service repair manual

1. SERVICE REPAIR
H2.00J H2.50J H3.00JS (Europe) [F003]
PART NO. 1510478 8000 SRM 988

2. GENERAL
This section has the repair procedures and troubleshoot-
ing for the single speed powershift transmission. The
INTRODUCTION
description and operation of the transmission and torque
converter are found in the SINGLE SPEED POWERSHIFT
TRANSMISSION Description and Operation.
FIGURE1.INSIDETHETRANSMISSION

3. Before removing the transmission from the lift truck, make
the checks described in Checks and Adjustments.
REMOVAL
A. Remove the engine and transmission together as de-
scribed in the ENGINE sections.
B. Remove the inspection plate at the top of the flywheel
housing. Loosen the two capscrews that hold the oil sump
tube to the transmission housing. Move the end of the tube
toward the center of the housing. See Figure 2.
C. Remove the 11 capscrews and lock washers that hold the
transmission to the engine.
REPAIRS
D. Use blocks or chains to prevent engine or transmission
damage when separating the transmission from the engine.
Do not let the weight of the transmission press on the torque
converter or oil sump tube. Slide the transmission from the
engine and torque converter. Do not damage oil sump tube.
Remove the gasket.
NOTE
Keep all the gaskets and seals that are removed
from the transmission. An old gasket is a refer-
ence to help select the correct new gasket. Al-
ways install new gaskets and seals.
Before removing the torque converter from the engine, put
alignment marks on the flywheel and torque converter.
E. Remove the starter motor.
DISASSEMBLY
Before disassembling the transmission, carefully clean the
transmission housing. Keep the parts in a clean container
when they are removed. Keep the parts of a unit together to
prevent the loss of parts.
FIGURE2.OILSUMPTUBE FIGURE3.CHECKINGTHEGEARCLEARANCE

4. A. Before disassembling the transmission, check the contact
pattern and gear clearance of the ring and pinion. See Steps V
to X in the Assembly section for the procedures. If the pat-
tern and clearance are the same as the specifications, the
pinion depth shims do not need to be changed. The shims for
the stator reaction sleeve and shims for the turbine shaft
must be changed if the pinion depth shims are changed.
B. Put identification marks on the side bearing caps and hous-
ing. Remove the adjuster retainer capscrews and the bearing
cap capscrews. Remove the caps and adjuster screws. Loosen
the locknut and remove the thrust screw for the ring gear
from the housing. Remove the ring gear and differential as-
sembly from the housing. Keep the bearing cups with the
same cones. See Figure 5.
FIGURE4.CHECKTHECONTACTPATTERNBEFOREDISASSEMBLY
FIGURE5.MAKEIDENTIFICATION
MARKSBEFOREDISASSEMBLY

5. FIGURE8.REMOVINGTHEDIFFERENTIALASSEMBLY
D. If the pinion depth adjustment is correct, use a dial indica-
tor to check the movement of the stator reaction sleeve.
Loosen 3 turns the 6 capscrews that hold the sleeve to the
end cover. Fasten the dial indicator base to the housing. Put
the plunger of the dial indicator on the end of the reaction
sleeve. See Figure 11. Push the sleeve toward the transmis-
sion. Set the dial indicator to zero. Pull the sleeve and mea-
sure the travel. The movement must be less than 0.005 inch
(0.012 mm). If the movement and the pinion depth are correct,
the same shims can be used when assembling the transmis-
sion.
E. If the pinion depth adjustment and the reaction sleeve clear-
ance are correct, use a dial indicator to check the turbine shaft
clearance. Move the dial indicator plunger to the end of the
turbine shaft. Push the shaft and set the dial indicator to zero.
Pull on the shaft and measure the travel. The clearance must
be0.001inch(0.025mm)to0.021inch(0.005mm). Iftheclear-
ance is correct, the same shims can be used when assembling
the transmission.
NOTE
If the pinion depth shims or the reaction sleeve
shims are changed, the turbine shaft shims must
be changed. The turbine shaft clearance must be
checked after assembling the transmission.
C. Put identification marks on each half of the case. Remove
the capscrews that hold the differential case together. Re-
move the spider gears, spider, thrust washers and side gears.
Do not remove the ring gear unless it is damaged. Remove
the bearings as shown in Figure 10.
FIGURE6.REMOVETHETHRUSTPLUG
FIGURE7.REMOVINGTHEBEARINGCAPS

6. FIGURE11.CHECKINGMOVEMENTOFTHE
STATORREACTIONSLEEVE
FIGURE9.DISASSEMBLYOFTHEDIFFERENTIAL
FIGURE10.REMOVINGTHESIDE
BEARINGS

7. FIGURE12.CHECKINGMOVEMENTOF
THETURBINESHAFT
F. Remove the two capscrews from the oil sump tube. Loosen
one the hose clamps. Remove the sump tube from the hous-
ing.
G. Loosen evenly the 8 capscrews that hold the end cover to
the housing. The cover has spring pressure against it. Re-
move the cover. See Figure 13.
FIGURE13.REMOVETHEENDCOVER
FIGURE14.REMOVINGTHEPISTONANDSEAL
H. Remove the piston and seal from the end cover. See Figure
14.
FIGURE15.REMOVINGTHEREACTIONSUNGEAR

8. FIGURE16.REMOVINGTHETURBINESHAFT
J. Remove the turbine shaft. Remove the thrust washer and
shims from the end of the pinion shaft. See Figures 16 and 17.
FIGURE17.REMOVINGTHETHRUSTWASHER,
SHIMSANDFORWARDCLUTCH
K. Remove the four separator plates and the two friction
discsfromtheforwardclutch.Removethespecialcapscrew
and O-ring that holds the pressure plate in position. Put
two capscrews in the threaded holes of the pressure plate
to remove the pressure plate. See Figures 18 and 19.
FIGURE18.REMOVINGTHESPECIALCAPSCREW
FIGURE19.USECAPSCREWSTOPULL
PRESSUREPLATE
L. Remove the separator plates and friction discs from the
reverse clutch. See Figure 20.
FIGURE20.REMOVETHEREVERSECLUTCH
I. Remove the reaction sun gear. Remove the 8 piston return
springs. See Figure 15.

9. M. Apply compressed air to the port shown in Figure 21.
Remove the reverse piston and seal.
FIGURE21.REMOVINGTHEREVERSECLUTCHPISTON
N. Remove the 6 place bolts that hold the pinion bearing
housing to the transmission housing. Press the pinion as-
sembly and pilot bearing from the transmission housing.
Make sure the assembly is not damaged when it separates
from the housing. Keep the shims together. See Figure 22.
FIGURE 22. CAPSCREWS FOR THE PINION BEARING
HOUSING
FIGURE23.REMOVINGTHECAPSCREWS
O. Disassemble the planetary gear carrier by removing the six
place bolts. Remove the carrier housing from the planetary
gears.
P. Remove the six thrust washers from the gears. Slide the
planetary gears from the shafts. Keep the gears with the same
shafts. Remove the three thrust washers and the shafts. See
Figure 24.
Q. To replace the needle bearings in the gears, remove the
snap rings. Use a press to remove the bearings.
R. Check the clearance between the thrust washer of the pin-
ion bearing housing and the reverse ring gear. The clearance
must be 0.015 inch (0.381 mm) to 0.025 inch (0.635 mm). If the
pinion bearing preload or pinion bearings are not changed,
the same shims can be used for the wear plate of the carrier
hub. See Figure 25.
S. Use a spring scale as shown in Figure 26 or a torque wrench
to measure the preload of the pinion bearings. The indication
must be 5 to 35 inch pounds (0.56 to 5 N.m). Changing the
bearing preload shims changes the clearance of the reverse
ring gear. If the preload is correct and the same bearings are
installed again, the same shims can be installed. See Figure 26.
T. To disassemble the pinion carrier assembly, bend the lock
plate from the pinion nut. Remove the nut with an air impact
wrench. See Figure 27.

10. FIGURE24.DISASSEMBLINGTHE
PLANETARYGEARCARRIER
FIGURE27.REMOVINGLOCKPLATE
AND NUT
FIGURE26.CHECKINGTHEPRELOAD
OFTHEPINIONBEARINGS
FIGURE25.CHECKTHECLEARANCE
HERE

11. FIGURE28.REMOVINGPLANETARYGEARHUB
U. Remove the carrier hub, reverse ring gear, O-rings and
thrust washer.
V. Use a press to push the pinion shaft from the bearing
cone. Remove the seal, bearing cone, spacer and shims. See
Figure 29.
W. Use a brass drift to remove the bearing cones from the
pinion bearing housing.
X. Use a press to remove the bearing cone and the pilot bear-
ing from the pinion.
WARNING
Theinnerracemusthavesupportwhenthepinion
is pushed from the bearing.
FIGURE30.CAPSCREWSTHATHOLD
CONTROLVALVE
Y. Remove the control valve by removing the five capscrews.
Use a plastic hammer to loosen the valve body from the gas-
ket. To disassemble the control valve, see Assembly.
CLEANING
Cleaning the Powershift transmission is a very important part
of the repair procedure. Before inspecting the bearings, all oil
and dirt must be removed. Use solvent to clean all parts of the
transmission. Use compressed air to dry the parts and clean
the oil passages.
CAUTION
Do not use a cloth to clean the parts. Particles
from the cloth can cause restrictions in the oil
passages of the transmission.
Make sure all of the gasket material is removed. Any piece of
gasket material that is not removed can cause a leak.
FIGURE29.REMOVINGTHEBEARING
CONEFROMTHEPINIONSHAFT

12. INSPECTION
A. Inspect the ring and pinion gears for wear or damage. The
ring and pinion must be replaced as a set if either is damaged.
Check the spider holes in the differential case for wear. In-
spect the spider, spider gears, thrust washers and side gears
for wear.
FIGURE31.INSPECTTHEDIFFERENTIALCASEFOR
WEAR
B. Visually inspect the races, balls, and rollers of all the bear-
ings. Replace the bearing assembly if any defect is found.
C. Inspect all the thrust washers and wear plates. Wear on
thrust washers and wear plates causes clearances to change.
D. Check the bushings, needle bearings and shafts for wear
or damage.
E. Make sure the piston return springs are all the same length
and not bent.
F. Check the torque converter hub for wear or grooves. In-
spect the bore of the end cover for wear.
G. Put snap ring pliers in the hub of the torque converter.
Expand the tips of the pliers so that they touch the splines of
the inner race of the stator clutch. Quickly turn the pliers
counterclockwise. The stator must turn with the inner race
and continue to turn counterclockwise after the inner race is
stopped. When the pliers are quickly turned in the clockwise
direction, only the inner race will turn.
H. Inspect the bore for the turbine shaft in the stator reaction
sleeve. Check for grooves on the surface for the metal seal-
ing ring.
I. Inspect the planetary gear teeth for wear or damage.
J. Inspect the clutch pressure plate for damage where the
separator plates touch. Replace the pressure plate if the pres-
sure plate has grooves or defects.
K. Check all parts with splines for damage to the splines.
L. Make sure the valve spools in the control valve move
freely. The spools and bores must not have scratches or
grooves. The edges of the spools must be sharp to keep dirt
from getting between the spool and the bore. Do not change
the shape of the spools.
ASSEMBLY
Assembling The Control Valve
A. Disassemble the control valve only in an area free of dirt.
Before disassembly, carefully clean the outside of the valve
body. Remove all gasket material. To keep the parts in the
correct positions, remove, clean and install the valves and
springs of one bore before removing the next assembly. Do
not disassemble the solenoid. Replace all seals and O-rings.
Make sure the spools move freely in the bores and the drain
holes are open.
CAUTION
Do not get any grease or oil on the brake fluid
seal or bore of the inching spool. Use alcohol to
clean the inching spool and bore.

13. FIGURE32.CONTROLVALVE
FIGURE33.LUBRICA
TIONOFINCHINGBORE

14. 1.FROMMONOTROLPEDAL
2.“2”SPRINGCAVITYDRAIN
3.“3”SPRINGCAVITYDRAIN
4.“3”REGULATORSUMP
5.MODULATIONSPRINGCAVITYDRAIN
6.TODIRECTIONSPOOL
7.DRAINFORFORWARDCLUTCH
8.TOREVERSECLUTCH
9. TOFORWARDCLUTCH
10.DIRECTIONSPOOLINLET
11.FROMSOLENOIDVALVE
12.TOSOLENOIDVALVE
13.SOLENOIDSUMP
14.REVERSECLUTCHDRAIN
15.TOINCHINGVALVE
FIGURE34.CONTROLVALVEPASSAGES
16.DIRECTIONSPOOLSPRINGDRAIN
17.CONTROLSPRINGDRAIN
18.INCHINGDRAIN
19.INCHINGVALVEINLET
20.MODULATIONVALVEINLET
21.MODULATIONPILOTPASSAGE
22.BALANCESPRINGDRAIN
23.HOLESFORCAPSCREWS
24.DRAINFORBRAKEFLUID
25.INLETFROMHOUSING
26.“1”REGULATOR
27.“2”REGULATOR
28.TOTORQUECONVERTER
29.“1”SPRINGCAVITYDRAIN

15. Assembling The Differential
NOTE
The parts must be completely clean and all gas-
ketmaterialmustberemoved.
B. If the carrier bearings were removed from the differential
case, press the bearings in position. The force must be ap-
plied to the bearing race. The bearing cups and cones must
be installed as a set.
C. If the ring gear was removed from the differential case put
the ring gear in water that is 160 to 180 degrees F (71 to 82
degrees C). After 10 minutes, remove the ring gear from the
water and put it on the differential case. Do not use a press
or hammer to install the ring gear.
D. Apply Loctite 277 and install the 12 bolts, lock washers
and nuts and tighten the nuts evenly to 85 to 115 foot pounds
(115to156N.m).
CAUTION
Make sure no dirt or metal particles are between
the ring gear and differential case.
E. Put the spider gears and thrust washers on the spider. In-
stall the assembly into the differential case. See Figure 37.
F. Align the identification marks on the differential case. Use
Loctite 277 on the capscrews and tighten the capscrews to 60
to 75 ft lb (82 to 102 N.m).
G. Press the pinion pilot bearing on the end of the pinion gear.
Press only on the inner race. Use a punch on the end of the
pinion gear to hold the bearing in position. See Figure 38.
H. Install the tapered roller bearing with the long rollers on the
pinion shaft. Press only on the inner race. See Figure 39.
FIGURE35.INCHINGVALVE

16. FIGURE36.ASSEMBLINGTHE
DIFFERENTIAL
I. Install the bearing cup in the pinion bearing carrier with the
tapered surface as shown in Figure 39.
J. Install the smaller bearing cup in the bearing carrier as
shown in Figure 39.
K. Install the bearing preload shims and spacer on the pinion
shaft. Lubricate the bearings and put the threaded end of the
pinion shaft through the bearing cups. Install the bearing
cone, thrust washer, reaction ring gear, carrier hub and nut.
L. Tighten the nut to 150 foot pounds (203 N.m). Use a spring
scale as shown in Figure 43 to measure the resistance to
turning. Multiply the reading from the spring scale by 2 to
get the turning torque in inch pounds. The carrier must be
turning when the reading is taken. The turning torque of the
carrier must be 5 to 35 inch pounds (0.56 to 5.3 N.m). If the
torque is less than the specification, disassemble the carrier
and remove shims. If the torque is greater than the specifica-
tion, add shims. The shims are available in three thicknesses;
0.020inch(0.5mm),0.007inch(0.18mm)and0.005inch(0.13
mm).
FIGURE38.PUNCHMARKSTOHOLD
PILOTBEARING
FIGURE37.ALIGNINGTHE
IDENTIFICATIONMARKS

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18. FIGURE39.PINIONBEARINGASSEMBLY

19. FIGURE40.INSTALLINGTHESPACER
FIGURE43.CHECKINGTHEBEARINGPRELOAD
N. When the clearance is correct, remove the nut, planetary
gear hub and reaction ring gear. Put the O-ring on the end of
the planetary gear hub. Put sealant around the outside diam-
eter of the seal. Put a small amount of oil on the lip of the seal.
Install the seal as shown in Figure 46.
O. Install the reaction ring gear, planetary gear hub,lock plate
FIGURE41.INSTALLINGTHEBEARINGCONF
M. When the bearing preload is correct, check the clearance
of’ the ring gear between the thrust washer and planetary
gear hub. The clearance must be 0.015 to 0.025 inch (0.38 l to
0.635 mm). If the clearance is not correct, change the shims
under the wear plate on the reaction ring gear. The shims are
available in three thicknesses; 0.020 inch (0.5 mm), 0.007 inch
(0.18 mm) and 0.005 inch (0. 13 mm). Use Loctite 290 on the
threads of the allen screws. Tighten the screws to 86 inch
pounds (9.7 N.m).
FIGURE42.INSTALLINGTHEREACTION
RINGGEAR

20. and nut. Tighten the nut to 150 foot pounds (203 N.m). Bend
the lock plate around the nut. See Figure 42.
FIGURE47.LOCKPLATEANDNUT
P. If the needle bearings were removed from the planetary
gears, use a press to install the bearings. Lubricate the bear-
ings and press against the end of the bearing that has the
writing. Do not use a hammer. Install the snap rings into the
grooves in the gears.
FIGURE46.INSTALLINGTHEPINION
SEAL
FIGURE45.CHANGINGTHESHIMS
FIGURE44.CHECKINGTHECLEARANCE
1. THRUSTPLATE
2. MOUNTINGSCREWS

21. R. Install the three long and three short planetary gears. Use
a light grease to hold the thrust washers in position on the
planetary carrier. Put the planetary carrier over the gears.
Install the capscrews and tighten to 20 foot pounds (27 N.m).
Align the shafts and install the thrust plate. Use Loctite 290
and tighten the screws with an allen wrench to 86 inch pounds
(0.97N.m).SeeFigure50.
FIGURE48.INSTALLINGTHEPLANETARYGEAR
SHAFTS AND THRUST WASHERS
Q. Lubricate with hydraulic oil and install the six shafts and
the three double thrust washers. The bronze side of the thrust
washer must be toward the planetary gears. See Figures 48
and 49. FIGURE50.TIGHTENINGTHECAPSCREWS
S. Put an O-ring on the pinion bearing carrier and install the
shims that were removed. Install the assembly in the trans-
mission housing. Install the capscrews and tighten to 35 foot
pounds (46 N.m).
FIGURE51.CAPSCREWSFORTHEPINION
BEARINGCARRIER
FIGURE49.INSTALLINGTHETHRUST
WASHERS