on the front cover. Tighten the capscrews to 19 N.m (14 Ibf ft FIGURE 4. INSTALLATION OF THE, ‘TRANSMISSION PUMP SCREEN TEMPERATURE SENSOR 1 2 3. TO THE OIL COOLER, 4. CHECK PORT, TORQUE CONVERTER PRESSURE 5. CHECK PORT, TRANSMISSION PUMP PRESSURE 6 . RELIEF VALVE, TRANSMISSION PUMP FIGURE 5. FRONT COVER OF THE TRANSMISSION ‘The FORWARD clutch assembly is shown in the photo- ‘graphs for this procedure. The procedure is similar for removal and disassembly of the REVERSE clutch as- sembly. Clutch Assemblies, Removal and issembly (See FIGURE 7.) NOTE: If the transmission pump does not require disas- sembly, the front cover and transmission pump can be removed from the transmission housing as a single unit. 1. CLUTCH HOUSING 2. CLUTCH PISTON 3, PISTON SEAL 4, O-RING 5. CLUTCH SPRING 6 7, 8. . RETAINER, SPRING. ‘SNAP RING . BALL BEARING 9. SEAL RING (3) 10. SEPARATOR DISC (5) 11. FRICTION DISC (5) 12, REACTION RING. 13. SNAP RING 14, HUB AND GEAR 45. BALL BEARING. 46. THRUST WASHER 17. THRUST NEEDLE BEARING (2) 48. THRUST WASHER (2) 19. SNAP RING 20. THRUST WASHER to 1 21. NEEDLE BEARINGS, HUB NOTE: See Step 4 of FIGURE 8. for the needle bearing arrangement for the hub and gear. FIGURE 6. CLUTCH ASSEMBLY STEP1. Remove the torque converter housing. Remove the transmission pump and front cover from the transmission hous- ing as a unit. If the transmission pump and front cover must be disassembled, remove the oll pump from the front cov- 1. TRANSMISSION HOUSING 2. FORWARD CLUTCH ASSEMBLY 3. REVERSE CLUTCH ASSEMBLY 4. OUTPUT GEAR, STEP 2. Pull the FORWARD clutch assembly straight from the transmission housing, Remove the REVERSE clutch assem- bly. Do not damage the seal rings on the end of the clutch shafts. NOTE: Do not remove the output gear from the pinion shaft unless the differential must be re- paired. STEP 3. |. HUB AND GEAR THRUST BEARING ASSEMBLY SNAP RING) REACTION RING. SNAP RING. SEAL RINGS. It the ball bearing did not stay in the transmission case, remove it from the clutch shaft. Remove the special thrust washer. Remove the snap ring, thrust washers, and thrust needle bearing, Re- ‘move the hub from the clutch assembly. Remove the large enap ring, then re~ ‘move the reaction ring. Remove the fric- tion disos and separator plates. 1 sso 1. THRUST BEARING ASSEMBLY 2. NEEDLE BEARINGS STEP 4. Remove the needle bearings from the shaft. Remove the other sel of thrust washers and thrust needle bearing, FIGURE 7. REMOVAL AND DISASSEMBLY OF CLUTCH ASSEMBLIES (1 OF 2) 1. PUNCH 2. SNAP RING 3. SPRING RETAINER 4. PISTON A WARNING “The spring fr the elute a compressed, Make sure the spring and spring retainer are not suddenly released ry when the snap ring ie removed. and eam STEP 5. Remove the piston only if there is a problem with the piston or seals. Use two punches to push the spring reteiner down. Remove the snap ring for the re- tainer. Remove the retainer, spring and piston. A CAUTION ‘Some service technicians make a special bracket so that the spring and retainer can be com- pressed in a press to remove the snap ring. The snap ring can also be removed by one person while another person compresses the spring and retainer. STEP 6. Pull the piston from the clutch housing. Remove the seal from the citcumfer- tence of the piston and the O-ring from the shaft. NOTE: Some service technicians put the rubber tip of a low pressure air nozzle in the oil passage at the tend of the olutch shaft to remove the piston. Apply air pressure to remove the piston from the clutch housing. FIGURE 7. REMOVAL AND DISASSEMBLY OF CLUTCH ASSEMBLIES (2 of 2) Clutch Assemblies, Inspection 1. Inspect the gears for the clutch assemblies and the dif- ferential gears for wear or damage. 2. Check all parts that have splines for damage to the splines. Check for notches worn in the splines. 3, Inspect the friction discs for bumed lining or bent sur- faces. Check for small holes in the lining. Replace the friction discs if one-half the depth of the oil grooves are ‘worn away or the discs are damaged. Discard a friction disc that has a thickness less than 1.57 mm (0.060 in). 4, The separator plates must not be bent, have damaged surfaces, or have large blue areas from too much heat. 5. Inspect the bearings for wear or damage. 6. Inspect the piston for damage. Make sure that the seal- ing surfaces are good. Make sure the orifice is clean. 7. Check for grooves or other damage on the machined surfaces of the shaft. Check the seal rings for damage and wear, Check the seal ring surfaces in the housing for damage. Clutch Assemblies, Assembly and Installation 1, PISTON SEAL 2. PISTON STEP 1. Lubricate all parts with transmission cil, instal the O-ring on the shaft and the seal in the piston. The lip of the seal must be towards the clutch hous- 1. PISTON 2. CLUTCH HOUSING Puta strong rubber band on the piston seal to compress the lip of the piston seal for approximately 15 minutes. Re- move the rubber band and quickly in- stall piston in the clutch housing before the lip seal expands. Make sure the pis- ton seal is not damaged during installa- tion. A damaged piston seal will prevent the correct operation of the transmission and will require complete disassembly again for repairs. STEP 2. STEP 3. 1. SNAP RING. 2. SPRING RETAINER Install the spring and retainer in the clutch housing. Compress the spring so that the snap ring can be installed. install the snap ring that holds the retainer on the shaft, FIGURE 8. ASSEMBLY AND INSTALLATION OF A CLUTCH ASSEMBLY (1 of 4) 1, NEEDLE BEARINGS (HUB)* STEP4. install the thrust washer assembly on the clutch shaft (see the needle bearing arrangement. Install the two sets of needle bearings for the hub on the shaft. “NOTE: On some transmissions, a one-piece needle bearing in a nylon cage (item 4) was used ‘and the two thrust washers (item 3) were a spe- cial design for this bearing. Ifthe thrust washers or the one-piece needle bearings are damaged or worn, these parts must be replaced with the fol lowing part numbers: (2) THRUST WASHER, Part No. 347767 (2) NEEDLE BEARINGS, Part No. 334454 ARRANGEMENT OF NEEDLE BEARINGS IN BPs 6 1 29 THECLUTCH THRUST WASHER: . THRUST NEEDLE BEARING |. THRUST WASHER* NEEDLE BEARINGS (HUB)* ‘SNAP RING THRUST WASHER CLUTCH SHAFT 1. HUB AND GEAR STEP 5. Install the hub and gear on the clutch shaft. Install the second thrust washer and thrust needle bearings. Install the snap ring. See the thrust washer anc thrust bearing arrangement in step 4 NOTE: Make sure the orientation of the cage of the thrust needle bearing and the snap ring is the ‘same as shown in the arrangement in step 4. STEP 6. Install the separator plates (5) and frc- tion discs (5). Begin with a separator plate against the piston and finish with a friction disk against the reaction ring FIGURE 8. ASSEMBLY AND INSTALLATION OF A CLUTCH ASSEMBLY (2 of 4) 10 Install the seal rings. The FORWARD clutch has one seal ring on the input shaft and two seal rings on the output end of the clutch shaft. The REVERSE clutch only has two seal rings on the ‘output end of the clutch shart. STEP 9. 1. REACTION RING. STEP 7. Install the reaction ring STEP 10. Install the ball bearings on the end of the clutch shaft that goes into the front cover of the transmission. Install the seal rings on the shaft. STEP 11. Make sure the special thrust washer is installed after the snap ring as shown in step 4. Install the balll bearing in the transmission housing. 1. FORWARD CLUTCH ASSEMBLY STEP 8. 2, REVERSE CLUTCH ASSEMBLY Install the snap ring. After assembly is ‘complete, there must be 0.64 to 2.74 mm (0.025 to 0.108 in) clearance in the STEP 12. Install the FORWARD and REVERSE clutch assembly. Put a straight edge across the clutch housing and measure the movement of the reaction ring in the clutch housing. clutch assemblies in the transmission housing. Make sure that the seal rings are not damaged when the clutch shafts are installed in the transmission housing. FIGURE 8, ASSEMBLY AND INSTALLATION OF A CLUTCH ASSEMBLY (3 of 4) STEP 13. Install the front cover. Use a new gasket and use gasket sealant on the metal sur- faces. Tighten the capscrews to 38 N.m (28 Ibt tt), STEP 15, Install he torque converter housing ‘on the transmission housing. Tighten the capscrews to 38 N.m (28 lft). ‘STEP 14. Install the O-ring and the oil pump on the front cover. Tighten the capscrews to 419 N.m (14 lof ft). STEP 16. Install the oil screen, spring and pug in the transmission housing. FIGURE 8. ASSEMBLY AND INSTALLATION OF A CLUTCH ASSEMBLY (4 of 4) Differential, Removal and Disassembly (See FIGURE 9.) 1. Disassemble only the parts of the differential that must be repaired. If the ring gear and pinion are not to be replaced, check the contact patter before disassembly ‘The pattem and gear clearance are used as references for assembly, See the Differential, Assembly And Installa- tion section for the procedures. NOTE: Two types of nuts have been used on the pinion shaft, Early models have a “prevailing torque nut” while later models use a stake nut and hardened washer. Fol- ow disassembly and assembly procedures carefully. 2. Loosen the nut for the output gear. When a stake nut is used, use a tool to remove the punch mark from the groove of the pinion shaft. The nut is tightened to 750 Nam (553 Ibf ft). NOTE: Some service technicians make a special tool from a discarded gear to hold the output gear when the nut is being installed or removed from the pinion shaft. 2 3, Loosen the thrust bolt for the ring gear. Remove the bearing caps, adjusting nuts and the differential assem- bly. 4, Use a hammer and soft driver to remove the pinion from the output gear and the transmission housing. Make a note of the shim and spacer arrangement. Ifthe pinion will not be replaced, the shim and spacer arrange- ment will be approximately the same when the differen- tial is assembled again, 5, Remove the bearings, oil seal, shims, and spacer from the transmission housing. 6, Remove the differential housing from the transmis- sion housing. 7. Disassemble the differential as needed to make re- pairs. Remove the ring gear from the differential case. Remove the bolts from the differential halves and re- move the spider gears and axle gears. 5 9 12 ASL | 1108 " PINION ‘STAKE NUT OUTPUT GEAR BEARING ‘SPACER, OIL SEAL OIL SEAL ‘SHIMS SPACER ‘SPACER BEARING RING GEAR DIFFERENTIAL HOUSING, TRANSMISSION HOUSING GAUGE DISTANCE =121 mm (4.72 in) HARDENED WASHER h 10 ZSeenepae po 12. 13. . BEARING. PINION PREVAILING TORQUE NUT OUTPUT GEAR BEARING SPACER, OIL SEAL OIL SEAL SHIMS, SPACER RING GEAR DIFFERENTIAL HOUSING ‘TRANSMISSION HOUSING GAUGE DISTANCE = 129 mm (6.04 in) FIGURE 10. DIFFERENTIAL $2.00-3.00XL (S40-60XL) 1. PINION 2. PREVAILING TORQUE NUT 3. OUTPUT GEAR 4. BEARING 5. SPACER, OIL SEAL 6. OIL SEAL 7. SHIMS: 8. BEARING 9. BEARING 0. RING GEAR 1. DIFFERENTIAL, HOUSING, 12, TRANSMISSION HOUSING) 18. GAUGE DISTANCE = 155 mm (6.05 in} FIGURE 11. DIFFERENTIAL H2.00-3.00XL (H40-60XL) Differential, Inspection 1. Check the pinion and ring gear for wear. Inspect the spider gears and axle gears for wom teeth. Inspect the cross for wear where the gears tum. The cross and the holes for the cross in the differential case must fit tightly. 2. Check all bearings for wear and damage. Use new parts as necessary. Differential, Assembly And Installation NOTES: 4 If the ring gear and pinion are worn or damaged, they must be replaced as a set, Always check that the gears are a set. The location of the marks are shown in FIGURE 12. There are two designs of ring and pinion gear sets used in these differentials. The designs are simi- Jar in appearance, but there is a variation in the adjustments between the ring and pinion set. ‘The ‘manufacturer calls the earlier design aconven- tional hypoid gear set” or “conventional gear set”. A later design is called a"Generoid gear set”. ‘* Examples of part numbers for gear sets: Conven- tional ring gear, 36786. Conventional drive pit ion, 36787. The last digit in the part numbers for Generoid gear sets is a letter or a letter and a num- ber. Generoid ring gear, 36786 K or 36786 K2. Generoid drive pinion, 36786 K or 36785 K2. an 2,3 1,2,3,4 1. PART NUMBER 2. TOOTH COMBINATION NUMBER, 3. IDENTIFICATION NUMBER FOR GEAR SET 4, VARIATION NUMBER FOR PINION CONE. FIGURE 12. POSSIBLE LOCATIONS OF IDENTIFICATION NUMBERS FOR GEAR SETS © A537 gear set has a S-tooth pinion and a 37-tooth ring gear. ‘© Both gears of a set have an identification aumber. ‘An example of this number for a gear set: M29. ‘When a new ring and pinion assembly is ‘The pinion cone variation number is used to ad- just the the depth of the pinion in the carrier. This procedure is described in the following para- graphs. The pinion cone variation numbers can be indicated in hundredths of millimetres or thou- sandths of an inch. If the pinion cone variation number is indicated, as examples: +01 or -.02, the measurement is in millimetres. If the pinion cone variation number is indicated, as examples: +3 or-5, the measurement is in thousandths of in- ches. The pinion cone variation number is nor- ‘mally indicated on the end of the gear head of the pinion or on the outer diameter of the ring gear. See FIGURE 13. FIGURE 13. PINION CONE VARIATION NUMBER stalled: ‘The pinion and ring gear are made in sets. Both the ring gear and pinion must have the same num- bers. When pinion bearings are replaced or the ring gear and pinion are replaced, the shim ar- rangement must be adjusted for the new parts. Most service technicians do not have the equip- ‘ment used by the manufacturer to find the shim arrangement before the differential is assembled. Service technicians must often make more than ‘one adjustment before the clearances are correct. ‘The differential must be disassembled for adjust- ‘ment and assembled again for checks. The adjust- ‘ments are correct when the gear clearance and the contact pattern between the pinion and ring gear are correct and the preload on the pinion bearings is correct. ». Look atthe pinion cone variation number on the pinion that is being replaced. ‘The dimension on the end of the pinion is the vari- ation from the standard Gauge Distance. The Gauge Distance is the distance from the center of the ring gear to the bearing shoulder behind the pinion, (See FIGURE 9., FIGURE 10., or FIGURE 11.) Shims must be added, or removed from between the pinion and the outer bearing to adjust for manufacturing tolerances. ¢. Look at the number on the pinion that was re- moved. Subtract variation number that is on the new pinion, The remainder is the amount of shim thickness that must be adjusted from the shim set on the pinion that was removed. (See FIGURE 14. for examples. In examples 3 and 4 you can see that a negative number shows that shims must be removed.) Examples 1 and 2 show that shims must be added to the original shim set. Use this shim set as a reference. The final adjust- ‘ment of the shim set is according to the contact, pattern on the ring gear teeth. See FIGURE 32. EXAMPLES Number on OLD PINION minus the number on the NEW PINION ‘SHINS tobe REMOVED FROM oF JADED TO the OLD SET EXAMPLES 3 ‘Number an OLD PINION minus the | + 0.26 umber on the NEW PINION. | (40.31) ‘SHIMS 19 be REMOVED FROM oF | —0.05 mm ADDED TO the OL SET. REMOVE FIGURE 14. ADJUSTMENT OF THE SHIMS FOR ‘THE PINION ASSEMBLY Installation of the pinion assembly: a, Install the shims on the pinion, Use a press to in- stall the shims, bearing cone, and spacers on the pinion, (See FIGURE 15.) The three arrange ments of the pinion assemblies are shown in FIGURE 9,, FIGURE 10., or FIGURE 11 15 - PINION BEARING CONE SPACER SHIMS . SPACER, OIL SEAL 6. PRESS. $2.00-3.00XL (S40-60XL) PINION ASSEMBLY SHOWN FIGURE 15. USE A PRESS TO INSTALL THE PARTS ON THE PINION b. Ifa new pinion is being installed, use a press to install the pilot bearing. The pilot bearing is held in position by five punch points. Use the press and a punch to form the metal and fasten the pilot bearing into position. See FIGURE 16. €. Install a new oil seal in the transmission housing. Install the bearing cups in the transmission hou ing. Make sure the spacer is installed behind the outer bearing cup for the pinion on the S/ HI.25-1.75XL (S/H25-35XL) transmission. In- stall the pinion in the transmission housing. In- stall the inner bearing cone on the pinion. Install the output gear, NOTE: On early models, a special nut called a “prevail- ing torque nut” is used on the end of the pinion shaft. Do ‘ot install the prevailing torque mut until the adjustments of the pinion are complete. Do not use a prevailing torque nut that has been removed. Use a new prevailing torque nut when the pinion assembly has been disas- 16 sembled. The installation and removal of the prevailing torque nut several times for adjustments will damage the threads om the pinion shaft so that the locking function of the nut will be destroyed. Ifthe threads are damaged on the pinion shaft, a new pinion and ring gear must be installed, (A standard 1-1/2 18 UNEF-2B nut is often not normally available from a supply in your werk area. Hyster Part Number 242882 can be used as the nut for making adjustments.) 1. PRESS 2. PUNCH 3. PILOT BEARING 4. SUPPORT TUBE FIGURE 16, FASTEN THE PILOT BEARING INTO ITS POSITION IN THE PINION 4d. Measure the preload on the pinion bearings. In- stall a standard 1-1/2 18 UNEF-2B nut (carly models) or te stake nut and washer (late models) and tighten the nut to 750 N.m (553 Ibf ft) to check the adjustments. Check the rotating torque of the pinion. The correct rotating torque is 1.2 0 3.4 N.m (10 to 30 Ibf in). €. Add or subtract shims to adjust the preload on the pinion bearings. Only when all the adjustments are correct, do the following: EARLY MODELS: Remove the standard nut and install the prevailing torque nut. Tighten the nut 10.750 N.m (553 Ibf ft). LATE MODELS: Tighten the stake nut to 750 N.m ($53 Ibf ft). Use a punch to push the flange of ‘the nut into the bottom of the groove in the shaft. 1, TORQUE WRENCH 2. OUTPUT GEAR FIGURE 17. INSTALLATION OF THE NUT FOR ‘THE PINION f, Use an adhesive sealant and install the differen- tial housing on the transmission housing. Tighten the capscrews to 38 N.m (28 Ibf ft). Assemble the differential and ring gear assembly (See FIGURE 18,): If the ring gear was removed from the differential ‘case, put the ring gear in hot water that is 82 to105°C (180 to 220°F)] for approximately 10 minutes. Remove the ring gear from the water and put it on the differential case. Do not use a press or a hammer to install the ring gear. Apply Loctite® 277 to the threads of the bolts or place bolts. Early model H2.00-3.00XL (H40-60XL) ‘units use bolts, lock washers and nuts. Tighten the nuts to 95 Nim (70 Ibf fi). Late model H2.00-3.00XL (H40-60XL) units use place bolts. Tighten the place bolts to 142 N.m (105 Ibf fi). The other two series of lift trucks use place bolts. Tighten the place bolts on the S/H 1.25-1.75XL (S/H25-35XL) and $2.00-3.00XL (S40-60XL) to 111 N.m (80 bf ft) DIFFERENTIAL ASSEMBLY CASE WASHER, SIDE GEAR (2) |. SIDE GEAR, DIFFERENTIAL, THRUST WASHER (4) SPIDER GEAR (4) ‘SPIDER (CROSS) . CAPSCREW (8) WASHER (8) RING GEAR AND PINICN BOLT (12) . WASHER. HARDENED (12) FIGURE 18. DIFFERENTIAL ASSEMBLY "7 a. Lubricate and install a side gear and thrust washer in the differential case as shown in FIGURE 19. 1. SIDE GEAR 2. THRUST WASHER 3. DIFFERENTIAL FIGURE 19. INSTALL A THRUST WASHER AND SIDE GEAR b. Install the spider (cross), differential pinions and thrust washers into the differential half as shown in FIGURE 20. . SPIDER, DIFFERENTIAL Bn PINIONS, AND (25, THRUST FIGURE 20. INSTALL THE SPIDER (CROSS), DIFFERENTIAL PINIONS AND THRUST WASHERS c, Install the second side gear and thrust washer ‘over the spider and differential pinions as shown in FIGURE 21. 18 1. SIDE GEAR 2. THRUST WASHER 3. DIFFERENTIAL HALF | FIGURE 21. INSTALL THE SECOND SIDE GEAR AND THRUST WASHER 4. Put the second half ofthe differential case over the first half and the gears as shown in FIGURE 22. Make sure the alignment marks are aligned. DIFFERENTIAL HALF ALIGNMENT FIGURE 22. INSTALL THE SECOND HALF OF ‘THE DIFFERENTIAL CASE . Install four capscrews in a cross pattern as shown in FIGURE 23. Tighten the capscrews to71 N.m (52 Ibf ft) on the H40-60XL and 50 N.m (37 Ib ft) on the S/H 1.25-1.75XL (S/H25-35XL) and '$2,00-3.00XL (S40-60XL). Install the remain- der of the capscrews and tighten them in a cross pattern, FIGURE 23. TIGHTEN THE CAPSCREWS IN A. ‘CROSS PATTERN f, Install the bearing cones on the differential case. See FIGURE 24. FIGURE 24. INSTALLATION OF THE BEARING CONES g. Apply axle lubricant on the inner diameter of the bearing cups and on both bearing cones that are installed on the differential. Do not permit lubri- ‘cant on the outer diameter of the bearing cups or the bearing bores of the differential housing. 1h, Install the differential assembly into the differen- tial housing, See FIGURE 25. The bearing cups must fit correctly into the bores of the bearing carriers. 1. BEARING CUP 2. BEARING CARRIER FIGURE 25. INSTALL THE DIFFERENTIAL. ASSEMBLY INTO THE CARRIER Install the two bearing adjusting nuts into posi- tion in the carrier bores. See FIGURE 26. Use your hand to tighten each adjusting nut against the bearing cup. 4. ADJUSTING NUT. 2. BEARING CARRIER FIGURE 26. INSTALL THE ADJUSTING NUTS. js Align the marks on the bearing caps with the marks on the housing, See FIGURE 27. Only tighten the capscrews forthe bearing caps so that the adjusting nuts can be installed, held in align- ment, and rotated for adjustment. » 1. BEARING CAP 2. ALIGNMENT MARKS. FIGURE 27. INSTALL THE BEARING CAPS k. Tighten the adjusting nuts to 14 N.m (10 Ibf ft) to remove the clearance between the adjusting nuts and the bearings, Make sure there is clearance be- tween the ring gear and pinion. Loosen the ad- jjusting nut only until there is zero clearance be- tween the bearings and the adjusting nuts. Tight- en one adjusting nut four notches more than zero Clearance to put a preload on the bearings. 1. RING GEAR . BEARING CAP. 3. ADJUSTING NUT FIGURE 28. THE INSTALLATION OF THE. BEARING CAPS AND ADJUSTING NUTS 1. Check the clearance between the ring gear and pinion. The ring gear and pinion must have a clearance of 0.20 to 0.28 mm (0.008 to 0.011 in). (See FIGURE 29.) Move the ring gear towards the pinion to decrease the clearance. Move the ring gear away from the pinion to increase the 20 clearance. Loosen one adjusting nut the same amount as the other adjusting nut is tightened to adjust the clearance between the ring gear and pinion. FIGURE 29. CHECK THE CLEARANCE BETWEEN THE RING GEAR AND PINION ‘m, Install an adapter so that you can rotate an axle gear with a torque wrench. Check the rotating torque of the ring gear. (See FIGURE 30.) The rotating torque must be 2.9 to 3.9 N.m (26 to 35 bf in). Loosen or tighten the adjusting nuts to ad- just the correct rotating torque. Tighten the bolts for the bearing caps to 110 N.m (80 Ibf ft) on the S/H1.25-1.75XL—(S/H25-35XL)_— and '$2.00-3.00XL (S40-60XL) and to 250 Nam (185 Ib ft) on the H2,00-3.00XL (H40-60XLi. FIGURE 30, CHECK THE ROTATING TORQUE, OF THE RING GEAR nn. Check the pattem on the teeth of the ring gear by applying grease to the teeth, Put a prybar between the ring gear and the housing to keep the rng gear from turning freely. Turn the pinion shaft. Ifthe gear set is a conventional hypoid type, compare the pattem on the ring gear teeth with the pattems shown in FIGURE 32. If the gear set is a Gener- oid type, compare the pattern on the ring gear teeth with the pattems shown in FIGURE 33. Ad- just the gear clearances as necessary. The contact pattems between the two types of gear sets are similar, but the Generoid gear set will normally indicate a larger contact pattern on the gear tooth when the adjustment is correct. ‘An adjustment of the pinion to move the contact, pattern also normally requires an adjustment of the ring gear clearance as described in step n. Install the retainers for the adjusting nuts. Some differentials have a lock plate for each adjusting nut, Tighten the capscrews to 19 N.m (14 Ibf ft). See FIGURE 31. Other differentials can have a special cotter pin or a roll pin used as a retainer. Always use same type of retainers that was origi- nally installed by the manufacturer. Install the thrust bolt, Tighten the thrust bolt until it touches the ring gear. Loosen the bolt until there is 0.25 to 0.38 mm (0,010 to 0.015 in) clearance between the bolt and the ring gear. Tighten the Jock nut to 68 to 95 N.m (50 to 70 Ibf ft. 2. ROLL PIN 3. LOCK PLATE 4, THREADED HOLES WHEN LOCK PLATE IS USED FIGURE 31. INSTALL THE RETAINERS NOTE: If adjustment of the thrust bolts required when the differential is installed, turn the thrust bolt clockwise until it contacts the ring gear. Then loosen the thrust bolt counterclockwise 1g of a turn. Tighten the lock nut a 2 CONTACT PATTERN, CONVENTIONAL HYPOID GEAR SET STEP 1. Apply a colored dye or grease to approximately 12 of the ring gear teeth. Apply a small friction load to the edge of the ring gear so that the ring gear does not turn easily. Rotate the ring gear one revolution by turning the pinion. Check the tooth contact pattern on the ring gear. Make sure that the pattern is checked on the side of the tooth where the pinion applies the force. NORMAL PALIERN. DURING ADJUSTMENT PATTERN WHEN IN LIFT TRUCK ‘The contact area is the center between the top and the bottom of the tooth. The contact area is toward the inner circumference of the ring gear. The contact area is the center between the top and the bottom of the tooth. The contact area will be almost the full length of the tooth. WRONG TOOTH CONTACT The pinion is too far away from the center of the ring gear. ‘Add shims to move pinion toward ring gear. Check that the clearance is Correct. Some movement of ring gear The pinion is too close to the center of the ring gear. Remove shims to move pinion away from the ring gear. Check that the clearance is correct. Some movement of the ring gear ‘away from the pinion can be necessary. toward the pinion can be necessary. FIGURE 32. ADJUST THE RING GEAR AND PINION TOOTH CONTACT. CONTACT PATTERN, GENEROID GEAR SET STEP 1. Apply a colored dye or grease to approximately 12 of the ring gear teeth. . Apply a small friction load to the edge of the ring gear so that the ring gear does not tum easily. Rotate the ring gear one revolution by turning the pinion. STEP 3, Check the tooth contact pattern on the ring gear. Make sure that the pattern is checked on the side ofthe tooth where the pinion applies the force. CORRECT TOOTH CONTACT NORMAL’ PATTERN PATTERN DURING WHEN IN ADJUSTMENT LIFT TRUCK The contact area is the center between the top and bottom of the gear tooth. The contact pattern is toward the inner circumference of the ring gear. WRONG TOOTH CONTACT ‘A good pattern will extend approximately the full length of the gear tooth The pinion is too far away from the center of the ring gear. La The pinion is too close to the center of the ring gear. ‘Add shims to move pinion toward ring gear. Check that the clearance is correct. Some movement of ring gear away from the pinion can be necessary. Remove shims to move pinion away trem the ring gear. Check that the clearance is correct. Some movement of the ring gear toward the pinion can be necessary. FIGURE 33, ADJUST THE RING GEAR AND PINION TOOTH CONTACT CONTROL VALVE ‘The control valve used with the MONOTROL pedal is

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