1300325, OPR, HYSTER, Hyster2, SRM

//-->.pos {position:absolute; z-index: 0; left: 0px; top: 0px;}TWO–SPEED POWERSHIFT TRANSMISSION (HYSTER T–40)GENERALThis section has the repair procedures and aTroubleshootingtable for the two–speed powershifttransmission (Hyster T–40).ally to have access to the capscrews. Push the torqueconverter toward the transmission.4. Put blocks under the engine to hold it in position. Putstraps around the transmission and connect a lifting de-vice to the straps. Make sure the lifting device is holdingthe weight of the transmission. Remove the capscrewsthat hold the engine mounts (on the torque converterhousing) to the frame. Remove the capscrews that holdthe engine mounts to the torque converter housing. Re-move the mounts.5. Lower the transmission and engine a small amountusing the lifting device. Make sure no parts of the enginetouch the firewall.6. Remove the capscrews that hold the torque converterhousing to the engine adapter. Move the transmissionfrom the engine and lift it from the lift truck. Make surethe torque converter does not fall from the transmission.Remove the torque converter from the transmission.7. Remove the plug from the transmission cover anddrain the oil from the transmission.TRANSMISSIONRemoval, Transmission And TorqueConverter1. Remove the floor plates. Remove the mount for theseat. Remove the drive shaft.2. Disconnect the linkages at the cranks on thecrossmember for the pedals. Make sure the links are ontop of the transmission. Put tags for identification on thewires at the transmission and disconnect the wires. dis-connect the oil lines at the transmission.3. Remove the access cover in the torque converterhousing. Remove the four capscrews that hold the driveplate to the flywheel. Rotate the engine flywheel manu-71. HOUSING, TORQUECONVERTER2. TRANSMISSION3. TRANSMISSION FILTER4. CONTROL VALVE5. REVERSE SOLENOID6. FORWARD SOLENOID7. DIPSTICK456312FIGURE 1. HYSTER T–40 TRANSMISSION1331524611664921034663011613117841.2.3.4.5.6.7.8.9.10.11.TRANSMISSION PUMPFRONT COVERINPUT SHAFTCOUNTERSHAFTOUTPUT SHAFTFORWARD SHAFTREVERSE–LOWCLUTCH ASSEMBLYREVERSE–HIGHCLUTCH ASSEMBLYFORWARD–LOWCLUTCH ASSEMBLYFORWARD–HIGHCLUTCH ASSEMBLYMANIFOLD BLOCK5FIGURE 2. TWO–SPEED POWERSHIFT TRANSMISSION (HYSTER T–40)2Transmission, Disassembly111221. USE ALIGNMENT PIN2. FRONT COVER11760117611. TORQUE CONVERTER HOUSING2. TRANSMISSION PUMPSTEP 1.Remove the torque converter housingfrom the transmission. Remove thetransmission pump only for inspectionor replacement. If the transmissionpump is worn or damaged, it must bereplaced as an assembly.41STEP 2.Install two alignment pins to support theweight of the front cover. (Usecapscrews with the heads removed.Install the capscrews in the holes shownhere.) Remove the capscrews that holdthe cover to the transmission housing.Remove the cover from the housing. Donot damage the seal ring on the inputshaft. Remove the regulator from thecover as necessary.STEP 3.Remove the external tube fromtransmission housing and the manifoldblock. Remove the manifold blocks fromthe transmission housing. Remove theseal rings from the forward and reverseshafts. Remove the snap rings from thebearings on the forward and reverseshafts.132117621. MANIFOLD BLOCKS2. SEAL RINGS (REVERSE SHAFTSHOWN, FORWARD SHAFT SIMILAR)3. SNAP RING (REVERSE SHAFTSHOWN, FORWARD SHAFT SIMILAR)4. TUBE11762FIGURE 3. DISASSEMBLY OF THE TRANSMISSION (1 of 2)3123445311681312116641. COUNTERSHAFT2. FORWARD SHAFT1. MANIFOLD BLOCK2. SPRING CAP3. SPRING4. REGULATOR5. SPOOL3. OUTPUT SHAFT4. INPUT SHAFTSTEP 4.Disassemble the manifold blocks asnecessary.STEP 5.Pull the shaft assemblies from thehousing. All of the shafts must be loosein the housing. Pull the countershaft first,then pull the forward shaft, output shaftand the input shaft.FIGURE 3. DISASSEMBLY OF THE TRANSMISSION (2 of 2)Reverse–Low Clutch, Disassembly123425611763STEP 1.Put the shaft in a vise. Remove the seal ring (1)from the shaft. Remove the snap ring (2) thatholds the ball bearing on the shaft. Use a bearingpuller to remove the bearing. Remove the thrustwasher (4). Remove the snap ring, thrust bearing,(5), and thrust washer (6).1.2.3.4.5.6.SEAL RINGSNAP RINGBALL BEARINGTHICK THRUST WASHERTHRUST BEARINGTHIN THRUST WASHERFIGURE 4. REVERSE–LOW CLUTCH, DISASSEMBLY (1 of 2)4112523344567891176411766551. RETAINER RING2. NEEDLE BEARINGS3. LOW SPEED PINIONAND HUB4. PRESSURE PLATE5. SEPARATORPLATES (9)6. FRICTION DISKS (9)NOTE:7. THIN THRUSTWASHER8. THRUST BEARING9. THICK THRUSTWASHER1.2.3.4.5.SNAP RINGSPRING RETAINERSPRINGPISTONPUNCH (TOOL)Keep the parts for each clutch assemblytogether. Do not mix parts between theassemblies. If the original friction disksand separator plates are going to beinstalled, be sure to keep them in thesame sequence.STEP 3.Remove the piston only if there is aproblem with the piston or seals. Use twopunches to push down on the springretainer. Remove the snap ring for theretainer. Remove the retainer, spring andpiston.STEP 2.Remove the retainer ring for the pressureplate. Remove the shaft from the vise andremove the pressure plate, clutch hub,separator plates and friction disks.Remove the thin thrust washer, thrustbearing and the thick thrust washer.FIGURE 4. REVERSE–LOW CLUTCH, DISASSEMBLY (2 of 2)5

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