Transm Iron Delta 1580510 1300SRM1129 (09 2009) Us en PDF

POWERSHIFT TRANSMISSION
REPAIR
S30FT, S35FT, S40FTS [E010];
H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, H40FTS) [F001];
S2.0-3.5FT (S40-70FT, S55FTS ) [F187];
H2.0-3.5FT (H40-70FT) [L177];
S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; S80, 100FTBCS;
S120FTS; S120FTPRS) [G004]; H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
H5.0-5.5FT (H80, 90, 100, 110, 120FT) [N005, P005]
This manual contains information that is confidential and/or proprietary to Hyster

Company, its subsidiaries and/or vendors. Copying or distribution of any sections of
this manual marked "Confidential/Proprietary" is prohibited.
PART NO. 1580510 1300 SRM 1129

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 Maintenance 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 hazardous situation which, if not avoided, could result in
death or serious injury.
CAUTION
Indicates a hazardous situation which, if not avoided, could result in
minor or moderate injury and property damage.
On the lift truck, the WARNING symbol and word are on orange back-
ground. The CAUTION symbol and word are on yellow background.
Powershift Transmission Table of Contents
TABLE OF CONTENTS
General ............................................................................................................................................................... 1
Serial Number................................................................................................................................................ 1
Charge Pump Repair ......................................................................................................................................... 2
Remove ........................................................................................................................................................... 2
Inspect ............................................................................................................................................................ 2
Install ............................................................................................................................................................. 2
Torque Converter Replace ................................................................................................................................. 3
Remove ........................................................................................................................................................... 3
Install ............................................................................................................................................................. 10
Front Cover Housing and Chain Drive Repair................................................................................................. 16
Remove ........................................................................................................................................................... 16
Clean .............................................................................................................................................................. 22
Inspect ............................................................................................................................................................ 22
Install ............................................................................................................................................................. 22
Clutch Packs Repair .......................................................................................................................................... 29
Remove and Disassemble .............................................................................................................................. 29
Transmission, Remove and Disassemble ................................................................................................. 29
Clutch Assemblies, Remove and Disassemble ......................................................................................... 40
Clean .............................................................................................................................................................. 45
Inspect ............................................................................................................................................................ 45
Assemble and Install ..................................................................................................................................... 46
Clutch Assemblies, Assemble and Install ................................................................................................ 46
Transmission, Assemble and Install ........................................................................................................ 53
Control Valve Repair.......................................................................................................................................... 59
Clean .............................................................................................................................................................. 62
Inspect ............................................................................................................................................................ 62
MONOTROL® Pedal Repair .............................................................................................................................. 64
Direction Control Lever ..................................................................................................................................... 68
Remove ........................................................................................................................................................... 68
Install ............................................................................................................................................................. 68
This section is for the following models:
S30FT, S35FT, S40FTS [E010];

H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, H40FTS) [F001];
S2.0-3.5FT (S40-70FT, S55FTS ) [F187];
H2.0-3.5FT (H40-70FT) [L177];
S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; S80, 100FTBCS;
S120FTS; S120FTPRS) [G004];
H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100,
110, 120FT) [N005, P005]
©2009 HYSTER COMPANY i

"THE
QUALITY
KEEPERS"
HYSTER
APPROVED
PARTS
1300 SRM 1129 General
General
This section has the repair procedures for the transmission.
SERIAL NUMBER
The transmission serial number is located on the
right side of the transmission control valve directly
below the floor plate. See Figure 1.
A. EARLY LIFT TRUCK MODELS EXCEPT

H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT
(H80, 90, 100, 110, 120FT) (N005, P005)
MODELS
B. NEWER LIFT TRUCK MODELS
Figure 1. Transmission Serial Number

Location
Confidential/Proprietary - Do Not Copy or Duplicate 1

Charge Pump Repair 1300 SRM 1129
Charge Pump Repair

REMOVE INSPECT
NOTE: The charge pump can be removed from the Inspect the splines on the shaft of the transmission
transmission while it is still in the lift truck but, charge pump for damage or worn areas that could
for the sake of clarity, the following procedures are affect the operation of the pump. If the splines are
shown with the transmission removed from the lift damaged, replace the transmission charge pump.
truck.
INSTALL
Remove four mounting capscrews, washers, trans-
mission charge pump, and gasket from the torque Install new gasket, transmission charge pump, four
converter housing. Discard the gasket. See Figure 2. mounting capscrews, and washers in the torque
converter housing. Tighten capscrews to 19 N•m
(168 lbf in).
NOTE: THE TRANSMISSION IS SHOWN REMOVED

FROM THE LIFT TRUCK FOR CLARITY.
(H80, 90, 100, 110, 120FT) (N005, P005)
MODELS
1. CAPSCREW
2. CHARGE PUMP
3. GASKET
4. TORQUE CONVERTER HOUSING
Figure 2. Transmission Charge Pump
2 Confidential/Proprietary - Do Not Copy or Duplicate

1300 SRM 1129 Torque Converter Replace
Torque Converter Replace

REMOVE (N005, P005) lift trucks, and Frame 100 SRM
1120 for S30FT, S35FT, S40FTS (E010); H1.6FT,
WARNING H1.8FT, 2.0FTS (H30FT, H35FT, H40FTS)
(F001); S2.0-3.5FT (S40-70FT, S55FTS) (F187);
Make sure the engine and transmission are
H2.0-3.5FT (H40-70FT) (L177) lift trucks.
held in position so that they will not fall and
cause an injury and damage to the equipment.
CAUTION
CAUTION Use care when disconnecting the wiring har-
ness connectors from electrical connectors on
Be careful that you do not damage parts of
the transmission and control valve. The con-
the torque converter or transmission when
nectors on the transmission and control valve
the transmission is separated from the engine.
are easily damaged.
Keep the transmission and engine in align-
ment until they are completely separated so NOTE: When disconnecting wiring harness connec-
parts of the transmission are not damaged. tors during disassembly, tag each connector to aid in
Use a crane or lifting device to separate the connecting the wiring harness during reassembly.
transmission from the engine.
2. Put the engine and transmission on solid blocks
1. Remove the engine and transmission as a unit on a work surface. Disconnect the connectors of
from the lift truck. See the section Frame 100 the transmission wiring harness from the control
SRM 1243 for S4.0, 4.5, 5.5FT, S5.5FTS, (S80, valve and transmission. Remove the transmis-
100, 120FT; S80, 100FTBCS; S120FTS; S120FT- sion wiring harness from the transmission. See
PRS) (G004) and H4.0FT5/FT6; H4.5FTS5, Figure 3.
H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT)

Torque Converter Replace 1300 SRM 1129

(H80, 90, 100, 110, 120FT) (N005, P005)
MODELS
1. GM 2.4L ENGINE 5. CAPSCREW
2. CAPSCREW 6. ACCESS COVER
3. TRANSMISSION WIRING HARNESS 7. CONTROL VALVE
4. TRANSMISSION
Figure 3. Engine-Transmission Combination

use your fingers to check for alignment of the

WARNING bolts with the access hole.
Make sure that the engine/transmission assem-
bly is stable before attempting to rotate the en- 3. Move each bolt into view through the access hole
gine. of the flywheel housing by rotating the crank-
shaft. Remove the four capscrews that attach the
Use a flashlight to see the bolts as they are ro- flywheel to the torque converter. See Figure 4.
tated into view through the access hole. Do not

Figure 4. Torque Converter Bolt Access

Legend for Figure 4

A. GM 2.4L ENGINE AND NEW FITTING DESIGN H4.5FT6; H5.0-5.5FT (H80, 90,
B. MAZDA ENGINE USED ON ENGINE AND 100, 110, 120FT) (N005, P005)
C. YANMAR ENGINE TRANSMISSIONS SHOWN IN LIFT TRUCK MODELS
D. GM 4.3L ENGINE ILLUSTRATIONS A THROUGH F. CUMMINS 4.5L DIESEL
E. ILLUSTRATES NEW DIPSTICK D, EXCEPT WHEN D IS USED ENGINE
AND BREATHER LOCATION ON H4.0FT5/FT6; H4.5FTS5,
1. ACCESS HOLE 2. FLYWHEEL HOUSING
4. Remove the access cover from the torque con- NOTE: The torque converter cannot be repaired and
verter housing. Install a lifting eye bolt into the must be replaced as a unit, if damaged.
rear access cover bolt hole, and connect a lifting
device to the eye bolt. Remove the 10 capscrews 5. Carefully remove the torque converter from the
that hold the torque converter housing to the fly- stator support. See Figure 5.
wheel housing on the engine. Carefully separate
the transmission from the engine.


(H80, 90, 100, 110, 120FT) (N005, P005)
MODELS
1. TRANSMISSION OIL FILTER 10. PLUG
2. DIPSTICK 11. CAPSCREW
3. DIPSTICK TUBE 12. WASHER
4. TRANSMISSION HOUSING 13. SMALL ACCESS COVER
5. VENT TUBE ASSEMBLY 14. TORQUE CONVERTER
6. TORQUE CONVERTER HOUSING 15. TRANSMISSION CHARGE PUMP
7. TRANSMISSION OIL TEMPERATURE SENSOR 16. STATOR SUPPORT
8. SUCTION SCREEN 17. PILOT HUB
9. SUCTION SCREEN SPRING
Figure 5. Torque Converter Removal

6. Remove the plug, suction screen spring, and suc-

tion screen from the torque converter housing,
and drain the oil from the transmission.
7. Remove the transmission charge pump and

transmission oil filter from the torque converter
housing.
NOTE: Step 8, Step 9, and the NOTE below ap-

ply to early lift truck models except H4.0FT5/FT6;
H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110,
120FT) (N005, P005) models.
8. Remove the dipstick from the dipstick tube,

and disconnect the vent tube assembly from the
transmission housing.
NOTE: The dipstick tube must be removed before the

torque converter housing can be removed from the
front cover housing.
9. Remove the dipstick tube from the torque con-

verter housing.
10. If damaged, remove the small access cover from

the torque converter housing. A. EARLY LIFT TRUCK MODELS EXCEPT
NOTE: Perform Step 11 only if repair of the of the (H80, 90, 100, 110, 120FT) (N005, P005)
MODELS
transmission chain drive is required. If the trans- B. NEWER LIFT TRUCK MODELS
mission clutch packs are in need of further repair,
see Clutch Packs Repair. 1. PRY POINTS
11. Remove 12 capscrews from the transmission 3. FRONT COVER HOUSING
housing and four mounting capscrews from the 4. TRANSMISSION HOUSING
front of the torque converter housing. Using
Figure 6. Pry Point Location
a small pry bar in the designated pry points,
remove the torque converter housing from the
front cover housing. Discard the O-rings and
gasket. See Figure 6 and Figure 7.


(H80, 90, 100, 110, 120FT) (N005, P005)
MODELS
1. CAPSCREW 4. GASKET
2. WASHER 5. FRONT COVER HOUSING
Figure 7. Torque Converter Housing
INSTALL 2. If removed, install the small access cover on the

torque converter housing. Tighten capscrews to
1. Install new O-rings and gasket and using four 7.9 N•m (69 lbf in). See Figure 8.
capscrews, install the torque converter housing
on the front cover housing and 12 capscrews on
the transmission housing. Tighten capscrews to
38 N•m (28 lbf ft). See Figure 7.


(H80, 90, 100, 110, 120FT) (N005, P005)
MODELS
1. TRANSMISSION OIL FILTER 10. PLUG
2. DIPSTICK 11. CAPSCREW
3. DIPSTICK TUBE 12. WASHER
4. TRANSMISSION HOUSING 13. SMALL ACCESS COVER
5. VENT TUBE ASSEMBLY 14. TORQUE CONVERTER
6. TORQUE CONVERTER HOUSING 15. TRANSMISSION CHARGE PUMP
7. TRANSMISSION OIL TEMPERATURE SENSOR 16. STATOR SUPPORT
8. SUCTION SCREEN 17. PILOT HUB
9. SUCTION SCREEN SPRING
Figure 8. Torque Converter Installation

NOTE: The information in Step 3 and Step 4 applies

only to early lift truck models except for H4.0FT5/ CAUTION
FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, Be careful that you do not damage parts of
110, 120FT) (N005, P005) models. the torque converter or transmission when
the transmission is joined to the engine. Keep
3. Clean the surface of the dipstick tube and dip- the transmission and engine in alignment un-
stick hole in the torque converter housing. Apply til they are completely joined so parts of the
adhesive (Hyster P/N 264159) to the entire sur- transmission are not damaged. Use a crane or
face of the hole in the housing. Insert the dipstick lifting device to join the transmission to the
tube until the collar bottoms on the housing and engine.
orient the tab against the housing flange.
11. Install the transmission to the engine. Install
4. Install the dipstick into the dipstick tube, and the capscrews that connect the torque converter
connect the vent tube assembly to the transmis- housing to the flywheel housing. Tighten the
sion housing. capscrews to 38 N•m (28 lbf ft). See Figure 9.
5. Install a new transmission oil filter on the torque
converter housing. CAUTION
Use care when connecting the wiring harness
6. Install the transmission charge pump on the connectors to electrical connectors on the
torque converter housing. Tighten capscrews to transmission and control valve. The connec-
19 N•m (168 lbf in). tors on the transmission and control valve are
7. Install the suction screen, suction screen spring, easily damaged.
and plug into the torque converter housing. 12. Install the transmission wiring harness on the
8. Install the torque converter onto the input shaft transmission. Connect the connectors of the
and stator support of the transmission. Make transmission wiring harness to the control valve
sure the splines are aligned and the converter and transmission. See Figure 9.
engages fully. 13. Rotate the engine crankshaft to position the
9. Lubricate the pilot hub on the torque converter flywheel mounting holes in line with the torque
with antiseize compound. See Figure 8. converter mounting holes. Install the capscrews
that hold the torque converter to the flywheel,
10. If removed, install a lifting eye bolt into the rear after coating the threads with Loctite™ 242,
access cover bolt hole, and connect a lifting de- through the access hole of the flywheel housing.
vice to the eye bolt. Align the torque converter See Figure 10. Tighten the capscrews to 56 N•m
housing with the flywheel housing. Make sure (41 lbf ft). Remove the lifting eye bolt, and install
the pilot hub on the torque converter engages the the access cover on the torque converter housing.
flywheel.


(H80, 90, 100, 110, 120FT) (N005, P005)
MODELS
4. TRANSMISSION


Legend for Figure 10

15. Fill the transmission to the correct level using
WARNING the correct transmission fluid and procedure
Make sure the engine and transmission are given in the section Periodic Maintenance
held in position so that they will not fall and 8000 SRM 1150 for S2.0-3.5FT (S40-70FT,
cause an injury and damage to the equipment. S55FTS) (F187); H2.0-3.5FT (H40-70FT)
(L177) lift trucks, Periodic Maintenance
14. Install the engine and transmission as a unit into
8000 SRM 1207 for S30FT, S35FT, S40FTS
the lift truck. See the section Frame 100 SRM
(E010); H1.6FT, H1.8FT, 2.0FTS (H30FT,
1243 for S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100,
H35FT, H40FTS) (F001) lift trucks, and Pe-
120FT; S80, 100FTBCS; S120FTS; S120FTPRS)
riodic Maintenance 8000 SRM 1248 for S4.0,
(G004) and H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT; S80,
H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005,
100FTBCS; S120FTS; S120FTPRS) (G004) and
P005) lift trucks, and Frame 100 SRM 1120 for
S30FT, S35FT, S40FTS (E010); H1.6FT, H1.8FT,
(H80, 90, 100, 110, 120FT) (N005, P005) lift
2.0FTS (H30FT, H35FT, H40FTS) (F001); S2.0-
trucks.
3.5FT (S40-70FT, S55FTS) (F187); H2.0-3.5FT
(H40-70FT) (L177) lift trucks.

Front Cover Housing and Chain Drive Repair 1300 SRM 1129
Front Cover Housing and Chain Drive Repair

REMOVE NOTE: When disconnecting wiring harness connec-
tors during disassembly, tag each connector to aid in
WARNING connecting the wiring harness during reassembly.
Make sure the engine and transmission are 2. Put the engine and transmission on solid blocks
held in position so that they will not fall and on a work surface. Disconnect the connectors of
cause an injury and damage to the equipment. the transmission wiring harness from the control
valve and transmission. Remove the transmis-
CAUTION sion wiring harness from the transmission. See
Keep the transmission and engine in alignment Figure 11.
until they are completely separated so parts of
the transmission are not damaged. Use a crane WARNING
or lifting device to separate the transmission Make sure that the engine/transmission assem-
from the engine. bly is stable before attempting to rotate the en-
gine.
1. Remove the engine and transmission as a unit
from the lift truck. See the section Frame 100 Use a flashlight to see the bolts as they are ro-
SRM 1243 for S4.0, 4.5, 5.5FT, S5.5FTS, (S80, tated into view through the access hole. Do not
100, 120FT; S80, 100FTBCS; S120FTS; S120FT- use your fingers to check for alignment of the
PRS) (G004) and H4.0FT5/FT6; H4.5FTS5, bolts with the access hole.
H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(N005, P005) lift trucks, and Frame 100 SRM 3. Move each bolt into view through the access hole
1120 for S30FT, S35FT, S40FTS (E010); H1.6FT, of the flywheel housing by rotating the crank-
H1.8FT, 2.0FTS (H30FT, H35FT, H40FTS) shaft. Remove the four capscrews that attach the
(F001); S2.0-3.5FT (S40-70FT, S55FTS) (F187); flywheel to the torque converter. See Figure 12.
H2.0-3.5FT (H40-70FT) (L177) lift trucks.
4. Remove the access cover from the torque con-
verter housing. Install a lifting eye bolt into the
CAUTION rear access cover bolt hole, and connect a lifting
To prevent possible damage to the transmis- device to the eye bolt. Remove the 10 capscrews
sion assembly when placing the assembly on a that hold the torque converter housing to the fly-
work surface, place blocks under the back side wheel housing. Carefully separate the transmis-
of the transmission housing for additional sup- sion from the engine.
port.
5. Carefully remove the torque converter from the
stator support. See Figure 13.
CAUTION
Use care when disconnecting the wiring har-
ness connectors from electrical connectors on
the transmission and control valve. The con-
nectors on the transmission and control valve
are easily damaged.

1300 SRM 1129 Front Cover Housing and Chain Drive Repair

(H80, 90, 100, 110, 120FT) (N005,P005) MODELS
4. TRANSMISSION




(H80, 90, 100, 110, 120FT) (N005, P005)
MODELS
1. TORQUE CONVERTER 5. SUCTION SCREEN SPRING
2. CAPSCREW 6. SUCTION SCREEN
3. WASHER 7. TORQUE CONVERTER HOUSING
4. PLUG 8. FRONT COVER HOUSING
Figure 13. Torque Converter Housing Removal

NOTE: The information in Step 6, Step 7, and the

NOTE below applies only to early lift truck mod-
els except H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005) mod-
els.
6. Remove the dipstick from the dipstick tube, and

disconnect the tube assembly from the transmis-
sion housing.
NOTE: The dipstick tube must be removed before the

torque converter housing can be removed from the
7. Remove the dipstick tube from the torque con-

verter housing.
8. Remove the plug, suction screen spring, and suc-

tion screen from the torque converter housing
and drain the oil from the transmission.
9. Remove the transmission charge pump from the

torque converter housing.
10. Remove the four mounting capscrews from the

front of the torque converter housing. Loosen A. EARLY LIFT TRUCK MODELS EXCEPT
the remaining 12 capscrews on the transmission H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT
(H80, 90, 100, 110, 120FT) (N005, P005)
housing and using a small pry bar, remove the MODELS
torque converter housing from the front cover B. NEWER LIFT TRUCK MODELS
housing. See Figure 14. Discard the O-rings on
the front cover housing and the gasket. 1. PRY POINTS
3. FRONT COVER HOUSING
4. TRANSMISSION HOUSING
Figure 14. Pry Point Location
NOTE: While performing Step 11, note the position

of the oil seal to aid in the proper installation of new
oil seal.
11. Remove and discard the oil seal from the rear of
the torque converter housing. See Figure 15.

A. EARLY LIFT TRUCK MODELS EXCEPT (H80, 90, 100, 110, 120FT) (N005, P005)
H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT MODELS
1. SNUBBER 8. O-RING 16. BAFFLE
2. PUMP DRIVE CHAIN 9. DRIVING SPROCKET 17. PLUG
3. BEARING 10. CAPSCREW 18. REGULATOR COMPRESSION
4. DRIVEN SPROCKET 11. LOCKWASHER SPRING
5. OIL SEAL 12. STATOR SUPPORT 19. REGULATOR SPOOL
6. ANGULAR CONTACT 13. SEALING RING 20. FRONT COVER HOUSING
BEARING 14. FRONT COVER HOUSING MOUNTING CAPSCREWS
7. BUSHING 15. TRANSMISSION HOUSING
Figure 15. Chain Drive

12. Remove the two snubbers from the front cover 1. Clean the snubbers with warm, soapy water and
housing. Carefully pull the driving and driven dry with compressed air.
sprockets, chain, and bearings from the front
cover housing as an assembly. Remove and dis- 2. Clean bearings, chain, stator support, and gears
card the O-ring from the driving sprocket. with solvent and dry with compressed air
13. Remove the stator support from the front cover INSPECT
housing. Remove and discard the sealing ring
and O-ring from the stator support. 1. Inspect the snubbers for cracks or wear. If dam-
aged or worn, replace both snubbers.
14. Remove the plug, regulator compression spring,
and regulator spool from the front cover housing. 2. Inspect the chain, gears, and stator support for
damage. If damage is present, replace the dam-
15. Remove the baffle from the front cover housing. aged component. Inspect the driving and driven
gears for damage or wear to the gear teeth. If
16. The front cover housing is held in alignment with the gear teeth are worn or damaged, replace the
the transmission housing with dowel pins. Re- gear. Inspect the splines on the input shaft for
move three mounting capscrews from the front of damage, and if damaged, replace the input clutch
the front cover housing. Remove the remaining pack. See Clutch Packs Repair.
12 capscrews from the transmission housing. To
separate the front cover housing from the trans- INSTALL
mission housing, use a small pry bar to loosen
the front cover housing. See Figure 14. Remove 1. Install new O-rings and gasket on the trans-
the front cover housing from the transmission mission housing. The front cover housing is
housing. Discard the O-rings on the transmis- held in alignment with the transmission hous-
sion housing and the gasket. ing with dowel pins. Install the front cover
housing on the transmission housing. Install
CLEAN 12 capscrews through the transmission housing
and front cover housing. Install the three front
WARNING cover housing capscrews and tighten to 38 N•m
(28 lbf ft) See Figure 16.
Cleaning solvents can be flammable and toxic
and can cause skin irritation. When using 2. Install the baffle in the front cover housing. See
cleaning solvents, always follow the solvent Figure 16.
manufacturer’s recommended safety proce-
dures. 3. Install the regulator spool, regulator compres-
sion spring, and plug into the front cover hous-
Compressed air can move particles so they ing.
cause injury to the user or to other personnel.
Make sure the path of the compressed air is 4. Install the new sealing ring and O-ring on the
away from all personnel. Wear protective gog- stator support. Install the stator support on the
gles or a face shield to prevent injury to the front cover housing. See Figure 16. Tighten the
eyes. capscrews to 38 N•m (28 lbf ft).

A. EARLY LIFT TRUCK MODELS EXCEPT (H80, 90, 100, 110, 120FT) (N005, P005)
H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT MODELS
1. SNUBBER 8. O-RING 16. BAFFLE
2. PUMP DRIVE CHAIN 9. DRIVING SPROCKET 17. PLUG
3. BEARING 10. CAPSCREW 18. REGULATOR COMPRESSION
4. DRIVEN SPROCKET 11. LOCKWASHER SPRING
5. OIL SEAL 12. STATOR SUPPORT 19. REGULATOR SPOOL
6. ANGULAR CONTACT 13. SEALING RING 20. FRONT COVER HOUSING
BEARING 14. FRONT COVER HOUSING MOUNTING CAPSCREWS
7. BUSHING 15. TRANSMISSION HOUSING
Figure 16. Chain Drive

5. On a lint-free cloth, place the driving sprocket 6. Install the new oil seal into rear of the torque
on the right side and the driven sprocket on the converter housing as noted during removal.
left side, and place the chain around both sprock-
ets (see Figure 16). Install the bearings on the 7. Install the new O-rings and gasket on the front
sprockets. The angular bearing should be in- cover housing. Using the front four mounting
stalled onto the driving sprocket with the thinner capscrews, install the torque converter housing
shoulder of the outer race towards the sprocket to the front cover housing. Install 12 capscrews
and the wider shoulder of the outer race (side from the back of the transmission housing.
marked with part number) towards the torque See Figure 17. Tighten 16 capscrews on the
converter housing. Carefully place the driving transmission housing and front cover housing to
and driven sprockets, chain, and bearings assem- 38 N•m (28 lbf ft).
bly on the front cover. Install two snubbers on the
A. EARLY LIFT TRUCK MODELS EXCEPT B. NEWER LIFT TRUCK MODELS

(H80, 90, 100, 110, 120FT) (N005, P005)
MODELS
1. TORQUE CONVERTER 5. SUCTION SCREEN SPRING
2. CAPSCREW 6. SUCTION SCREEN
3. WASHER 7. TORQUE CONVERTER HOUSING
4. PLUG 8. FRONT COVER HOUSING
Figure 17. Torque Converter Housing Installation

8. Install the suction screen, suction screen spring, housing with the flywheel housing. Make sure
and plug into the torque converter housing. the pilot hub on the torque converter engages the
flywheel.
NOTE: The information in Step 9 and Step 10 applies
only to early lift truck models except H4.0FT5/FT6; 15. Install the transmission to the engine. Install
H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, the capscrews that connect the torque converter
120FT) (N005, P005) models. housing to the flywheel housing. Tighten the
capscrews to 38 N•m (28 lbf ft). See Figure 18.
9. Clean the surface of the dipstick tube and dip-
stick hole in the torque converter housing. Apply
adhesive (Hyster P/N 264159) to the entire sur- CAUTION
face of the hole in the housing. Insert the dipstick Use care when connecting the wiring harness
tube until the collar bottoms on the housing and connectors to electrical connectors on the
orient the tab against the housing flange. transmission and control valve. The connec-
tors on the transmission and control valve are
10. Install the dipstick into the dipstick tube, and easily damaged.
connect the tube assembly to the transmission
housing. 16. Install the transmission wiring harness on the
transmission. Connect the connectors of the
11. Install the torque converter onto the input shaft transmission wiring harness to the control valve
and stator support of the transmission. Make and transmission. See Figure 18.
sure the splines are aligned and the converter
engages fully. 17. Rotate the engine crankshaft to position the
flywheel mounting holes in line with the torque
12. Lubricate the pilot hub on the torque converter converter mounting holes. Install the capscrews
with antiseize compound. See Figure 17. that hold the torque converter to the flywheel,
after coating the threads with Loctite™ 242,
13. Install the transmission charge pump on the
through the access hole of the flywheel housing.
torque converter housing. Tighten the cap-
See Figure 19. Tighten the capscrews to 56 N•m
screws to 19 N•m (168 lbf in).
(41 lbf ft). Remove the lifting eye bolt, and install
14. If removed, install a lifting eye bolt into the rear the access cover on the torque converter housing.
access cover bolt hole, and connect a lifting de-
vice to the eye bolt. Align the torque converter

A. EARLY LIFT TRUCK MODELS EXCEPT B. NEWER LIFT TRUCK MODELS

(H80, 90, 100, 110, 120FT) (N005, P005)
MODELS
4. TRANSMISSION

18. Install the engine and transmission as a unit into 19. Fill the transmission to the correct level using
the lift truck. See the section Frame 100 SRM the correct transmission fluid and procedure
1243 for S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100, given in the section Periodic Maintenance
120FT; S80, 100FTBCS; S120FTS; S120FTPRS) 8000 SRM 1150 for S2.0-3.5FT (S40-70FT,
(G004) and H4.0FT5/FT6; H4.5FTS5, H4.5FT6; S55FTS) (F187); H2.0-3.5FT (H40-70FT)
H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005, (L177) lift trucks, Periodic Maintenance
P005) lift trucks, and Frame 100 SRM 1120 for 8000 SRM 1207 for S30FT, S35FT, S40FTS
S30FT, S35FT, S40FTS (E010); H1.6FT, H1.8FT, (E010); H1.6FT, H1.8FT, 2.0FTS (H30FT,
2.0FTS (H30FT, H35FT, H40FTS) (F001); S2.0- H35FT, H40FTS) (F001) lift trucks, and Pe-
3.5FT (S40-70FT, S55FTS) (F187); H2.0-3.5FT riodic Maintenance 8000 SRM 1248 for S4.0,
(H40-70FT) (L177) lift trucks. 4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT; S80,
100FTBCS; S120FTS; S120FTPRS) (G004) and
(H80, 90, 100, 110, 120FT) (N005, P005) lift
trucks.


1300 SRM 1129 Clutch Packs Repair

Clutch Packs Repair

REMOVE AND DISASSEMBLE CAUTION
Transmission, Remove and Disassemble To prevent possible damage to the transmis-
sion assembly when placing the assembly on a
work surface, place blocks under the back side
WARNING of the transmission housing for additional sup-
Make sure the engine and transmission are port.
held in position so that they will not fall and
cause an injury and damage to the equipment.
CAUTION
CAUTION ness connectors from electrical connectors on
Be careful that you do not damage parts of the transmission and control valve. The con-
the torque converter or transmission when nectors on the transmission and control valve
the transmission is separated from the engine. are easily damaged.
Keep the transmission and engine in align-
ment until they are completely separated so NOTE: When disconnecting wiring harness connec-
parts of the transmission are not damaged. tors during disassembly, tag each connector to aid in
Use a crane or lifting device to separate the connecting the wiring harness during reassembly.
transmission from the engine.
2. Put the engine and transmission on solid blocks
1. Remove the engine and transmission as a unit on a work surface. Disconnect the two connectors
from the lift truck. See the section Frame 100 of the chassis wiring harness from the transmis-
SRM 1243 for S4.0, 4.5, 5.5FT, S5.5FTS, (S80, sion wiring harness. Disconnect the connectors
100, 120FT; S80, 100FTBCS; S120FTS; S120FT- of the transmission wiring harness from the con-
PRS) (G004) and H4.0FT5/FT6; H4.5FTS5, trol valve and transmission. Remove the trans-
H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) mission wiring harness from the transmission.
(N005, P005) lift trucks, and Frame 100 SRM See Figure 20.
H1.8FT, 2.0FTS (H30FT, H35FT, H40FTS)
(F001); S2.0-3.5FT (S40-70FT, S55FTS) (F187);
and H2.0-3.5FT (H40-70FT) (L177) lift trucks.

Clutch Packs Repair 1300 SRM 1129

(H80, 90, 100, 110, 120FT) (N005, P005)
MODELS
4. TRANSMISSION

use your fingers to check for alignment of the

WARNING bolts with the access hole.
Make sure that the engine/transmission assem-
bly is stable before attempting to rotate the en- 3. Move each bolt into view through the access hole
gine. of the flywheel housing by rotating the crank-
shaft. Remove the four capscrews that attach the
Use a flashlight to see the bolts as they are ro- flywheel to the torque converter. See Figure 21.
tated into view through the access hole. Do not

A. GM 2.4L ENGINE C. YANMAR ENGINE E. ILLUSTRATES NEW DIPSTICK

B. MAZDA ENGINE D. GM 4.3L ENGINE AND BREATHER LOCATION

AND NEW FITTING DESIGN H4.5FT6; H5.0-5.5FT (H80, 90,

USED ON ENGINE AND 100, 110, 120FT) (N005, P005)
TRANSMISSIONS SHOWN IN LIFT TRUCK MODELS
ILLUSTRATIONS A THROUGH F. CUMMINS 4.5L DIESEL
D, EXCEPT WHEN D IS USED ENGINE
ON H4.0FT5/FT6; H4.5FTS5,
4. Remove the access cover from the torque con- 5. Remove the torque converter housing and the
verter housing. Install a lifting eye bolt into the front cover housing from the transmission hous-
rear access cover bolt hole, and connect a lifting ing. See Front Cover Housing and Chain Drive
device to the eye bolt. Remove the 10 capscrews Repair, Remove, Step 4 through Step 16.
that hold the torque converter housing to the fly-
wheel housing. Carefully separate the transmis- 6. On the two-speed transmission, remove the idler
sion from the engine. gear and two bearings. See Figure 22.

Figure 22. Output Gear Removal


A. 1-SPEED TRANSMISSION B. 2-SPEED TRANSMISSION
1. BEARING 9. YOKE
2. IDLER GEAR 10. WASHER
3. SNAP RING 11. LOCKWASHER
4. SPECIAL NUT 12. BOLT
5. OUTPUT GEAR 13. REVERSE GEAR
6. TRANSMISSION HOUSING 14. FORWARD CLUTCH PACK
7. OIL SEAL 15. 2 SPEED HIGH FORWARD
8. SPACER CLUTCH PACK
NOTE: The procedure for removal of the output gear 9. Remove the oil seal from the back of the trans-
is the same for both transmissions. mission.
7. Remove the bolt, three washers, and yoke from 10. Remove the bearings, snap ring, special nut, and
the back of the transmission. See Figure 22. output gear from the transmission.
8. Remove the spacer from the yoke. 11. Disassembly of the clutch assemblies follows.
The procedures are the same for removal and
NOTE: Note the position of the oil seal during re- disassembly of the clutch pack assemblies for
moval to aid in installation. both the 1- and 2-speed transmissions. See Fig-
ure 23, Figure 24, and Figure 25.

Figure 23. 1- and 2-Speed Forward Clutch Packs


A. 1-SPEED TRANSMISSION FORWARD CLUTCH B. 2-SPEED TRANSMISSION FORWARD CLUTCH
1. SEAL 9. CONICAL PLATE
2. BEARING 10. FRICTION DISK
3. GEAR ASSEMBLY DRUM 11. SEPARATOR PLATE
4. PISTON SEAL 12. PRESSURE PLATE
5. PISTON 13. SPACER
6. SPRING 14. OUTPUT GEAR
7. SPRING GUIDE 15. BACK PLATE
8. SNAP RING

Figure 24. 1- and 2-Speed Reverse Clutch Packs


A. 1-SPEED TRANSMISSION REVERSE CLUTCH B. 2-SPEED TRANSMISSION REVERSE CLUTCH
1. SEAL 9. CONICAL PLATE
2. BEARING 10. FRICTION DISK
3. GEAR ASSEMBLY DRUM 11. SEPARATOR PLATE
4. PISTON SEAL 12. PRESSURE PLATE
5. PISTON 13. SPACER
6. SPRING 14. OUTPUT GEAR
7. SPRING GUIDE 15. BACK PLATE
8. SNAP RING
1. SEAL 6. SPRING 11. SEPARATOR PLATE

2. BEARING 7. SPRING GUIDE 12. PRESSURE PLATE
3. GEAR ASSEMBLY DRUM 8. SNAP RING 13. BACK PLATE
4. PISTON SEAL 9. CONICAL PLATE 14. SPACER
5. PISTON 10. FRICTION DISK 15. OUTPUT GEAR
Figure 25. 2-Speed High Clutch Pack

Clutch Assemblies, Remove and Disassemble

NOTE: The 1-speed forward clutch assembly is shown in the illustrations for the disassembly procedures.
STEP 1.
Pull the forward clutch assembly straight from the
transmission housing.
1. REVERSE CLUTCH
2. FORWARD CLUTCH
3. TRANSMISSION INPUT SPEED SENSOR (TISS)
4. TRANSMISSION OUTPUT SPEED SENSOR
(TOSS)
STEP 2.
Remove the shaft seal and bearing from the input
shaft. Discard the shaft seal.
1. SHAFT SEAL
2. BEARING
3. INPUT SHAFT

STEP 3.
Remove the snap ring from the output gear. Remove
the output gear from the input shaft
1. SNAP RING
2. BEARING
3. OUTPUT GEAR
NOTE: Before removing the seal bearing, note the position of the seal on the bearing.
STEP 4.
Remove seal from the output gear. Remove seal bear-
ing, snap ring, spacer, snap ring, and bearing from
the output gear.
1. SEAL BEARING
2. SNAP RING
3. SPACER
4. SEAL
5. OUTPUT GEAR
6. BEARING
NOTE: On 2-speed transmissions, there will be a back plate in front of the pressure plate.

STEP 5.
Remove the snap ring and pressure plate from the

gear assembly drum.
1. SNAP RING
2. PRESSURE PLATE
3. GEAR ASSEMBLY DRUM
STEP 6.
Remove the friction disks and separator plates alter-
nately until all have been removed from the gear as-
sembly drum
1. FRICTION DISK
2. SEPARATOR PLATE
STEP 7.
Remove the conical plate from the gear assembly
drum.
1. CONICAL PLATE

WARNING
The springs for the piston are compressed. Make sure the springs and spring retainer cannot cause
injury when the snap ring is removed.
NOTE: Remove the piston only if there is a problem with the piston or piston seals.
STEP 8.
Using the spring compression tool Hyster P/N 867890
and a press, place the spring compression tool on
the spring guide with the opening of the tool above
the opening of the snap ring, and compress the large
and small springs just enough to allow removal of
the snap ring from the spring guide. Slowly release
the press to decompress the springs.
1. SPRING COMPRESSION TOOL

2. SPRING GUIDE

STEP 9.
Remove the snap ring, spring guide, large spring, and
small spring from the input shaft.
1. SNAP RING
2. SPRING GUIDE
3. LARGE SPRING
4. SMALL SPRING
5. INPUT SHAFT
STEP 10.
Remove the piston from the gear assembly drum and
the piston seal from the piston. Discard the piston
seal.
1. PISTON
2. PISTON SEAL
4. SHAFT SEAL

STEP 11.
Remove the shaft seals and bearing from the input
shaft. Discard shaft seals.
1. SHAFT SEALS
2. BEARING
3. INPUT SHAFT
CLEAN 4. The conical plate and separator plates must not

be bent, have damaged surfaces, or have large
WARNING blue areas from too much heat. If any of the
above conditions exist, replace the damaged com-
ponent.
and can cause skin irritation. When using
cleaning solvents, always follow the solvent 5. Check the "H" dimension of the conical plate as
manufacturer’s recommended safety proce- shown in Figure 26. If the dimension is less than
dures. 3.2 mm (0.126 in.), replace the conical plate.
Clean all metal parts with cleaning solvent and place 6. Check the "t" dimension of the conical plate as
on a lint-free cloth to dry. Ensure that the cleaning shown in Figure 26. If the dimension is less than
and assembly environment is free of dust, dirt, and 2.4 mm (0.094 in.), replace the conical plate.
any other foreign matter that would affect the per-
formance of the parts.
INSPECT
1. Inspect the gear teeth on clutch assemblies and
all other gears for wear or damage. If the gear
teeth are worn or damaged, replace the damaged
component.
2. Check all parts that have splines for damage

to the splines. Check for notches worn in the
splines. Replace the clutch pack or gears that Figure 26. Conical Plate Inspection
have spline damage.
7. Inspect the bearings for wear or damage. If the
3. Inspect the friction discs for burned lining or bent bearings are damaged, replace them.
surfaces. Check for small holes in the lining. Re-
place the friction discs if one-half the depth of the 8. Inspect the piston for damage. Make sure that
oil grooves is worn away or the discs are dam- the sealing surfaces are good. Make sure the ori-
aged. Discard a friction disc that has a thickness fice is clean.
less than 2.2 mm (0.087 in.).
9. Check for grooves or other damage on the ma-
chined surfaces of the clutch pack shafts and

transmission housing. Check the mounting and alignment is not correct, damage to the trans-
sealing surfaces in the housing for damage. If mission assembly could occur.
there is evidence of any damage, replace the
housing or transmission. If the clutch pack shaft 11. Inspect dowel pins and dowel pin holes. If any
is damaged, replace the clutch pack. dowel pin is damaged at all, replace the dowel
pin. If a dowel pin hole is damaged, replace the
10. Inspect all hardware and mounting surfaces for housing.
the presence of rust, sealing compounds, and us-
able condition. If the hardware is to be reused, 12. Check the fit of bearings in the transmission
clean all rust and sealing compounds from the housings. If the bearings fit too loosely into the
threaded areas. If the hardware is not in usable housings, this could mean that the bores are
condition, replace the hardware. oversized. Replace housings as necessary.
ASSEMBLE AND INSTALL

CAUTION
The dowel pins are used to properly align the
housings for proper mating to each other. If the
Clutch Assemblies, Assemble and Install

NOTE: The 1-speed forward clutch assembly is shown in the illustrations for the assembly procedures.
STEP 1.
Install the bearing and new shaft seals on the input
shaft.
1. SHAFT SEALS
2. BEARING
3. INPUT SHAFT
NOTE: Perform STEP 2 through STEP 5 only if the piston was removed.

STEP 2.
Lubricate all parts with clean transmission oil. In-
stall the shaft seal on the shaft and the piston seal
on the piston.
1. PISTON SEAL
2. PISTON
STEP 3.
Install the piston into the gear assembly drum.
1. PISTON
2. PISTON SEAL
4. SHAFT SEAL
STEP 4.
Install the small spring, large spring, spring guide,
and snap ring on the input shaft.
1. SNAP RING
2. SPRING GUIDE
3. LARGE SPRING
4. SMALL SPRING
5. INPUT SHAFT

STEP 5.
Using the spring compression tool Hyster P/N 867890
and a press, place the spring compression tool on
the spring guide with the opening of the tool above
the opening of the snap ring, and compress the large
and small springs just enough to allow installation
of the snap ring in the spring guide. Slowly release
the press.
1. SPRING COMPRESSION TOOL

2. SPRING GUIDE
NOTE: The conical plate is properly installed when the inner diameter is touching the piston, and the outer
diameter of the conical plate is touching the outer diameter of the friction disk.

STEP 6.
Install the conical plate into the gear assembly drum.
1. CONICAL PLATE
STEP 7.
Install the separator plates and friction disks alter-
nately until all have been installed in the gear assem-
bly drum.
1. FRICTION DISK
2. SEPARATOR PLATE
NOTE: On 2-speed transmissions, install the back plate in front of the pressure plate.

STEP 8.
Install the pressure plate and snap ring in the gear

assembly drum. Using a dial indicator or feeler
gauge, check the clearance between the snap ring
and pressure plate. There must be 1.8±0.2 mm
(0.071±0.008 in.) of clearance for a single speed
transmission, and 2.7±0.2 mm (0.106±0.008 in.)of
clearance for a 2 speed trnasmission. If the clearance
is not correct, see the Parts Manual for the correct
pressure plate.
1. SNAP RING
2. PRESSURE PLATE
NOTE: Make sure the seal on seal bearing is in correct position as noted during removal.
STEP 9.
Install seal onto output gear. Install the bearing,
snap ring, spacer, snap ring, and seal bearing into
output gear.
1. SEAL BEARING
2. SNAP RING
3. SPACER
4. SEAL
5. OUTPUT GEAR
6. BEARING

STEP 10.
Install the output gear on the input shaft. Install
bearing and snap ring in the output gear.
1. SNAP RING
2. BEARING
3. OUTPUT GEAR
STEP 11.
Install the bearing and shaft seal on the input shaft.
1. SHAFT SEAL
2. BEARING
3. INPUT SHAFT

STEP 12.
Install the reverse clutch assembly in the transmis-
sion housing. Do not damage the seal rings on the
end of the clutch shaft.
Check the gap between the TOSS and TISS sensors

and reverse gear. The allowable gap for the TOSS
sensor is 0.8 to 1.8 mm (0.031 to 0.071 in.). The al-
lowable gap for the TISS sensor is 0.8 to 2.0 mm
(0.031 to 0.080 in.).
1. REVERSE CLUTCH
2. FORWARD CLUTCH
3. TISS SENSOR
4. TOSS SENSOR
STEP 13.
Install the forward clutch assembly in the transmis-
sion housing. Do not damage the seal rings on the
end of the clutch shaft.
1. REVERSE CLUTCH
2. FORWARD CLUTCH
3. TISS SENSOR
4. TOSS SENSOR

Transmission, Assemble and Install 1. Install the bearing, output gear, special nut, snap
ring, and bearing on the transmission. See Fig-
NOTE: The procedure for installation of the output ure 27.
gear is the same for both transmissions.

Figure 27. Output Gear Installation


A. 1 SPEED TRANSMISSION B. 2 SPEED TRANSMISSION
1. BEARING 7. OIL SEAL
2. IDLER GEAR 8. SPACER
3. SNAP RING 9. YOKE
4. SPECIAL NUT 10. WASHER
5. OUTPUT GEAR 11. LOCKWASHER
6. TRANSMISSION HOUSING 12. CAPSCREW
2. Install the oil seal into the back of the transmis-

sion as noted during removal.
CAUTION
Use care when connecting the wiring harness
3. Install the spacer in the yoke. connectors to electrical connectors on the
transmission and control valve. The connec-
4. Install the yoke, three washers, and bolt in the tors on the transmission and control valve are
back of the transmission. Tighten the bolt to easily damaged.
38 N•m (28 lbf ft). See Figure 27.
7. Install the transmission wiring harness on the
5. On the 2-speed transmission, install the two transmission. Connect the connectors of the
bearings and idler gear. See Figure 27. transmission wiring harness to the control valve
and transmission. Connect the two connectors of
6. Install the front cover housing and the torque
the chassis wiring harness to the transmission
converter housing on the transmission. See
wiring harness. See Figure 28.
Front Cover Housing and Chain Drive Repair,
Install, Step 1 through Step 15.

A. EARLY LIFT TRUCK MODELS EXCEPT H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110,
120FT) (N005, P005) MODELS
4. TRANSMISSION

8. Rotate the engine crankshaft to position the 3.5FT (S40-70FT, S55FTS) (F187); H2.0-3.5FT
flywheel mounting holes in line with the torque (H40-70FT) (L177) lift trucks.
converter mounting holes. Install the capscrews
that hold the torque converter to the flywheel 10. Fill the transmission to the correct level us-
through the access hole of the flywheel housing. ing the correct transmission fluid and proce-
See Figure 29. Tighten the capscrews to 56 N•m dure given in section Periodic Maintenance
(41 lbf ft). Remove the lifting eye bolt, and install 8000 SRM 1150 for S2.0-3.5FT (S40-70FT,
the access cover on the torque converter housing. S55FTS) (F187); H2.0-3.5FT (H40-70FT)
(L177) lift trucks, Periodic Maintenance
9. Install the engine and transmission as a unit into 8000 SRM 1207 for S30FT, S35FT, S40FTS
the lift truck. See the section Frame 100 SRM (E010); H1.6FT, H1.8FT, 2.0FTS (H30FT,
1243 for S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100, H35FT, H40FTS) (F001) lift trucks, and Pe-
120FT; S80, 100FTBCS; S120FTS; S120FTPRS) riodic Maintenance 8000 SRM 1248 for S4.0,
(G004) and H4.0FT5/FT6; H4.5FTS5, H4.5FT6; 4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT; S80,
H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005, 100FTBCS; S120FTS; S120FTPRS) (G004) and
P005) lift trucks, and Frame 100 SRM 1120 for H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT
S30FT, S35FT, S40FTS (E010); H1.6FT, H1.8FT, (H80, 90, 100, 110, 120FT) (N005, P005) lift
2.0FTS (H30FT, H35FT, H40FTS) (F001); S2.0- trucks.


1300 SRM 1129 Control Valve Repair

Control Valve Repair

REMOVE AND DISASSEMBLE
CAUTION
nesses from the connectors. The connectors
are easily damaged.
1. Clean the area around the control valve. Put

identification tags on the wire harness connec-
tors and the connectors on the transmission and
control valve. Disconnect the wiring harness con-
nectors from transmission and control valve con-
nectors, and remove the cable connector from the
standoff located on the torque converter housing.
See Figure 30.
2. Remove the capscrews that attach the control

valve to the transmission. Remove the control
valve assembly and discard the gasket. Put a
cover on top of the transmission to keep dirt out H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT
of the transmission. See Figure 31. (H80, 90, 100, 110, 120FT) (N005, P005)
MODELS
2. HARNESS STANDOFF
3. TRANSMISSION WIRING HARNESS
Figure 30. Transmission Assembly

Control Valve Repair 1300 SRM 1129
3. Remove two capscrews and the transmission

input speed sensor (TISS). Remove two cap-
screws and the transmission output speed sensor
(TOSS) from the transmission.
NOTE: Disassemble the control valve only to the ex-

tent to complete any repairs that are required.
NOTE: Disassemble the control valve in a clean, con-

tamination-free area.
4. Remove two pressure transducers, two fittings,

capscrew, lockwasher, and clip from the control
valve body. See Figure 32.

(H80, 90, 100, 110, 120FT) (N005, P005)
MODELS
1. TRANSMISSION ASSEMBLY
2. GASKET
3. CONTROL VALVE ASSEMBLY
4. LOCKWASHER
5. CAPSCREW
6. TRANSMISSION INPUT SPEED SENSOR (TISS)
7. TRANSMISSION OUTPUT SPEED SENSOR
(TOSS)
Figure 31. Control Valve Removal

1. CONTROL VALVE BODY 9. PLUG
2. PRESSURE TRANSDUCER 10. FORWARD PROPORTIONAL VALVE
3. FITTING 11. SOCKET HEAD CAPSCREW
4. CLIP 12. TORQUE CONVERTER REGULATOR SPOOL
5. LOCKWASHER 13. REVERSE PROPORTIONAL VALVE
6. CAPSCREW 14. TRANSMISSION ENABLE VALVE
7. PROPORTIONAL SUPPLY REGULATOR SPOOL 15. SUPPLY SPOOL
8. SPRING

Figure 32. Control Valve Arrangement

Control Valve Repair 1300 SRM 1129
INSPECT
WARNING
There are compressed springs under the plugs 1. Make sure there are no scratches or damage on
in the control valve. Carefully remove the the spools or in the bores of the control valve
plugs so that the compressed springs do not body. If the control valve body bores are dam-
cause injury. aged, replace the control valve.
5. Remove the plug for the proportional supply reg- 2. Inspect the control valve body for the presence of
ulator spool. Discard the O-ring. Remove the burrs. Burrs may be removed using a fine file,
spring and proportional supply regulator spool emery cloth, or crocus cloth.
from the control valve body.
3. Check that the springs are not bent or damaged.
6. Remove the plug for the torque converter reg- Make sure the spools move freely in their bores.
ulator spool. Discard the O-ring. Remove the
spring and torque converter regulator spool from 4. Inspect the connectors on the proportional and
the control valve body. solenoid valves and, if they are damaged, replace
the damaged proportional or solenoid valves.
7. Remove the plug for the supply spool. Discard
the O-ring. Remove the spring and supply spool ASSEMBLE AND INSTALL
from the control valve body.
NOTE: Lubricate the parts of the control valve with
8. Remove the socket head screws and forward pro- clean transmission oil during assembly.
portional valve from the control valve body. Re-
peat for the reverse proportional valve. 1. Install the transmission enable valve and socket
head screws into the control valve body. Tighten
9. Remove the socket head screws and transmission socket head screws to 3 to 4 N•m (27 to 35 lbf in).
enable valve from the control valve body. See Figure 32.
CLEAN 2. Install the reverse proportional valve, forward

proportional valve, and socket head capscrews
into the control valve body. Tighten socket head
WARNING screws to 3 to 4 N•m (27 to 35 lbf in).
and can cause skin irritation. When using 3. Install the supply spool and spring into the
cleaning solvents, always follow the solvent control valve body. Install the plug with a new
manufacturer’s recommended safety proce- O-ring.
dures.
4. Install the torque converter regulator spool and
Compressed air can move particles so they spring into the control valve body. Install the
cause injury to the user or to other personnel. plug and new O-ring.
Make sure the path of the compressed air is
away from all personnel. Wear protective gog- 5. Install the proportional supply regulator spool
gles or a face shield to prevent injury to the and spring into the control valve body. Install
eyes. the plug and new O-ring.
6. Install the clip, lockwasher, capscrew, two fit-

CAUTION tings, and two pressure transducers into the con-
Do not allow cleaning solvent to come in control valve body.
tact with rubber or plastic components as it
7. Install the transmission input speed sensor (tiss)
can damage those components.
and two capscrews in the transmission. Install
Clean all metal components in solvent and dry with the transmission output speed sensor (toss) and
compressed air. two capscrews in the transmission. Tighten all
capscrews to 6.9 N•m (61 lbf in).

8. Install a new control valve gasket on the trans-

mission. Install the control valve on the trans- CAUTION
mission. See Figure 31. Install the capscrews Use care when connecting the wiring har-
that hold the control valve on the transmission. nesses to the connectors. The connectors are
Do not tighten at this time. easily damaged.
9. Tighten capscrews to 13.3 N•m (118 lbf in) in 10. Install the cable connector in the standoff and
the sequence shown in Figure 33. Retighten cap- connect the wiring harness connectors to the
screws to 19 N•m (168 lbf in) in the sequence transmission and control valve as tagged during
shown in Figure 33. removal. See Figure 30.
Figure 33. Control Valve Mounting Screw

Tightening Sequence

MONOTROL® Pedal Repair 1300 SRM 1129
MONOTROL® Pedal Repair

REMOVE AND DISASSEMBLE
1. Remove five screws, dash panel, and kick plate
from the lift truck. See the section Frame 100
SRM 1243 for S4.0, 4.5, 5.5FT, S5.5FTS, (S80,
100, 120FT; S80, 100FTBCS; S120FTS; S120FT-
PRS) (G004) and H4.0FT5/FT6; H4.5FTS5,
H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(N005, P005) lift trucks, and Frame 100 SRM
(F001); S2.0-3.5FT (S40-70FT, S55FTS) (F187);
H2.0-3.5FT (H40-70FT) (L177) lift trucks. Re-
move three capscrews and swing the hydraulic
lever assembly toward the operator’s seat. Dis-
connect two cable assemblies from the pedal
assembly. See Figure 34.
1. CAPSCREWS
2. PEDAL ASSEMBLY
3. COWL
Figure 35. MONOTROL Pedal Removal
3. Remove two pan head screws, lockwashers, and

accelerator position sensor from throttle base.
See Figure 36.
CAUTION
Use care when removing the connector from its
holder as the connector can be easily damaged.
NOTE: Remove only those components necessary to

complete the repair of the MONOTROL pedal.
4. Remove the connector from the connector holder

on the throttle base. Remove the outer and inner
1. CAPSCREW springs from the throttle base and MONOTROL
2. HYDRAULIC LEVER ASSEMBLY pedal assembly.
Figure 34. Hydraulic Lever Relocation 5. Remove the e-clip and throttle base from the
throttle pedal shaft. Remove the roll pin and the
2. Remove three capscrews that hold the throttle
throttle pedal shaft from the MONOTROL pedal
base to the cowl, and remove the pedal assembly
assembly. Discard the roll pin.
from the lift truck. See Figure 35.

1300 SRM 1129 MONOTROL® Pedal Repair
1. PAN HEAD SCREW 6. THROTTLE PEDAL SHAFT

2. LOCKWASHER 7. E-CLIP
3. ACCELERATOR POSITION SENSOR (APS) 8. ROLL PIN
4. PEDAL FRAME 9. INNER AND OUTER SPRINGS
5. CONNECTOR 10. MONOTROL
Figure 36. MONOTROL Pedal Bracket Disassembly
NOTE: Tag wires prior to removing from mi- 7. Remove two hex head screws, lockwashers, nuts,
croswitches to aid in connecting. and microswitch from the pedal pad. Repeat for
remaining microswitch and remove the wiring
6. Remove u-clip, foam lock seal, and wiring har- harness from the pedal frame.
ness from the pedal frame. Remove four pan
head screws, lockwashers, washers, pedal pad, 8. If damaged, remove the stop screw and nut from
and springs from the pedal frame. If any metal the pedal frame.
inserts in the pedal pad are damaged, replace as
necessary. See Figure 37.

MONOTROL® Pedal Repair 1300 SRM 1129
1. WIRING HARNESS 9. METAL INSERT

2. FOAM LOCK SEAL 10. NUT
3. U-CLIP 11. LOCKWASHER
4. PAN HEAD SCREW 12. MICROSWITCH
5. LOCKWASHER 13. HEX HEAD SCREW
6. WASHER 14. SPRING
7. STOP SCREW 15. PEDAL PAD
8. NUT 16. PEDAL FRAME
Figure 37. MONOTROL Pedal Disassembly

1300 SRM 1129 MONOTROL® Pedal Repair
ASSEMBLE AND INSTALL 4. Install the wiring harness in the pedal frame. In-
stall the foam lock seal and u-clip. Install pedal
1. If removed, install the stop screw and nut on the pad and springs in the pedal frame. Coat the
pedal frame. See Figure 37. threads of four pan head screws with Loctite 222.
Install pan head screws, lockwashers, and wash-
2. Install the microswitch and two hex head screws
ers in the pedal pad. Tighten pan head screws to
in the pedal pad. Coat the exposed threads of
2.25 to 2.50 N•m (19 to 32 lbf in).
the hex head screws with Loctite™ 222. Install
the two lockwashers and nuts on the hex head 5. Using an ohmmeter, check for continuity be-
screws. Do not tighten the nuts at this time. Re- tween pins 3 and 4 of the MONOTROL wiring
peat for the other microswitch. harness connector with the MONOTROL pedal
in the reverse position, and between pins 1 and
3. Put the wires through the hole in the pedal
2 with the pedal in the forward position. See
frame. The white banded wire is for the reverse
Figure 39.
microswitch, and the blue banded wire is for the
forward microswitch. Adjust each microswitch
in its mount so that the measurement between
the edge of the mount and the base of the mi-
croswitch equals 0.0 to 0.5 mm (0.0 to 0.02 in.).
Tighten the mounting nuts of each microswitch
as adjustment is completed. See Figure 38.
1. WIRING HARNESS CONNECTOR

2. WIRING HARNESS
Figure 39. Microswitch Continuity Check
6. Install the throttle pedal shaft and new roll pin

in the MONOTROL pedal assembly. Install the
throttle base and e-clip on the throttle pedal
shaft. See Figure 36.
CAUTION
Use care when installing the connector in its
holder as the connector can be easily damaged.
7. Install the inner and outer springs on the throt-

tle base and MONOTROL pedal assembly. In-
stall the connector in the connector holder on the
throttle base.
1. MICROSWITCH MOUNT 8. Install the actuator and magnet in the throttle
2. MICROSWITCH BASE base. Install the accelerator position sensor,
lockwashers, and two pan head screws in the
Figure 38. Microswitch Adjustment
throttle base. Tighten screws to 2.25 N•m
(19 lbf in).

Direction Control Lever 1300 SRM 1129
9. Apply adhesive compound to the three mounting 120FT; S80, 100FTBCS; S120FTS; S120FTPRS)
bolts. Using the three capscrews that hold the (G004) and H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
throttle base to the cowl, install the pedal assem- H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005,
bly on the lift truck. Tighten the bolts to 19 to P005) lift trucks, and Frame 100 SRM 1120
25 N•m (168 to 221 lbf in). See Figure 35. for S30FT, S35FT, S40FTS (E010); H1.6FT,
10. Connect two cable assemblies to the pedal as- (F001); S2.0-3.5FT (S40-70FT, S55FTS) (F187);
sembly. Swing the hydraulic lever assembly H2.0-3.5FT (H40-70FT) (L177) lift trucks.
toward the cowl and install three capscrews.
See Figure 34. Install the dashboard on the 11. Depress the MONOTROL pedal until it stops.
lift truck. See the section Frame 100 SRM Unscrew stop screw until it contacts the metal
1243 for S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100, floor plate. Tighten the nut to 10 N•m (89 lbf in).
Direction Control Lever

REMOVE the interior lock of the display panel. See B, Fig-
ure 40.
NOTE: There is no repair of the direction control
lever. 3. Repeat the above steps on the opposite side of
the direction control lever. Remove the direction
1. Insert a small, flat-blade screwdriver with a control lever from the display panel.
3.175 mm (0.125 in.) or less, wide blade into
the opening on the display panel on an outward INSTALL
angle enough to compress the spring tab on the
direction control lever. See A, Figure 40. Slide the direction control lever into the opening on
the left side of the display panel until the locking tabs
2. Pry the spring tab toward the body of the direc- are engaged in the display panel.
tion control lever and, at the same time, pull on
the handle of the lever enough to free the tab of

1300 SRM 1129 Direction Control Lever
NOTE: DISPLAY PANEL SHOWN OUTSIDE OF THE LIFT TRUCK FOR CLARITY.
A. STEP 1 B. STEP 2
1. DIRECTION CONTROL LEVER 3. DISPLAY PANEL
2. FLAT-BLADE SCREWDRIVER
Figure 40. Direction Control Lever Removal

NOTES
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70
TECHNICAL PUBLICATIONS
1300 SRM 1129 9/09 (7/08)(3/07)(10/06)(6/06)(3/06)(6/05)(5/05)(12/04) Printed in U.S.A.

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POWERSHIFT TRANSMISSION

This manual contains information that is confidential and/or proprietary to Hyster

PART NO. 1580510 1300 SRM 1129

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

• Wear safety glasses.

• Use the correct tools for the job.

• Keep the tools clean and in good condition.

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

This section is for the following models:

S30FT, S35FT, S40FTS [E010];

©2009 HYSTER COMPANY i

A. EARLY LIFT TRUCK MODELS EXCEPT

Figure 1. Transmission Serial Number

Confidential/Proprietary - Do Not Copy or Duplicate 1

Charge Pump Repair

NOTE: THE TRANSMISSION IS SHOWN REMOVED

Figure 2. Transmission Charge Pump

2 Confidential/Proprietary - Do Not Copy or Duplicate

Torque Converter Replace

Confidential/Proprietary - Do Not Copy or Duplicate 3

A. EARLY LIFT TRUCK MODELS EXCEPT

Figure 3. Engine-Transmission Combination

4 Confidential/Proprietary - Do Not Copy or Duplicate

use your fingers to check for alignment of the

Confidential/Proprietary - Do Not Copy or Duplicate 5

Figure 4. Torque Converter Bolt Access

6 Confidential/Proprietary - Do Not Copy or Duplicate

Legend for Figure 4

Confidential/Proprietary - Do Not Copy or Duplicate 7

A. EARLY LIFT TRUCK MODELS EXCEPT

Figure 5. Torque Converter Removal

8 Confidential/Proprietary - Do Not Copy or Duplicate

6. Remove the plug, suction screen spring, and suc-

7. Remove the transmission charge pump and

NOTE: Step 8, Step 9, and the NOTE below ap-

8. Remove the dipstick from the dipstick tube,

NOTE: The dipstick tube must be removed before the

9. Remove the dipstick tube from the torque con-

10. If damaged, remove the small access cover from

Confidential/Proprietary - Do Not Copy or Duplicate 9

A. EARLY LIFT TRUCK MODELS EXCEPT

Figure 7. Torque Converter Housing

INSTALL 2. If removed, install the small access cover on the

10 Confidential/Proprietary - Do Not Copy or Duplicate

A. EARLY LIFT TRUCK MODELS EXCEPT

Figure 8. Torque Converter Installation

Confidential/Proprietary - Do Not Copy or Duplicate 11

NOTE: The information in Step 3 and Step 4 applies

12 Confidential/Proprietary - Do Not Copy or Duplicate

A. EARLY LIFT TRUCK MODELS EXCEPT

Figure 9. Engine-Transmission Combination

Confidential/Proprietary - Do Not Copy or Duplicate 13

Figure 10. Torque Converter Bolt Access

14 Confidential/Proprietary - Do Not Copy or Duplicate

Legend for Figure 10

Confidential/Proprietary - Do Not Copy or Duplicate 15

Front Cover Housing and Chain Drive Repair

16 Confidential/Proprietary - Do Not Copy or Duplicate

A. EARLY LIFT TRUCK MODELS EXCEPT

Figure 11. Engine-Transmission Combination

Confidential/Proprietary - Do Not Copy or Duplicate 17

Figure 12. Torque Converter Bolt Access

18 Confidential/Proprietary - Do Not Copy or Duplicate