FOUR-SPEED

POWERSHIFT
TRANSMISSION
REPAIR
(HR 36000)
H36.00-48.00E (H800-1050E) [D117];
RS45-30CH, RS46-35CH, RS45-25IH, RS46-30IH,
RS45-46TP, RS45-46TBP [A222];
HR45-25, HR45-27, HR45-31, HR45-40S, HR45-36L, HR45-40LS,
HR45-45LSX, HR45H [A227, B227]

PART NO. 897949 1300 SRM 635

 SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly
fastened, and that the load being lifted is balanced. Make sure the crane, cables, and
chains have the capacity to support the weight of the load.

• Do not lift heavy parts by hand, use a lifting mechanism.

• Wear safety glasses.

• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair

on electric lift trucks.

• Disconnect the battery ground cable on internal combustion lift trucks.

• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT
THE LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Mainte-
nance section.

• Keep the unit clean and the working area clean and orderly.

• Use the correct tools for the job.

• Keep the tools clean and in good condition.

• Always use HYSTER APPROVED parts when making repairs. Replacement parts
must meet or exceed the specifications of the original equipment manufacturer.

• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before
using force to remove parts.

• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs,
or if the unit needs repairs.

• Be sure to follow the WARNING and CAUTION notes in the instructions.

• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel
are flammable. Be sure to follow the necessary safety precautions when handling these
fuels and when working on these fuel systems.

• Batteries generate flammable gas when they are being charged. Keep fire and sparks
away from the area. Make sure the area is well ventilated.

NOTE: The following symbols and words indicate safety information in this
manual:

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 ......................................................................................................................... 2
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 .......................................................................................................... 6
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 ........................................... 16
First-Speed Shaft and Clutch, Disassemble and Assemble .................................................................... 18
Input Shaft, Disassemble and Assemble.................................................................................................. 20
Speed Sensor, Install ..................................................................................................................................... 20
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

This section is for the following models:

H36.00-48.00E (H800-1050E) [D117];

RS45-30CH, RS46-35CH, RS45-25IH, RS46-30IH,
RS45-46TP, RS45-46TBP [A222];
HR45-25, HR45-27, HR45-31, HR45-40S, HR45-36L, HR45-40LS,
HR45-45LSX, HR45H [A227, B227]

©2003 HYSTER COMPANY i

"THE
QUALITY
KEEPERS"

HYSTER
APPROVED
PARTS
1300 SRM 635 General

General
This four-speed powershift transmission is an
HR-36000 series transmission manufactured by
Spicer-Clark.
This section has the repair procedures for the
torque converter, transmission, control valve, and
the oil pump for the transmission. See the section
Four-Speed Powershift Transmission Descrip-
tion and Operation 1300 SRM 634 for information
on the operation of this transmission. The transmis-
sion assembly is shown in Figure 1.
ALWAYS replace all seals, O-rings, metal seal rings,
gaskets, and snap rings with new ones. Lubricate all
seals with clean transmission oil before installation.
Lubricate metal seal rings with multipurpose grease
#2 before installation. Use care with seals especially
during installation to prevent damage.
If possible, use magnaflux to check all gears and
shafts. Check gear teeth for wear, pitting, chipping,
nicks, cracks, or scoring. If gears show spots where
hardened surface has worn through, replace gear.
Make sure shafts are not bent or the splines twisted.

1. TRANSMISSION OIL PUMP 8. TRANSMISSION HOUSING 14. TORQUE CONVERTER

2. FORWARD CLUTCH 9. OIL SUMP AND PAN HOUSING
3. THIRD CLUTCH 10. FOURTH CLUTCH 15. TURBINE OF TORQUE
4. REAR COVER 11. SECOND CLUTCH CONVERTER
5. FIRST CLUTCH 12. REVERSE CLUTCH 16. INPUT SHAFT AND GEAR
6. OUTPUT YOKE 13. IMPELLER HUB GEAR 17. PUMP DRIVE GEAR
7. OUTPUT GEAR

Figure 1. Transmission (HR-36000)

1
Torque Converter Repair
Torque Converter Repair
TORQUE CONVERTER, REMOVE
The torque converter is removed during removal of
the transmission. See Remove, Transmission Only
procedures for the transmission.
TORQUE CONVERTER, DISASSEMBLE
If it is necessary to disassemble the torque converter,
do so as follows and as shown in Figure 2:
1. Remove capscrews and lockwashers that fasten
drive plates and bearing cover to impeller cover.
Remove backing ring, drive plates, bearing cover,
and O-ring.
2. Remove two rings and washer spacer that fas-
tens the turbine hub. One ring is thicker than
the hub locating ring.
NOTE: Use a drain pan for the oil in the converter
section that did not drain during initial drain of oil.
3. Remove screws and washers that fasten impeller
cover. Use a screwdriver at the slots to remove
impeller cover, turbine, and turbine hub. Re-
move large O-ring for the cover.
4. Remove locating snap ring from under turbine
hub. This ring is thinner than the retainer ring
of Step 2. Remove snap ring that fastens stator
to stator support. The stator support is fastened
to the stator with a dowel. Do not remove spacer
if stator or spacer will not be replaced.
5. Remove retainer for oil baffle (Figure 3). Use a
special removal tool to remove impeller and oil
baffle. The special removal tool is very similar to
a gear puller, but is for larger diameter parts.
6. Remove screws and washers that fasten stator
support to converter housing. Rotate stator sup-
port so there is clearance between stator support
and pump drive gear. The "cutout" in the stator
support allows this clearance.
7. Remove snap ring for the impeller hub gear (Fig-
ure 3). Remove hub gear from impeller hub. Re-
move oil baffle, oil seal, and baffle seal ring.
2
1300 SRM 635
8. Remove screws and washers that fasten hub to
impeller. Remove backing ring. Remove impeller
from hub. Remove O-ring between hub and im-
peller.
9. Straighten locking tabs for hub bolts. Remove
turbine-to-hub bolts and washers. Remove tur-
bine hub.
If necessary, disassemble turbine and impeller cover.
Install blocks under the edges of the impeller cover to
suspend the turbine and hub. Remove bearing snap
ring and spacer. Use a drift and hammer to remove
turbine and hub from impeller cover bearing.
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.
Clean the parts of the torque converter in solvent.
Dry parts with compressed air. Inspect splines and
gear teeth for damage. Inspect shafts, bearings,
and bearing surfaces for scratches, wear, or damage.
Clean holes that have threads and capscrews where
a thread-locking compound is used.
TORQUE CONVERTER, ASSEMBLE
If the turbine and impeller cover were not disassem-
bled, go to Step 3.
If disassembled, assemble turbine and impeller cover
as follows (see Figure 2):
1. Align holes in turbine and turbine hub and in-
stall lock tabs, hub bolts, and washers. Tighten
hub bolts to 122 to 134 N•m (90 to 99 lbf ft). Bend
a corner of lock tab over bolt heads.
2. Align impeller cover over turbine and hub. In-
stall bearing for impeller cover in cover and over
turbine hub. Install new O-ring. Install spacer
on turbine hub. Install bearing rings.
1300 SRM 635 Torque Converter Repair

Figure 2. Torque Converter and Flywheel

3
Torque Converter Repair 1300 SRM 635

Legend for Figure 2

1. TURBINE HUB 9. BACKING RING
2. SNAP RING 10. BEARING COVER
3. REACTION MEMBER 11. RING
4. SPACER 12. IMPELLER COVER
5. BEARING 13. LOCK TAB
6. IMPELLER HUB 14. TURBINE
7. O-RING 15. FLYWHEEL
8. IMPELLER 16. DRIVE PLATES

1. SNAP RING 10. TUBE

2. BEARING 11. WASHER
3. BEARING SUPPORT 12. INPUT SHAFT
4. HYDRAULIC PUMP GEAR 13. RETAINER
5. TURBINE HOUSING 14. BAFFLE
6. SPRING 15. SEAL RING
7. PISTON RING 16. OIL SEAL
8. SLEEVE 17. IMPELLER GEAR
9. STATOR SUPPORT

Figure 3. Input Shaft and Pump Drive Gears

4
1300 SRM 635 Torque Converter Repair

3. Make sure the surface of impeller hub and holes
for screws are clean and dry. Put new O-ring on
impeller hub. If removed, use a drift or press the
same size as the bearing and install hub bearing
and snap ring in hub.
RELIEF VALVE FOR LUBE PRESSURE,
DISASSEMBLE AND ASSEMBLE
If the unit has this relief valve, disassemble, clean, or
replace and assemble the valve as shown in Figure 4.

4. Align holes in impeller with hub holes. Do NOT

damage O-ring. The two dimples that are 180
degrees apart on backing ring must be installed
toward engine flywheel. Install backing ring
and install new special self-locking screws and
washers. Tighten screws to 79 to 87 N•m (58 to
64 lbf ft).

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
There is a sleeve at the front end of the forward,
6. Carefully install oil baffle on impeller without
reverse, and fourth-gear clutch shafts. Remove the
damaging oil seal. Install a new sealing ring for
sleeves ONLY if they are to be replaced.
oil baffle. Install hub gear on impeller hub and
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.

If necessary, disassemble converter housing assem- 3. Remove sleeve using a puller.

bly as follows:
4. Use a press or a driver to prevent damage to the
1. Remove snap ring for front bearing of input shaft. sleeve during installation. Make sure the notch
Use a hammer with a soft face to lightly hit input in the new sleeve is aligned with the sleeve lock
shaft to remove it and bearing from housing. notch.

2. Put a mark on each pump gear for correct loca-
tion during installation. Remove bearing sup-
port screws and lockwashers for the drive (cen-
ter) gear. Remove drive gear and bearing assem-
bly. Remove other two pump gear and bearing
assemblies using the same procedure.
5. Put sleeve lock in position. Install capscrew and
washer. Tighten capscrew.
6. Install locating ring for front bearing of clutch
shaft in ring groove.

5
Transmission Repair
TORQUE CONVERTER HOUSING,
ASSEMBLE
Assemble converter housing assembly as follows and
as shown in Figure 3:
1. Install two pump drive gears as marked during
disassembly. Install transmission pump gear at
center location. Tighten all mount capscrews.
2. Install input shaft and gear. Use a hammer with
a soft face to tap shaft so bearing snap ring can
be installed. Install snap ring and continue to tap
shaft so snap ring is against shoulder in housing.
3. Open locating ring for the front bearing of the
reverse clutch. See Figure 15. Use a hammer
Transmission Repair
REMOVE, TRANSMISSION ONLY
NOTE: The transmission can be removed from under
the lift truck or as a complete assembly with the en-
gine. If an inspection pit is not available, the truck
must be raised 500 mm (19.7 in.) from the ground to
provide easier access and removal.
1. Place truck on level surface.
2. Shut down engine.
3. Apply parking brake.
4. Operate all hydraulics to release pressure in the
system.
NOTE: When removing battery cables, remove
ground cable first.
5. Disconnect the cables at the battery.
6. Remove floor plates and covers to provide access
to the hydraulic pump and transmission.
7. Close shut-off valves on hydraulic tank.
8. Disconnect the drive shaft at the differential.
9. Remove the drive shaft between the transmis-
sion and the differential.
10. Disconnect the wiring harness on top of the
transmission.
11. Disconnect the wires at the solenoids on the
transmission control valve.
6
1300 SRM 635
with a soft face to tap shaft of the reverse and
second clutch until locating ring is completely in
groove of converter housing.
4. Open locating ring for the front bearing of the
fourth-speed clutch. See Figure 7. Use a hammer
with a soft face to tap shaft of the fourth-speed
clutch until locating ring is completely in groove
of converter housing.
5. Install the front bearing of the forward clutch.
TORQUE CONVERTER, INSTALL
The torque converter is assembled in the torque con-
verter housing and is installed with the transmis-
sion. See Install, Transmission .
12. Disconnect the wires at the pressure and temper-
ature sending unit on the transmission.
13. Place tags on lines for identification.
14. Remove the drain plug from the transmission
sump.
15. Drain the oil.
16. Put plugs and caps on open fittings.
17. Disconnect the hoses at the hydraulic pumps.
18. Put plugs and caps on open fittings.
NOTE: The hydraulic pumps are fastened to the
transmission with 4 capscrew each.
The drive shaft of the hydraulic pump is engaged in
splines in the drive gear.
The drive shaft of the hydraulic pump will slide from
the drive gear when the hydraulic pump is removed.
19. Remove the hydraulic pumps.
20. Disconnect and remove the dipstick assembly.
21. Install blocks and a jack under the flywheel end
of the engine as a support.
22. Disconnect exhaust system to avoid possible
damage.
1300 SRM 635
WARNING
Verify the lifting device has the minimum ca-
pacity of 725 kg (1600 lb).
23. Connect a lifting device to the transmission.
24. Remove the transmission mounts to the frame.
See Figure 5.
NOTE: RS45-30CH, RS46-35CH, RS45-25IH, RS46-
30IH (A222) SHOWN.
1. TRANSMISSION 3. FRAME MOUNT
HOUSING 4. FRAME BRACKET
2. TRANSMISSION 5. ISOLATOR
MOUNT
Figure 5. Transmission Mount
25. Remove the 8 bolts securing the drive plates to
the torque converter.
26. Remove all fasteners between engine flywheel
housing and torque convertor housing.
27. Verify all the connections have been removed.
28. Carefully slide back the transmission from the
frame approximately 40 mm (1.60 in.) to permit
the transmission to be lowered.
WARNING
The transmission is heavy, verify that the lift-
ing devices are securely positioned.
Transmission Repair
29. Carefully, to avoid damage to the flex plate, lower
the transmission assembly past the cross mem-
ber support.
REMOVE, TRANSMISSION AND ENGINE
ASSEMBLY
NOTE: The transmission can be removed from under
the lift truck or as a complete assembly with the en-
gine. If an inspection pit is not available, the truck
must be raised 500 mm (19.7 in.) from the ground to
provide easier access and removal.
1. Place truck on level surface.
2. Shut down engine.
3. Apply parking brake.
4. Operate all hydraulics to release pressure in the
system.
NOTE: When removing battery cables, remove
ground cable first.
5. Disconnect the cables at the battery.
6. Remove floor plates and covers to provide access
to the hydraulic pump and transmission.
7. Close shut-off valves on hydraulic tank.
8. Disconnect the drive shaft at the differential.
9. Remove the drive shaft between the transmis-
sion and the differential.
10. Disconnect the wiring harness on top of the
transmission.
11. Disconnect the wires at the solenoids on the
transmission control valve.
12. Disconnect the wires at the pressure and temper-
ature sending unit on the transmission.
13. Place tags on lines for identification.
14. Remove the drain plug from the transmission
sump.
15. Drain the oil.
16. Put plugs and caps on open fittings.
17. Disconnect the hoses at the hydraulic pumps.
18. Put plugs and caps on open fittings.
7
Transmission Repair
NOTE: The hydraulic pumps are fastened to the
transmission with 4 capscrew each.
The drive shaft of the hydraulic pump is engaged in
splines in the drive gear.
The drive shaft of the hydraulic pump will slide from
the drive gear when the hydraulic pump is removed.
19. Remove the hydraulic pumps.
20. Disconnect and remove the dipstick assembly.
21. Install blocks and a jack under the flywheel end
of the engine as a support.
22. Disconnect exhaust system to avoid possible
damage.
23. Remove engine hood and ballast cover.
24. Disconnect the air cleaner intake elbow.
25. Drain coolant from the cooling system.
26. Disconnect cooling lines.
27. Remove the radiator and transmission oil cooler.
28. Remove the tubing between the engine and air
cleaner.
29. Disconnect fuel lines at the fuel filter.
30. Disconnect the throttle linkage.
31. Disconnect wires and wiring harnesses at the en-
gine.
32. Disconnect the heater hoses at the engine.
NOTE: Verify that the lifting device has a capacity of
at least 1360 kg (3000 lb).
33. Connect a lifting device to the engine.
34. Remove the capscrews that hold the engine
mount at the fan end of the engine. See Figure 6.
35. Remove the capscrews that hold the two rear en-
gine mount brackets to the frame.
NOTE: Verify all the connections to the engine or
transmission have been removed.
36. Carefully lift the engine and transmission as-
sembly from the frame.
8
1300 SRM 635
1. REAR MOUNT (FAN END OF ENGINE)
2. FRONT MOUNT
Figure 6. Engine Mounts
TRANSMISSION, DISASSEMBLE
Make sure to keep the parts for each clutch together
during disassembly. Make a note of the order of the
friction discs and separator plates of each clutch.
Also make a note of which way each bearing seal
is facing for correct installation. Disassemble the
transmission as follows:
1. Remove torque converter assembly from trans-
mission. If necessary, disassemble torque con-
verter as described in Torque Converter, Disas-
semble.
2. Remove solenoid dust cover from transmission
control valve. Remove screws and lockwashers
that fasten control valve cover. Remove cover as-
sembly of control valve, seal plate, and inner and
outer gaskets. Remove control valve housing and
gasket.
3. Remove screws that fasten stator support. Ro-
tate stator support so curved "cutout" section is
aligned with pump drive gear to allow removal.
See Figure 3. Remove stator support.
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.
5. Remove snap ring that fastens front bearing for
the fourth clutch to the torque converter housing.
1300 SRM 635
It can be necessary to use a prybar to remove the
fourth-speed clutch assembly from housing.
6. Remove snap ring that fastens the front bearing
for the second and reverse clutch to the torque
converter housing. See Figure 15. It can be nec-
essary to use a prybar to remove the second and
reverse clutch assembly from housing.
7. Remove output shaft nut, washers, yoke, seal,
and yoke from output shaft. Remove seal and
spacer. Remove bearing cap nuts and lockwash-
ers for rear bearing of output shaft. Remove
bearing cap and O-ring. See Figure 7.
8. Remove bearing cap nuts and lockwashers for
bearing of the third-speed shaft. Remove bearing
cap, O-ring, rings, and washer. See Figure 10.
9. Remove bearing cap nuts and lockwashers for the
bearing of the first-speed (low) shaft. Remove
bearing cap, shims, O-ring, and ring. See Fig-
ure 17. Keep cap and shims together. If cap,
clutch, front or rear bearings, transmission case,
or rear cover are not replaced, the same shims
will be used during assembly.
10. Remove clutch pressure and lube tubes and
O-rings at the holes under bearing cap for the
first-speed shaft bearing.
11. Remove locating rings for the rear bearings of the
third-speed and output shafts.
12. Remove nuts, screws, and lockwashers that fas-
ten the rear cover of the transmission. Remove
oil screen plug and oil screen. Tap on the end of
the output shaft and clutch shafts while prying
cover off to remove cover. Using aligning studs
can help in the removal. Remove cover gasket.
13. Remove retaining ring for the fourth-speed hub.
Remove hub. Remove three retaining rings for
the second-speed hub. Remove hub.
14. Use a bearing puller to remove the rear bearing
of the output shaft. Remove first-speed clutch
and output shaft simultaneously. Remove front
bearing for output shaft.
15. Remove clutch assembly of the third-speed
clutch.
16. Remove oil baffle screws, lockwashers, and oil
baffle from cover. Remove bolts and lockwashers
Transmission Repair
of the suction tube. Remove suction tube and
O-ring.
17. Have another person release the bearing snap
ring for the rear bearing of the forward shaft.
Use a hammer that has a soft face to tap the end
of the shaft for removal.
18. Remove forward clutch assembly. See Figure 12.
Remove outer race of the rear bearing of the in-
put shaft. Remove bearing cup and oil baffle
spacer of the first-speed shaft.
Output Shaft, Disassemble and Assemble
NOTE: The following procedures describe the disas-
sembly of each of the shaft assemblies and clutches.
These assemblies have been removed from the trans-
mission as assemblies in the previous procedures.
Disassemble only the shaft or clutch assembly nec-
essary to make repairs.
CAUTION
Inspect all bearings for damage and wear.
Bearings are normally replaced during a ma-
jor disassembly and assembly such as this.
Inspect clutch plates for wear of friction mate-
rial and damage to the separator plates.
Make sure to keep all parts of each clutch as-
sembly together. Some of these parts look the
same, but are not. Using the wrong part can
cause incorrect operation or damage.
Always use new seals, seal rings, and snap
rings during assembly. Apply a thin coat of
multipurpose grease #2 to all seals before in-
stallation. Fill all seal grooves with this same
grease.
The following procedure describes the disassembly
and assembly of the output shaft. See Figure 7:
1. Remove inner race of the front bearing of the out-
put shaft.
2. Remove front retaining ring for the output gear.
Remove spacers and gear from shaft. If neces-
sary, remove rear retaining ring.
9
Transmission Repair 1300 SRM 635

1. SEPARATOR DISC (TEETH 7. SPRING RETAINER 15. CLUTCH DRUM AND GEAR
OUTSIDE) 8. HUB FOR FOURTH SPEED
2. FRICTION DISC (TEETH 9. TRANSMISSION HOUSING 16. PISTON
INSIDE) 10. BEARING 17. OUTPUT SHAFT
3. BACKING PLATE 11. RETAINER 18. BEARING CAP
4. RING 12. SPACER 19. O-RING
5. SEAL 13. OUTPUT GEAR 20. PLUG
6. SPRING 14. REAR COVER 21. YOKE

Figure 7. Fourth-Speed Shaft and Output Shaft

3. If removed, install rear retaining ring on output
shaft. Install spacers and gear with long hub
toward rear. Install front retaining ring.
4. Install retainer and press front bearing on out-
put shaft with race shoulder facing gear. Install
bearing and outer race on inner race.
5. Install clutch hub on shaft using retaining rings.
Fourth-Speed Shaft, Disassemble and
Assemble
The following procedure describes the disassembly
and assembly of the fourth-speed shaft: See Figure 7
and Figure 8.
1. Remove oil sealing rings from the fourth-clutch
shaft. Remove snap ring for front bearing and
remove bearing using a bearing puller. Remove
other ring.

10
1300 SRM 635 Transmission Repair

2. Remove snap ring for the backing plate of the

clutch disc and remove backing plate. Remove
all friction and separator discs.

3. Remove seal. Compress wave spring and remove

retaining ring from its groove. Release wave
spring and remove snap ring and retainer for the
spring. Remove wave spring and thrust washer.
Turn assembly over and tap shaft on a block of
wood to remove seals and piston.

4. Make sure the bleed valve is clean in the piston

removed in Step 3. Install inner and outer seal
rings on piston. Lock ring joint and apply grease
to stabilize it in the ring groove. Carefully posi-
tion piston in drum without damaging seal rings.

5. Install seal, thrust washer, wave spring, spring

retainer, and retainer snap ring on shaft. Com-
press wave spring and install retainer snap ring
in shaft groove. Install a separator disc (teeth on
outside) in clutch drum.

6. Alternately install six friction discs and the other

five separator discs in drum. The last disc must
be a friction disc.

7. Install backing plate and snap ring in drum.

8. Press front bearing against shoulder on shaft

with snap ring groove toward drum. Install snap
ring. Install grease in groove for seal rings and
install seals in grooves.

Third-Speed Shaft, Disassemble and

Assemble
The following procedure describes the disassembly
1. HUB 8. SEPARATOR DISC
and assembly of the third-speed shaft (see Figure 9
2. RING (TEETH OUTSIDE)
and Figure 10): 3. SPRING RETAINER 9. PISTON
4. SPRING 10. CLUTCH SHAFT,
1. Remove sealing ring from shaft. Remove snap 5. SEAL DRUM, AND GEAR
ring for rear bearing. Use a bearing puller to 6. BACKING PLATE FOR FOURTH
remove rear bearing. 7. FRICTION DISC SPEED
(TEETH INSIDE) 11. BEARING
2. Remove retaining ring for outer bearing of the
third gear. Use a hammer that has a soft face Figure 8. Fourth-Speed Clutch
to tap the third gear with the outer bearing from
clutch drum.

3. Remove snap ring for clutch backing plate. Re-

move backing plate.

11
Transmission Repair 1300 SRM 635

4. Use a bearing puller to remove inner bearing for

the third-speed gear. Remove snap ring for inner
bearing.

5. Remove all friction and separator discs. Com-

press wave spring and remove retaining ring
from its groove. Release wave spring and re-
move snap ring and retainer for the spring.
Remove wave spring.

6. Remove clutch piston and seals.

7. Make sure the bleed valve is clean in the piston

removed in Step 6. Install inner and outer seal
rings on piston. Lock ring joint and apply grease
to stabilize it in ring groove. Carefully position
piston in drum without damaging seal rings.

8. Put retainer for wave spring, wave spring, wave

spring retainer, and snap ring for retainer on
shaft. Compress wave spring and install retainer
ring for spring into groove of shaft. Make sure re-
tainer ring is completely in groove.

9. Install snap ring for inner bearing on shaft. In-

stall a separator disc (teeth on outside) in clutch
drum.

10. Alternately install 12 friction discs and the other

11 separator discs in drum. The last disc must be
a friction disc.

11. Install backing plate and snap ring in drum.

12. Install inner bearing for the third-speed gear.

This bearing does not have an oil shield. Care-
fully install the third gear and hub. Make sure
the hub splines engage the splines of all friction
discs. To avoid damage, do not force the hub
through the discs.

13. Install outer bearing of the third gear. This bear-

ing has an oil shield. The oil shield must face
away from the gear. Install retaining ring for
1. SPRING RETAINER 9. FRICTION DISC bearing.
2. SPRING (TEETH INSIDE)
3. RETAINING RING 10. SEPARATOR DISC 14. Install rear bearing on shaft. The groove in the
4. RING (TEETH OUTSIDE) bearing must be toward the end of the shaft. In-
5. BEARING 11. PISTON stall snap ring for bearing. Install oil seal ring in
6. GEAR AND HUB 12. SEAL
7. SNAP RING 13. CLUTCH SHAFT, the groove near the end of the shaft. Use grease
8. BACKING PLATE DRUM, AND GEAR to hold the oil seal ring in place.
FOR THIRD SPEED

Figure 9. Third-Speed Clutch Assembly

12
1300 SRM 635 Transmission Repair

1. TRANSMISSION HOUSING 10. RETAINING RING

2. REAR COVER 11. SPRING
3. BEARING 12. SPRING RETAINER
4. WASHER 13. BACKING PLATE
5. RING 14. FRICTION DISC (TEETH INSIDE)
6. O-RING 15. SEPARATOR DISC (TEETH OUTSIDE)
7. BEARING CAP 16. PISTON
8. PLUG 17. SEAL
9. HUB AND GEAR 18. CLUTCH DRUM, SHAFT, AND GEAR

Figure 10. Third-Speed Shaft

13
Transmission Repair 1300 SRM 635

Forward Shaft and Clutch, Disassemble

and Assemble
The following procedure describes the disassembly
and assembly of the forward shaft and clutch (see
Figure 11 and Figure 12):

1. Remove piston rings from forward clutch shaft.

Remove retainer ring for inner race of front bear-
ing. Use prybars to remove bearing inner race.
Remove retainer ring for outer bearing.

2. Use prybars to remove clutch gear/hub and outer

bearing together.

3. Use a bearing puller to remove inner bearing for

hub.

4. Remove retainer ring for clutch backing plate.

Remove backing plate. DO NOT LOSE THE
BALL AND SPRING OF THE BACKING
PLATE. Remove all friction and separator discs.

5. Compress disc springs and remove retaining

rings from grooves. Release disc springs and
remove snap ring and retainer for spring. Re-
move disc springs. Make sure to keep these disc
springs together and with the other clutch parts.
Remove clutch piston and seals.

6. Remove retainer ring and thrust washer for rear

bearing. Not all units have the thrust washer.
Use a bearing puller to remove rear bearing.

7. Get a section of pipe that has approximately the

same outer diameter as the bearing outer race.
Use the pipe and a hammer or a press to install
rear bearing. The groove in the bearing must
be toward the end of the shaft. If installed, put
thrust washer on shaft. Install retaining ring for
rear bearing.
1. RETAINER 8. SEAL
8. Install inner and outer seal rings on piston. Lock 2. SPRING 9. PISTON
ring joint and apply grease to stabilize it in ring 3. RING 10. SEPARATOR DISC
groove. Carefully position piston in drum with- 4. BEARING (TEETH OUTSIDE)
out damaging seal rings. 5. CLUTCH HUB AND 11. FRICTION DISC
GEAR (TEETH INSIDE)
9. Install one friction disc (teeth on inner diame- 6. PISTON RING 12. BACKING PLATE
7. CLUTCH DRUM 13. SNAP RING
ter). Install one separator disc, then alternately AND GEAR
install the other 10 friction discs and the other
nine separator plates. The first and last clutch Figure 11. Forward Clutch Assembly
disc must be a friction disc. This is the sequence
of installation when the clutch has an iron pis-
ton.

14
1300 SRM 635 Transmission Repair

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

Figure 12. Forward Clutch and Shaft Assembly

10. Install detent spring and ball in backing plate.

See Figure 13. Install backing plate in clutch
drum making sure not to lose the spring or ball.
Compress clutch discs and disc springs and in-
stall retainer ring for backing plate.

11. Install disc springs and retainer for piston. Make

sure the disc spring with the large diameter is
toward the piston.

12. Compress disc springs and install rings fully in

grooves. Install inner bearing and ring. This
bearing does not have a shield in it. Carefully
install hub and gear in drum. Make sure hub
splines engage splines of all friction discs. To
avoid damage, do not force hub through the discs. 1. CLUTCH PLATE 4. DETENT BALL
2. RETAINER RING 5. CLUTCH DRUM
3. DETENT SPRING

Figure 13. Detent

15
Transmission Repair 1300 SRM 635

13. Install rings in outer bearing with shield toward

gear. Install inner race of front bearing. The
large diameter must be toward gear. Install re-
tainer for front bearing.

14. Put grease in groove for piston rings. Install pis-

ton rings in grooves. Align piston rings at center
of groove.

Reverse and Second-Speed Shaft and

Clutch, Disassemble and Assemble
The following procedure describes the disassembly
and assembly of the reverse and second-speed shaft
and clutch (see Figure 14 and Figure 15):

1. Remove piston rings at the reverse clutch end of

shaft. Remove retaining ring for front bearing.
Use prybars to move front bearing enough to in-
stall bearing puller. Use bearing puller to remove
front bearing.

2. Remove retainer ring for outer bearing of hub

gear. Use pry bars to carefully pry hub gear up
for clearance to install a gear puller. Remove hub
gear and outer bearing.

3. Remove retainer ring for clutch backing plate.

Remove backing plate. DO NOT LOSE THE
BALL AND SPRING OF THE BACKING
PLATE.

4. Remove all clutch discs. Use a bearing puller to

remove inner bearing.

5. Compress disc springs and remove retaining ring

from its groove. Release disc springs and re-
move retainer ring and retainer for spring. Re-
move disc springs. Make sure to keep these disc
springs together and with the other clutch parts.
Remove clutch piston.

6. Put a coat of grease on seal rings and install

seal rings on piston. Carefully position piston in
drum without damaging seal rings.

7. Install disc springs for piston. Make sure disc

spring with the large diameter is toward piston. 1. SEAL 8. SPRING
Install retainer ring for disc springs. Install re- 2. PISTON 9. RING
3. SEPARATOR DISC 10. BEARING
tainer for spring retainer ring. Compress disc (TEETH OUTSIDE) 11. CLUTCH HUB AND
springs and install retainer ring fully in groove. 4. FRICTION DISC GEAR
Use a press to install inner bearing. This bearing (TEETH INSIDE) 12. PISTON RING
does not have a shield in it. 5. BACKING PLATE 13. CLUTCH DRUM
6. SNAP RING AND GEAR
7. RETAINER

Figure 14. Reverse and Second-Speed Clutch

16
1300 SRM 635 Transmission Repair

1. PISTON RING 9. FRICTION DISC (TEETH INSIDE)

2. RING 10. SEPARATOR DISC (TEETH OUTSIDE)
3. BEARING 11. PISTON
4. SNAP RING 12. SEAL
5. REVERSE CLUTCH HUB AND GEAR 13. CLUTCH DRUM AND GEAR
6. SPRING 14. HUB AND GEAR FOR SECOND-SPEED CLUTCH
7. SPRING RETAINER 15. TRANSMISSION HOUSING
8. BACKING PLATE

Figure 15. Reverse and Second-Speed Shaft

8. Install one friction disc (teeth on inner diame-
ter). Install one separator disc, then alternately
install the other 10 friction discs and the other
nine separator plates. The first and last clutch
disc must be a friction disc. This is the sequence
of installation when the clutch has an iron pis-
ton.
Compress clutch discs and disc springs and in-
stall retainer ring for backing plate.
10. Carefully install hub and gear in drum. Make
sure hub splines engage splines of all friction
discs. To avoid damage, do not force hub through
the discs.

9. Install detent spring and ball in backing plate. 11. Install outer bearing with shield toward gear. In-
See Figure 13. Install backing plate in clutch stall retainer ring for outer bearing. Install front
drum making sure not to lose the spring or ball.

17
Transmission Repair 1300 SRM 635

bearing. The groove in the bearing must be to-

ward gear. Install retainer ring for front bearing.

12. Put grease in groove for sealing rings. Install

sealing rings in grooves. Align sealing rings at
center of groove.

13. Remove snap ring for backing plate of second

clutch. Remove backing plate and all clutch
discs.

14. Compress wave spring and remove retaining ring

from its groove. Release wave spring and remove
snap ring and retainer for spring. Remove wave
spring and thrust washer. Remove second clutch
piston.

15. Make sure the bleed valve is clean in the second-

gear piston removed in Step 14. Install inner and
outer seal rings on piston. Lock ring joint and
apply grease to stabilize it in ring groove. Care-
fully position second-gear piston in drum without
damaging seal rings.

16. Put thrust washer, wave spring, wave spring re-

tainer, and snap ring for retainer on shaft. Com-
press wave spring and install retainer ring for
spring into the groove of the shaft. Make sure
retainer ring is completely in groove.

17. Install a separator disc (teeth on outside) in

clutch drum. Alternately install the six friction
discs and the other five separator discs in drum.
The clutch disc next to the piston is a separator
disc. The last clutch disc is a friction disc.

18. Install backing plate and snap ring in drum.

First-Speed Shaft and Clutch, Disassemble

and Assemble
The following procedure describes the disassembly
and assembly of the first-speed shaft and clutch (see
Figure 16 and Figure 17): 1. BEARING 10. SEPARATOR DISC
2. WASHER (TEETH OUTSIDE)
1. Remove seal rings near end of shaft at tapered 3. HUB AND GEAR 11. PISTON
roller bearing. Use prybars to carefully move ta- 4. RING 12. PISTON SEAL
pered roller bearing for clearance to use a bearing 5. SPACER 13. SEAL
6. RING 14. CLUTCH SHAFT,
puller. Use the bearing puller to remove tapered 7. SPRING WASHERS DRUM, AND GEAR
roller bearing. Remove bearing thrust washer. 8. BACKING PLATE FOR FIRST SPEED
9. FRICTION DISC 15. THIRD-SPEED
2. Use a gear puller to remove first-speed gear with (TEETH INSIDE) GEAR
outer bearing.
Figure 16. First-Speed Clutch

18
1300 SRM 635 Transmission Repair

1. TRANSMISSION HOUSING 12. HUB AND GEAR

2. REAR COVER 13. WASHER
3. O-RING 14. THIRD-SPEED GEAR
4. BEARING CAP 15. CLUTCH SHAFT, DRUM, AND GEAR FOR FIRST
5. RING SPEED
6. SHIM SET 16. SEAL
7. PLUG 17. PISTON SEAL
8. BACKING PLATE 18. PISTON
9. SPRING WASHERS 19. SEPARATOR DISC (TEETH OUTSIDE)
10. SPACER 20. FRICTION DISC (TEETH INSIDE)
11. BEARING

Figure 17. First-Speed Shaft

19
Transmission Repair
3. Remove snap ring for backing plate. Remove
backing plate and all clutch discs.
4. Use a bearing puller to remove inner bearing of
the first-speed gear. Remove spacer.
5. Compress wave spring and remove retaining ring
from its groove. Release wave spring and remove
snap ring and retainer for spring. Remove wave
spring and the other wave spring ring. Remove
piston and seals for the first-speed clutch.
6. Use a gear puller to remove driven gear together
with front bearing.
7. Install driven gear on clutch shaft with long hub
of gear toward end of shaft. Use a press to install
tapered roller bearing. The small diameter of the
bearing must be toward the end of the shaft.
8. Install inner and outer seal rings on clutch pis-
ton. Lock ring joint and apply grease to stabi-
lize it in the ring groove. Carefully position the
first-speed piston in drum without damaging seal
rings.
9. Put retainer for wave spring, wave spring, wave
spring retainer, and snap ring for retainer on
shaft. Compress wave spring and install retainer
ring for spring into the groove of shaft. Make
sure retainer ring is completely in groove.
10. Install a separator disc (teeth on outside) in
clutch drum. Alternately install the 10 friction
discs and the other nine separator discs in the
drum. The last disc is a friction disc. Install
backing plate and snap ring in drum.
11. Install gear spacer and inner bearing. The bear-
ing does not have an oil shield. Use a press to in-
stall bearing. Carefully install hub gear. Make
sure hub splines engage splines of all friction
discs. To avoid damage, do not force the hub
through the discs.
20
1300 SRM 635
12. Install outer bearing for hub gear. This bearing
has an oil shield. The shield must be toward the
end of the shaft. Install washer. Use a press to
install tapered roller bearing. The small diame-
ter of the bearing must be toward end of shaft.
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.
Input Shaft, Disassemble and Assemble
The following procedure describes the disassembly
and assembly of the input shaft (see Figure 3):
1. Remove piston ring from input shaft.
2. Remove bearing snap ring and bearing washer.
3. Use prybars to move bearing enough to install
a bearing puller. Use bearing puller to remove
bearing. Use a press to install bearing with
groove in bearing away from gear.
4. Install bearing washer and snap ring. Fill groove
for piston ring with grease. Install piston in cen-
ter of groove.
SPEED SENSOR, INSTALL
Temporarily install bushings for speed sensors. Use
a depth micrometer to measure the depth at each
speed sensor bushing. Add shims to get the correct
dimensions as shown in Figure 18. Clean threads of
bushing and housing using Loctite© cleaner. Install
shims under the head of the bushing. Use Loctite®
number 270 or number 262 on both the bushing and
housing threads. Install shims and tighten bushings
to 61 to 68 N•m (45 to 50 lbf ft). After the Loctite®
has set, install speed sensors and tighten them to
54 N•m (40 lbf ft).
1300 SRM 635 Transmission Repair

1. SPEED SENSOR LOCATION 4. DEPTH MICROMETER

2. TRANSMISSION 5. BUSHING
3. SHIM LOCATION

Figure 18. Speed Sensor Installation

21
Transmission Repair 1300 SRM 635

TRANSMISSION, 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.

Clean the parts of the transmission in solvent. Dry

parts with compressed air. Inspect splines and gear
teeth for damage. Inspect shafts, bearings, and
bearing surfaces for scratches, wear, or damage.
1. LOCATING RING
Make sure separator plates are smooth. Inspect fric- 2. SPACER (OIL BAFFLE)
tion discs for burned or damaged friction material. 3. BEARING CUP
Clean holes that have threads and capscrews where 4. TRANSMISSION HOUSING
a thread-locking compound is used.
Figure 19. Bearing Installation Detail
TRANSMISSION, ASSEMBLE
7. Install new gasket and O-ring on rear of trans-
NOTE: If a new transmission or converter housing mission housing. A thin coat of grease will help
will be used, install speed sensors in new housing. hold gasket in place on housing. Install align-
See the procedure in Speed Sensor, Install and Fig- ing studs to help align rear cover. Install rear
ure 18. cover, tapping cover with a hammer that has a
soft face. Install cover screws and washers and
1. Install new O-ring on suction tube for transmis- tighten screws.
sion pump. Install tube in transmission case.
Install screws and washers for suction tube. 8. Install locating ring for bearing outer race of out-
Tighten screws. put shaft. Install spacer for output flange on out-
put shaft.
2. Set oil baffle in transmission case. Install and
tighten oil baffle screws. 9. Apply a thin coat of Loctite® 683 (green) on outer
diameter of oil seal. Press seal in bearing cup
3. Set froward clutch assembly into rear bearing of output shaft with lip of seal toward bearing.
bore of transmission case. Push rear bearing Use new O-rings and install bearing cap for the
through bore far enough to install outer locating output shaft bearing. Install lockwashers and
ring. Push bearing back in bore until locating nuts and tighten nuts.
ring is against shoulder of bore.
10. Install output flange, O-ring, washer, and elas-
4. Install third-speed clutch assembly. tic flange nut. Use a bar to prevent flange from
turning and tighten flange nut to torque speci-
5. Install locating ring in front bearing bore for low fied in Table 1.
clutch bearing. Install spacer (oil baffle) and
front bearing cup as shown in Figure 19. Table 1. Flange Nut Torque
NOTE: The first-speed clutch and the output shaft N•m
Thread Size lbf ft
must be installed simultaneously. Another person
can be helpful during this installation. 1" - 20 203 - 271 150 - 200

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.

14. Turn transmission housing so that rear cover is

to the rear. Install disc hub of the second-speed
clutch on shaft of the first-speed clutch. Install
retainer ring for hub. Install retainer for retainer
ring. Install snap ring for retainer ring of re-
tainer. See Figure 20.

1. CONVERTER HOUSING
2. PASSAGE OPEN FOR INTERNAL LUBE
INSTALLATION

Figure 21. Low-Speed Clutch Lube Passage

18. Install alignment studs and install converter

housing on transmission housing while rotat-
ing output shaft. Rotation of the output shaft
will help the clutch hub (Step 14) and discs to
1. DISC HUB align correctly. Do NOT push the two housings
2. SNAP RING FOR RETAINER OF RETAINER together too hard. Allow hub to align and enter
RING clutch discs. Install and tighten bolts that fasten
3. HUB RETAINER RING housings together.
4. CLUTCH SHAFT
5. RETAINER FOR RETAINER RING
19. Fill the groove for the oil sealing ring of the sta-
Figure 20. Retainer Ring Detail tor support using grease. Install sealing ring. In-
stall inner race of impeller hub bearing on stator
15. Install bearing outer race for input shaft. Install support. Align notch in stator support with pump
a new converter housing gasket and O-rings on gear and install support on input shaft. Align
transmission housing. A thin coat of grease will mount holes of stator support with holes in hous-
help hold the gasket in place on the housing. ing and install and tighten screws to fasten sta-
tor support.

23
Transmission Repair 1300 SRM 635

20. Install impeller and oil baffle assembly in con-

verter housing. Install retaining ring for oil baf-
fle. Make sure the turbine and dowel pin are in
place and install turbine on stator support. In-
stall snap ring (thicker snap ring) to fasten the
reaction member.
21. Install turbine snap ring (thinner snap ring). In-
stall new impeller O-ring on impeller cover. In-
stall impeller cover and turbine assembly on in-
put shaft. Install impeller cover, lockwashers,
and screws that fasten impeller cover. Tighten
screws.
22. Install snap ring (thickest snap ring) for tur-
bine hub. Install new O-ring on bearing cap
for impeller. Stack drive plates so that all the
fingers are aligned. Concave sides are toward
flywheel and the weld nuts are toward the cover.
Align holes of backing ring and drive plates. In-
stall drive plates, backing ring, and place bolts.
Tighten the 0.4375-inch place bolts to 71 to
77 N•m (52 to 57 lbf ft). Tighten the 0.3750-inch
place bolts to 45 to 49 N•m (33 to 36 lbf ft).
CAUTION
Make sure mount screws for control valve are
installed in the correct location to prevent
damage. All of the screws are not the same.
2. Install a seal plate gasket, seal plate, and the
other seal plate gasket on studs against control
valve. Install control valve cover and screws.
Items 1, 2, 3, 4, and 5 are 3/8 - 16 x 4-1/4 inch
capscrews. Items 12, 13, and 14 are 3/8 - 16 x
1 inch capscrews. Items 6 and 7 are flanged 12
point 3/8 - 16 x 3 inch capscrews. Items 8, 9,
10, and 11 are flanged 12 point 3/8 - 16 x 1-1/4
inch capscrews. Tighten screws in the sequence
(A through N) shown in Figure 22.
3. Install solenoid protection cover, washers, and
nuts. Tighten stud nuts in the sequence shown
in Figure 22.

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.

Clean all parts in solvent. Inspect spools, bores, and

springs for damage. Make sure spools move freely in
the bores.

Assemble and Install

Lubricate all parts with transmission oil. Always use
new O-rings and gaskets. During assembly, make
sure all spools move freely in their bores. Connect
wires to solenoids as marked during removal.

1. Put gasket for control valve on converter housing

on alignment studs. Install control valve assem- Figure 22. Control Valve Installation (Bottom
bly on studs. Install the two valves to housing View)
screws.

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.

21. Remove identification tags on lines.

25
Automatic Powershift Control (APC 100)
22. Replace the drain plug from the transmission
sump.
23. Replace the transmission oil.
24. Connect the wires at the pressure and tempera-
ture sending unit on the transmission.
25. Connect the wires at the solenoids on the trans-
mission control valve.
26. Connect the wiring harness on top of the trans-
mission.
27. Replace the drive shaft between the transmission
and the differential.
28. Connect the drive shaft at the differential.
29. Open shut-off valves on the hydraulic tank.
30. Replace floor plates and covers.
NOTE: When replacing battery cables, replace the
ground cable last.
31. Connect the cables to the battery.
32. Start engine.
33. Operate hydraulic functions and check for leaks.
CLEAN OIL SYSTEM OF TRANSMISSION
AFTER MAJOR REPAIR
NOTE: The complete oil system of the transmission
must be cleaned after every major repair. This clean-
ing is necessary to make sure the transmission oper-
ates correctly.
Automatic Powershift Control (APC 100)
FUNCTIONAL DESCRIPTION
The APC 100 control unit performs the following
functions (see Figure 23 and Table 2):
• Direction Change Protection
FORWARD to REVERSE/REVERSE to FOR-
WARD - When the gear selector direction is re-
versed, throttle reduction is automatically applied,
setting engine speed to idle. The transmission will
downshift as the vehicle slows until first gear
is obtained. The transmission will then change
directions and shift to first gear.
NEUTRAL to FORWARD or REVERSE - Nei-
ther forward nor reverse can be selected when the
engine speed is too high (more than 1000 rpm).
26
1300 SRM 635
Clean the system as follows:
1. Drain the entire system completely.
2. Disconnect and clean all oil lines for the trans-
mission. If possible, remove oil lines completely
to clean them.
3. Remove filter elements and clean filter can. In-
stall new filter elements.
4. Use oil and compressed air with flow opposite the
normal direction to flush the oil cooler. Do NOT
use flushing compounds.
5. Assemble all components and oil lines. Fill trans-
mission with the correct oil to the LOW mark
(dipstick or lower fill plug). Install new gaskets
and hydraulic pumps for the hydraulic systems of
the lift truck to the flange on the transmission.
Connect hydraulic lines as necessary. See the
Hydraulic System. Fill hydraulic tank of lift
truck with correct amount and type of hydraulic
oil.
6. Operate engine at idle speed for two minutes
to fill all hydraulic lines and filters. Check
for leaks. Check oil level of transmission with
engine operating. Add oil as necessary to the
LOW mark. If necessary, install the fill and level
plugs.
7. Operate engine at stall until oil is 82 to 93 C (180
to 200 F) and check for leaks. See Torque Con-
verter Stall Speed Check.
FORWARD, NEUTRAL, FORWARD - When
driving in a certain direction and when putting the
gear selector in NEUTRAL and back in the same
direction, NEUTRAL will be selected until the
engine speed is low enough (less than 1000 rpm).
• Overspeed Control
No shifts will be made that can cause overspeeding
of the transmission or the engine. A light on the
instrument panel indicates overspeeding.
• Turbine Sensor Failure
Since automatic shifting is based on a speed ratio,
a failure of the torque converter turbine results in
a speed ratio of zero, causing the transmission to
downshift. The control unit prevents downshifts
1300 SRM 635
that would cause excess speed while driving due to
a turbine failure.
• Automatic Shifting
An automatic shift to a higher gear is made when
the throttle pedal is pressed, the turbine speed ex-
ceeds a minimum speed, and the speed ration has
reached a certain value. No upshifts are allowed in
the braking mode (throttle pedal released).
An automatic shift to a lower gear is made when
the tractive effort in the lower gear exceeds the
tractive effort in the higher gear.
• Declutch
The transmission shifts to neutral under certain
conditions for load handling procedures.
The following paragraphs describe the pin connec-
tions at the APC 100 control unit.
1. Diagnostic LEDs (See Figure 23)
a. RED LED - ON when internal failure pre-
vents correct operation.
b. GREEN LED - Light reflects the position of
the idle/not idle switch (pin no. 23). When
the throttle is at idle, the light is OFF. The
light is ON when the throttle is pressed.
c. YELLOW LED - ON when turbine rpm=0
(truck not moving) or when engine rpm=0
(engine stopped).
A. FRONT COVER
1. INDICATOR LIGHTS
RED - INTERNAL MALFUNCTION
YELLOW - ZERO RPM, ENGINE OR TORQUE
CONVERTER
GREEN - THROTTLE PEDAL DEPRESSED
Figure 23. APC 100 Control Unit
Automatic Powershift Control (APC 100)
2. Switch Descriptions
a. Idle/Not Idle (pin no. 23). Switch open -
throttle pedal is depressed. Switch closed -
engine is idling, throttle pedal released.
b. Automatic/Manual (pin no. 9). Switch open
- APC 100 is shifting automatically. Switch
closed - APC 100 in manual mode, operator
decides when to shift. Downshifts or direc-
tion changes at high speeds are inhibited.
c. Declutch Request (pin no. 8). Switch open -
no declutch is applied. Switch closed - when
declutch is requested, the control unit will
shift the transmission to NEUTRAL when
vehicle speeds are less than a preset value,
depending on the unit. When the request is
dropped, the direction is engaged again.
d. Parking Brake request (pin no. 27). Switch
open - parking brake is not applied. Switch
closed - when parking brake is applied, con-
trol unit will shift the transmission to NEU-
TRAL.
e. Second Gear Start Request (pin no. 7). 24
volts applied - transmission starts in first
gear when transmission control lever is set
for second gear or lower. No voltage applied
- transmission starts in second gear when
transmission control lever is set for fourth
gear.
B. REAR COVER
2. CONNECTOR FOR LIFT TRUCK HARNESS
3. CONNECTOR FOR CHECKOUT KIT
27
Automatic Powershift Control (APC 100) 1300 SRM 635

Table 2. APC 100 Control Module (Pin Connections)

Pin No. Function Pin No. Function

1 Forward Switch (input) 17-19 Not Used
2 Range Switch 1 (input) 20 Reverse Switch (input)
3 Range Switch 3 (input) 21 Range Switch 2 (input)
4-6 Not Used 22 Not Used
7 Second Gear Start 22* Third Gear Limit - Twist Locks (input)
8 Declutch Request (input) 23 Idle/Not Idle
9 Manual/Automatic 24-25 Not Used
10-11 Not Used 26 Checkout Speed Ratio Display Request
11* Ground 27 Parking Brake
12 Forward Solenoid (output) 28, 29 Engine Speed Sensor (input)
13 Reverse Solenoid (output) 30, 31 Turbine Speed Sensor (input)
14 Range Solenoid 1 (output) 32-35 Not Used
15 Range Solenoid 2 (output) 34* 24 km/h (15 mph) limit (output)
16 Range Solenoid 3 (output) 36 Throttle Reduction (output)
17* 24-volt Supply 37 Overspeed Warning Light (output)
*A227 units only.

28
1300 SRM 635
FUSES
The APC 100 uses two fuses to protect its circuits.
See Figure 24. The 315 mA fuse is located behind the
front cover. To check or replace the 10A fuse, remove
the rear cover and pull out the circuit board. Be sure
to replace the fuses with the same type.
1. 315 mA FAST ACTING
2. 10A FAST FUSE
Figure 24. APC 100 Control Unit Fuses
Location
Automatic Powershift Control (APC 100)
TRANSMISSION CONTROL LEVER
The transmission control lever (Figure 25) is in-
stalled on the steering column. If the unit does not
operate correctly, check the wiring and connectors.
See the schematic in Figure 26 and Figure 27 and
Table 3. Check the operation of the APC 100 control
unit. If the control lever does not operate, install a
new lever.
NOTE: RS45-30CH, RS46-35CH, RS45-25IH,
RS46-30IH (A222) SHOWN.
Figure 25. Transmission Control Lever
29
Automatic Powershift Control (APC 100) 1300 SRM 635

Figure 26. Transmission Control Electrical Schematic

30
1300 SRM 635 Automatic Powershift Control (APC 100)

Legend for Figure 26

NOTE: H36.00-48.00E [H800-1050E (D117)] SHOWN.

NOTE: *CLARK GEAR SELECTOR SHOWN. HOBBS GEAR SELECTOR SHOWN IN FIGURE 27.

NOTE: HOBBS GEAR SELECTOR USED ON MODEL H36.00-48.00E [H800-1050E (D117)].

Figure 27. Electrical Schematic for Hobbs Gear Selector

Table 3. Hobbs Gear Selector Connections

Contact Description Wire

F Forward DE
N Neutral DH
R Reverse DA
SW1 Direction Selector Switch
SW2 Neutral Switch
SW3 Speed Selector Switch
SW4 Speed Selector Switch

31
First-Speed Shaft Bearings Adjustment 1300 SRM 635

Table 3. Hobbs Gear Selector Connections (Continued)

Contact Description Wire

1 First Gear Position DJ, DG, and DC
2 Second Gear Position DJ and DG
3 Third Gear Position DJ
4 Fourth Gear Position None
Supply +12 to 24 VDC CB and DB

First-Speed Shaft Bearings Adjustment

If the cap, clutch, front or rear bearings, transmis-
sion case, or rear cover is replaced, the clearance for
the bearings must be adjusted using shims at the cap.
If none of these parts were replaced, the old shim set
can be used without doing this procedure.
Adjust the bearings as follows:
1. Move transmission assembly so rear of transmis-
sion is up. If the bearing cap for the first-speed
shaft is installed, remove bearing cap. Make sure
the cap O-ring, clutch pressure sleeve, and oil
seal ring are removed.
2. Use a micrometer depth gauge C to measure the
thickness of the bearing cap at positions A and B
as shown in Figure 28. Thickness D is dimension
E minus dimension F. Add the two dimensions (D
at A and B) together and divide by 2 to get the
average thickness of the bearing cap.
Example: 22.12 mm (0.871 in.)
+22.17 mm (0.873 in.)
44.29 mm (1.744 in.)
÷ 2 = 22.14 mm (0.872 in.)
For the example, average thickness is 22.14 mm
(0.872 in.).
4. Rotate the output shaft to help seat the
tapered roller bearings while the nuts are
tightened. Tighten the nuts in a cross sequence
to 20 to 27 N•m (15 to 20 lbf ft). Use a soft-faced
hammer to lightly hit the rear cover of the trans-
mission while tightening nuts.
5. Remove the two nuts from cover that are 180
apart. These nuts are NOT the nuts G shown
in Figure 28. Loosen the other two nuts (G) until
they can be rotated with your fingers.
6. Set the micrometer depth gauge C firmly against
raised machined surfaces A and B of the bearing
cap as shown in Figure 28.
7. Use a torque wrench to alternately tighten
nuts G from 1.13 N•m (10 lbf in) to 11.3 N•m
(100 lbf in) in 1.13 N•m (10 lbf in) steps. Rotate
output shaft while tightening nuts. Measure the
depth at A and B at each step. The difference be-
tween A and B must not be greater than 0.13 mm
(0.005 in.) at any step. If the difference is greater
at any step, start over at the beginning of this
step. Add the two measurements and divide by 2
to get the average depth. Use the following chart
to record the average measurement at each step.
See Table 4.

3. Lubricate the bearing and the bore of the bearing

cap. Install bearing cap on studs. Install all four
nuts.

32
1300 SRM 635 First-Speed Shaft Bearings Adjustment

Table 4. Example Torque Values at (Figure 29). In the example, the line crosses
Dimensions Shown the zero line at 23.42 mm (0.922 in.). The av-
erage thickness of the bearing cap is 22.14 mm
Torque Value Gap Dimension (0.872 in.). Subtracting the thickness from the
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
1.1 10 23.39 0.921 0.15 ±0.02 mm (0.006 ±0.001 in.) to this dimen-
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
5.6 50 23.16 0.912 the graphs before using them. See Figure 30.
6.8 60 23.14 0.911 9. Select shims for the total shim thickness found in
7.9 70 23.06 0.908 Step 8. Measure the thickness of the shim pack
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
11.3 100 22.91 0.902 and bearing cap. Install pressure sleeve. In-
stall the correct shim pack and bearing cap on
8. Draw a straight line through the points on the studs. Install lockwashers and nuts. Alternately
chart as shown in Figure 29. The value where the tighten nuts to 55.6 to 61.0 N•m (41 to 45 lbf ft).
line crosses the zero line minus the average value Rotate output shaft to make sure bearings are
recorded for the thickness of the bearing cap of seated and check the torque of the nuts again.
Step 2 is the no-end-play, no-preload shim dimen-
sion. Add 0.15 ±0.02 mm (0.006 ±0.001 in.) to 11. Install lubrication line from bearing cap to check
this dimension for the final shim gap dimension port for lubricating pressure in front housing.
(total shim thickness). See the example chart

Figure 28. Adjusting Bearing Clearance

33
First-Speed Shaft Bearings Adjustment 1300 SRM 635

Figure 29. Example Values Chart

Figure 30. Plotting Chart

34
1300 SRM 635
Torque Converter Stall Speed Check
This stall check is a measurement of maximum en-
gine rpm with the engine working against the torque
converter at full stall. This test will help find prob-
lems in the transmission, torque converter, or engine.
1. Make sure the coolant level in the cooling system
is correct. Make sure the oil level in the trans-
mission is correct.
2. Put the lift truck against a wall or other object
that cannot move. The parking brake can also
be applied and blocks installed at the wheels to
prevent wheel movement. The wheels must not
turn during this test.
3. Connect a tachometer to the engine. Make sure
the parking brake is engaged. Also apply the
brakes.
CAUTION
Do not keep the lift truck in a stall condition for
more than 30 seconds at a time. Transmission
damage will occur at 120 C (250 F).
Transmission Oil Pressures Check
NOTE: If the correct pressure cannot be reached, see
the Troubleshooting at the end of this section. Dur-
ing all pressure checks, the drive wheels must be
raised from the floor.
Attach pressure gauges to the check ports. Check
that the oil level in the transmission is correct. Op-
erate the transmission in all ranges and directions
until the oil in the transmission is 83 to 94 C (180 to
200 F). Connect a tachometer to the engine. Be sure
to use the hydraulic schematic shown in Figure 31.
CLUTCH PRESSURES CHECK
1. Connect gauges to port S. See Table 5.
2. Run the engine at idle (400 to 600 rpm) and 83
to 94 C (180 to 200 F) transmission oil tempera-
ture, with brake pedals up and park brake set.
All clutch pressures must be within 34.5 kPa
(5 psi) of each other.
Transmission Oil Pressures Check
4. Select the highest gear. With the engine running
in FORWARD or REVERSE, slowly increase
engine speed to approximately one-half throttle
and hold that throttle position for no more than
30 seconds at a time. Repeat this process un-
til the oil temperature of the transmission (con-
verter outlet) is 83 to 94 C (180 to 200 F).
5. The correct stall speed is approximately
1900 rpm.
6. If the reading is 50 to 200 rpm below the speci-
fications, the engine does not produce full power.
The problem can be the engine, fuel system, or
other engine systems.
7. If the reading is 50 to 200 rpm above the specifi-
cations, the transmission or torque converter can
be the problem. A high reading in only one direc-
tion or speed range indicates a problem in that
clutch assembly.
3. Operate the transmission in both directions and
at each of the speed ranges. The correct oil pres-
sure is 1655 to 2068 kPa (240 to 300 psi) for all
of the direction and range clutches.
4. If a clutch pressure is not within the specifica-
tions of Step 2, repair that clutch.
TORQUE CONVERTER (TORQUE
CONVERTER REGULATOR) OIL
PRESSURE CHECK
1. Connect a gauge to the check port.
2. Make sure the transmission oil temperature is
83 to 94 C (180 to 200 F), the brake pedals are
up, and the park brake is set. The correct oil
pressure is 172 kPa (25 psi) min. @ 2000 rpm
and 483 kPa (70 psi) @ governed speed.
35
Transmission Oil Pressures Check 1300 SRM 635

Table 5. Transmission Pressures

Port Pressure Check Pressure

FC (@ Control Valve) Forward Clutch Pack 1655 to 2068 kPa (240 to 300 psi)*
RC (@ Control Valve) Reverse Clutch Pack 1655 to 2068 kPa (240 to 300 psi)*
S (Top of Transmission) First-Gear Clutch Pack 1655 to 2068 kPa (240 to 300 psi)*
2C (@ Control Valve) Second-Gear Clutch Pack 1655 to 2068 kPa (240 to 300 psi)*
S (Top of Transmission) Third-Gear Clutch Pack 1655 to 2068 kPa (240 to 300 psi)*
S (Top of Transmission) Fourth-Gear Clutch Pack 1655 to 2068 kPa (240 to 300 psi)*
R (AQ to Heat Exchanger) Torque Converter Regulator 172 kPa (25 psi) min @ 2000 rpm
483 kPa (70 psi) @ gov. speed**
*At engine idle (400 to 600 rpm) and 83 to 94 C (180 to 200 F) transmission oil temp., brake pedals up, and
park brake set. All clutch pressures must be within 34.5 kPa (5 psi) of each other or repair clutch.
** 83 to 94 C (180 to 200 F) transmission oil temp., brake pedals up, and park brake set.

1. Port S
2. Port R

36
1300 SRM 635 Troubleshooting

Troubleshooting

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

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.

Bearings or shafts in the transmis- Replace damaged parts.

sion are damaged.

Lift truck is operating in the wrong Have operator change operation.

speed range for a long period of time.

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.

Friction discs in the clutch are worn. Replace damaged parts.

Transmission has internal oil leaks. Check oil pressure to locate problem.
Replace damaged parts.

Oil pressure is not correct. Check oil pressure to locate problem.

Control valve does not operate cor- Repair control valve.

rectly.

Solenoid(s) or electrical circuit is Install new solenoid or repair wiring.

damaged.

Gears in transmission are damaged. 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.

Regulator for torque converter cir- Check and adjust regulator.

cuit does not operate correctly.

Oil level is not correct or oil is the Check oil type and level.
wrong type.

37
Troubleshooting 1300 SRM 635

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

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.

There is a restriction in the cooling Check and repair cooling circuit.

circuit.

Lift truck is operating in the wrong Have operator change operation.

speed range for a long period of time.

Torque converter makes too Bearings are damaged. Replace damaged parts.
much noise.

Torque converter drive plate is loose Repair or replace drive plate.

or damaged.

Oil pressure in the torque Transmission pump is worn. Replace pump.

converter circuit is low.

Relief valve for torque converter is Check and repair.

open.

Oil pressure in the torque There is a restriction in the torque Check passages for restrictions.
converter circuit is high. converter circuit.

TRANSMISSION CONTROLLER (APC 100)

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.

Fuse in controller is damaged. Replace fuse.

The red light is on continu- There is no power to the controller. Check and repair wiring as neces-
ously. sary.

The wiring harness is damaged. Repair wiring as necessary.

The controller is damaged. Replace controller.

38
1300 SRM 635 Diagrams, Schematics, or Arrangements

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

The transmission remains in The 10-amp fuse is damaged. Replace fuse.

NEUTRAL when power is
available to the controller.

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

Figure 31. Transmission Hydraulic Diagram

41
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 TECHNICAL PUBLICATIONS

1300 SRM 635 11/03 (4/03)(1/00)(9/98) Printed in U.S.A.