Hyster Four-Speed Powershift Transmission Description And Operation (HR 36000) Maintenance And Repair

Description

• Model List:
  • Four-Speed Powershift Transmission Description And Operation (HR 36000)

• 1. RM0634-(03-2005)-UK-EN_2
• 1.1. Four-Speed Powershift Transmission
• 1.2. Safety Precautions Maintenance and Repair
• 1.3. General
• 1.4. Automatic Powershift Control
• 1.5. Transmission Control System
• 1.6. Transmission Control Lever
• 1.7. Mechanical Description and Operation
• 1.8. General
• 1.9. Torque Converter
• 1.10. Description
• 1.11. Operation
• 1.12. Clutch Assemblies
• 1.13. Description
• 1.14. Operation
• 1.15. Transmission Operation in Neutral
• 1.16. Input Shaft, Forward Shaft, and Clutch Assembly
• 1.17. Description
• 1.18. Operation
• 1.19. Reverse, Second-Speed, and First-Speed Shaft and Clutch Assembli
• 1.20. Description
• 1.21. Operation
• 1.22. Third-Speed Shaft, Gear, and Clutch Assembly
• 1.23. Description
• 1.24. Operation
• 1.25. Fourth-Speed Shaft and Clutch
• 1.26. Description
• 1.27. Operation
• 1.28. Output Shaft
• 1.29. Description
• 1.30. Operation
• 1.31. Hydraulic Description and Operation
• 1.32. Sump, Filter, and Pump
• 1.33. Transmission Charge Pump
• 1.34. Pressure Regulator Valve
• 1.35. Relief Valve
• 1.36. Transmission Control Valve
• 1.37. Solenoid Valves
• 1.38. Direction Spools
• 1.39. Range Spools
• 1.40. Modulator Valves
• 1.41. Table 1. Solenoid Controls
• 2. RM0635-(06-2007)-UK-EN_2
• 2.1. Four-Speed Powershift Transmission
• 2.2. Safety Precautions Maintenance and Repair
• 2.3. General
• 2.4. Torque Converter Repair
• 2.5. Torque Converter, Remove
• 2.6. Torque Converter, Disassemble
• 2.7. Clean and Inspect
• 2.8. Torque Converter, Assemble
• 2.9. Torque Converter (Turbine) Housing, Disassemble
• 2.10. Relief Valve for Lube Pressure, Disassemble and Assemble
• 2.11. Oil Sealing Rings Sleeve, Replace
• 2.12. Torque Converter Housing, Assemble
• 2.13. Torque Converter, Install
• 2.14. Transmission Repair
• 2.15. Remove, Transmission Only
• 2.16. Transmission and Engine Assembly, Remove
• 2.17. Transmission, Disassemble
• 2.18. Output Shaft, Disassemble and Assemble
• 2.19. Fourth-Speed Shaft, Disassemble and Assemble
• 2.20. Third-Speed Shaft, Disassemble and Assemble
• 2.21. Forward Shaft and Clutch, Disassemble and Assemble
• 2.22. Reverse and Second-Speed Shaft and Clutch, Disassemble and Assem
• 2.23. First-Speed Shaft and Clutch, Disassemble and Assemble
• 2.24. Input Shaft, Disassemble and Assemble
• 2.25. Speed Sensor, Install
• 2.26. Transmission, Clean and Inspect
• 2.27. Transmission, Assemble
• 2.28. Control Valve
• 2.29. Clean and Inspect
• 2.30. Assemble and Install
• 2.31. Install, Transmission
• 2.32. Install, Transmission and Engine Assembly
• 2.33. Clean Oil System of Transmission After Major Repair
• 2.34. Automatic Powershift Control (APC 100)
• 2.35. Functional Description
• 2.36. Transmission Control Lever
• 2.37. First-Speed Shaft Bearings Adjustment
• 2.38. Torque Converter Stall Speed Check
• 2.39. Transmission Oil Pressures Check
• 2.40. Clutch Pressures Check
• 2.41. Torque Converter (Torque Converter Regulator) Oil Pressure Check
• 2.42. Troubleshooting
• 2.43. Transmission Controller (APC 100)
• 2.44. Table 1. Flange Nut Torque
• 2.45. Table 2. APC 100 Control Module (Pin Connections)
• 2.46. Table 3. Hobbs Gear Selector Connections
• 2.47. Table 4. Example Torque Values at Dimensions Shown
• 2.48. Table 5. Transmission Pressures
• 3. RM0047-(10-2011)-UK-EN
• 3.1. Planetary Gear Axle
• 3.2. Safety Precautions Maintenance and Repair
• 3.3. General
• 3.4. Description
• 3.5. Operation
• 3.6. Planetary Gear Axle Repair
• 3.7. Disassemble
• 3.8. Planetary Axle, Disassemble
• 3.9. Assemble and Install
• 3.10. Planetary Axle, Assemble
• 3.11. Torque Specifications
• 3.12. Troubleshooting
• 3.13. Table 1. Axle-to-Frame Fasteners
• 3.14. Table 2. Standard Torque Values for Axle Fasteners
• 3.15. Table 3. Drive Wheel Nut Torque
• 4. RM0046-(11-2014)-UK-EN_2
• 5. RM0231-(01-2016)-UK-EN_2
• 5.1. General
• 6. RM0776-(10-2014)-UK-EN_2
• 7. RM0786-(07-2006)-UK-EN
• 7.1. Steering System YardMaster
• 7.2. Safety Precautions Maintenance and Repair
• 7.3. General
• 7.4. Description
• 7.5. Steering Control Unit Repair
• 7.6. Description
• 7.7. Operation
• 7.8. Load-Sensing Steering
• 7.9. Disassemble
• 7.10. Assemble
• 7.11. Install
• 7.12. Steering Axle Repair
• 7.13. Description
• 7.14. Install
• 7.15. Steering Cylinder Repair
• 7.16. Clean and Inspect
• 7.17. Assemble
• 7.18. Install
• 7.19. Hubs Repair
• 7.20. Install
• 7.21. Spindles Repair
• 7.22. Install
• 7.23. System Air Removal
• 7.24. Relief Valve Adjustment for Steering System
• 7.25. Antitipping Device Adjustment
• 7.26. Troubleshooting
• 8. RM0783-(01-2004)-UK-EN
• 8.1. Hydraulic System YardMaster
• 8.2. Safety Precautions Maintenance and Repair
• 8.3. Description
• 8.4. Main Hydraulic Tank
• 8.5. Main Hydraulic Pump
• 8.6. Description
• 8.7. Load Sensing Pressure
• 8.8. Main Pump Controller
• 8.9. LS Servo
• 8.10. LS Control Valve
• 8.11. Power Servo
• 8.12. Load Sensing Pressure LS1
• 8.13. Load Sensing Pressure LS2
• 8.14. Standby Pressure
• 8.15. Power Control Valve
• 8.16. Main Control Valve
• 8.17. Description
• 8.18. Adjustment
• 8.19. Relief Pressures
• 8.20. Flow Control Settings
• 8.21. Derricking Down Speed
• 8.22. Derricking Up Speed
• 8.23. Telescoping Speeds
• 8.24. Steering
• 8.25. Description
• 8.26. Pilot System
• 8.27. Pilot Pump
• 8.28. Telescoping Retract Control Valve
• 8.29. Engine Radiator Fan Motor
• 8.30. Manipulator Pressure Valve
• 8.31. Engine Accelerator System
• 8.32. Joystick
• 8.33. Hydraulic Cooling System
• 8.34. Description
• 8.35. Brake Oil Cooling System
• 8.36. Description
• 8.37. Bar Relief Valve
• 8.38. Service Brakes
• 8.39. Description
• 8.40. Parking Brake
• 8.41. Description
• 8.42. Table 1. Main Control Valve Torque Specifications
• 8.43. Table 2. Pressures in Relation to the Position of Solenoids and
• 9. RM0787-(11-2003)-UK-EN
• 9.1. Boom YardMaster
• 9.2. Safety Precautions Maintenance and Repair
• 9.3. Description and Operation
• 9.4. Hydraulic System
• 9.5. Derricking
• 9.6. Description
• 9.7. Derricking Up
• 9.8. Derricking Down
• 9.9. Holding Valve
• 9.10. Adjustments
• 9.11. Telescoping
• 9.12. Description
• 9.13. Telescoping Out (Extend)
• 9.14. Telescoping In (Retract)
• 9.15. Adjustments
• 9.16. Dampening
• 9.17. Description
• 9.18. Adjustment of the 4 bar ( 58 psi) Pressure Reducer
• 9.19. Boom Repair
• 9.20. Spreader
• 9.21. Install
• 9.22. Install
• 9.23. Dampening Cylinder
• 9.24. Install
• 9.25. Pivot Bearing
• 9.26. Removal
• 9.27. Install
• 9.28. Derricking Cylinder
• 9.29. Install
• 9.30. Disassemble
• 9.31. Clean, Inspect, and Repair
• 9.32. Assemble
• 9.33. Install
• 9.34. Telescoping Cylinder
• 9.35. Install
• 9.36. Shimming Key Clearance
• 9.37. Wear Pads
• 9.38. General
• 9.39. Side Wear Pads
• 9.40. Clean and Inspect
• 9.41. Install
• 9.42. Horizontal Front Wear Pads
• 9.43. Clean and Inspect
• 9.44. Install
• 9.45. Horizontal Rear Wear Pads
• 9.46. Clean and Inspect
• 9.47. Install
• 9.48. Hydraulic Cylinder Repair
• 9.49. General Inspection and Assembly Instructions
• 9.50. Derricking Cylinder
• 9.51. Disassembly
• 9.52. Clean and Inspect
• 9.53. Assemble
• 9.54. Telescoping Cylinder
• 9.55. Disassemble
• 9.56. Clean and Inspect
• 9.57. Assemble
• 9.58. Dampening Cylinder
• 9.59. Disassemble
• 9.60. Clean and Inspect
• 9.61. Assemble
• 10. RM0784-(03-2003)-UK-EN
• 10.1. Diagrams
• 10.2. Safety Precautions Maintenance and Repair
• 11. RM0780-(06-2005)-UK-EN
• 11.1. Periodic Maintenance YardMaster
• 11.2. Safety Precautions Maintenance and Repair
• 11.3. General
• 11.4. Serial Number Data
• 11.5. How to Move Disabled YardMaster
• 11.6. How to Tow YardMaster
• 11.7. How to Put YardMaster on Blocks
• 11.8. How to Raise Drive Tires
• 11.9. How to Raise Steering Tires
• 11.10. Maintenance Schedule
• 11.11. Daily Inspections
• 11.12. First Inspection After First 100 Hours of Operation
• 11.13. Periodic Maintenance Schedule
• 11.14. Boom Maintenance
• 11.15. Spreader Maintenance
• 11.16. PPM Spreader Maintenance
• 11.17. Maintenance Procedures Every 8 Hours or Daily
• 11.18. How to Make Checks With Engine Stopped
• 11.19. Tires and Wheels
• 11.20. Safety Labels
• 11.21. Fuel, Oil, or Coolant Leaks Check
• 11.22. Drive Belts
• 11.23. Battery
• 11.24. Engine Oil
• 11.25. Drain Water From Fuel Filter
• 11.26. Hydraulic System
• 11.27. Brake System Oil
• 11.28. Cooling System
• 11.29. Boom and Spreader
• 11.30. Hook, Winch, and Boom (HR45H)
• 11.31. How to Make Checks With Engine Running
• 11.32. Gauges, Indicator Lights, Horn, Circuit Breakers, and Relays
• 11.33. Air Filter
• 11.34. Air Conditioning
• 11.35. Control Levers and Pedals
• 11.36. Electrical System
• 11.37. Transmission Oil
• 11.38. Steering System
• 11.39. Service Brakes
• 11.40. Parking Brake
• 11.41. Engine Oil
• 11.42. Cooling System
• 11.43. Hydraulic System
• 11.44. Boom and Spreader Operation
• 11.45. Maintenance Procedures Every 50 Hours or Weekly
• 11.46. PPM Spreader
• 11.47. Rotator and Extension Transmissions
• 11.48. Rotator Motor
• 11.49. Rotator Assembly
• 11.50. Twist Locks
• 11.51. Wear Pads (Extension Beam)
• 11.52. Sideshift Cylinders
• 11.53. Maintenance Procedures Every 250 Hours or 6 Weeks
• 11.54. Engine Oil and Filter
• 11.55. Fuel Filter/Water Separator
• 11.56. Drive Belts
• 11.57. Steering Axle
• 11.58. Battery
• 11.59. Wheel Nuts
• 11.60. Winch Oil Level
• 11.61. Steering Axle Tie Rods and King Pins
• 11.62. Drive Shaft Joints
• 11.63. General Lubrication
• 11.64. ELME Spreader
• 11.65. Rotator and Extension Transmission
• 11.66. Rotator Assembly
• 11.67. Twist Locks
• 11.68. Maintenance Procedures Every 500 Hours or 3 Months
• 11.69. Air Filter
• 11.70. Hydraulic Oil Filters
• 11.71. Transmission Oil Filter
• 11.72. Differential and Wheel End Housings Oil
• 11.73. Hydraulic Tank Breather
• 11.74. Boom Horizontal Wear Pads
• 11.75. Boom Side Wear Pads
• 11.76. Sideshift Cylinder
• 11.77. Stop Cylinders (ELME Option)
• 11.78. ELME Sideshift Wear Pads
• 11.79. Wear Pads (Extension Beams)
• 11.80. Maintenance Procedures Every 1000 Hours or 6 Months
• 11.81. Coolant Filter
• 11.82. Hydraulic Accumulators
• 11.83. Brake Accumulator
• 11.84. Transmission Oil
• 11.85. Disc Brake
• 11.86. Inspect
• 11.87. Brake System Oil and Filter
• 11.88. Air Filter Primary Element
• 11.89. Hydraulic Tank Breather
• 11.90. PPM Spreader
• 11.91. Extension Beam Horizontal Pads
• 11.92. Extension Beam Side Wear Pads
• 11.93. Ring Gear Fixation Bolts
• 11.94. ELME Spreader
• 11.95. Wear Pads (Extension Cylinder)
• 11.96. Winch Oil
• 11.97. Pedals, Levers, Hinges, and Seat Rails (General Lubrication)
• 11.98. Maintenance Procedures Every 2000 Hours or Yearly
• 11.99. Engine Valve Adjustment
• 11.100. Hydraulic Relief Pressures
• 11.101. Counterweight Fixation
• 11.102. Load Sensing System
• 11.103. Door and Window Seals
• 11.104. Drive Axle and Differential Oil
• 11.105. Hydraulic Oil
• 11.106. Change Hydraulic Oil
• 11.107. Steer Wheel Hub Bearing Cavity
• 11.108. Brake System Oil and Filter
• 11.109. Rotor and Extension Transmission Fixation Bolts
• 11.110. Rotator and Extension Transmission Oil
• 11.111. Maintenance Procedures Every 6000 Hours or 2 Years
• 11.112. Engine Coolant
• 11.113. Vibration Damper
• 11.114. Twist Locks
• 11.115. Maintenance Procedures Every 8000 Hours
• 11.116. PPM Spreader
• 11.117. Wheel and Tire Replacement
• 11.118. Wheels, Remove
• 11.119. Remove Tire From Wheel
• 11.120. Install Tire on Wheel
• 11.121. Install Wheel in Tire
• 11.122. Add Air to Tires
• 11.123. Wheels, Install
• 11.124. General Maintenance
• 11.125. Spreader
• 11.126. Twist Locks
• 11.127. Rotator Assembly
• 11.128. How to Store YardMaster
• 11.129. Short-Term Storage
• 11.130. Long-Term Storage
• 11.131. How to Move YardMaster On Transport
• 11.132. Loading
• 11.133. Unloading
• 11.134. Preparation for Use
• 11.135. Preparation After Transport
• 11.136. Preparation After Storage
• 11.137. Table 1. Condition Check
• 11.138. Table 2. Fluid Level Check
• 11.139. Table 3. Checks With Engine Running
• 11.140. Table 4. Initial 100-Hour Inspection
• 11.141. Table 5. Inspect and Adjust
• 11.142. Table 6. Lubricate
• 11.143. Table 7. Change
• 11.144. Table 8. Inspect and Adjust
• 11.145. Table 9. Lubricate
• 11.146. Table 10. Initial 100-Hour Inspection
• 11.147. Table 11. Inspect and Adjust