Transmissão 2007

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]
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 Mainte-
nance section.
• Keep the unit clean and the working area clean and orderly.
• Use the correct tools for the job.
• Keep the tools clean and in good condition.
• Always use HYSTER APPROVED parts when making repairs. Replacement parts
must meet or exceed the specifications of the original equipment manufacturer.
• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before
using force to remove parts.
• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs,
or if the unit needs repairs.
• Be sure to follow the WARNING and CAUTION notes in the instructions.
• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel
are flammable. Be sure to follow the necessary safety precautions when handling these
fuels and when working on these fuel systems.
• Batteries generate flammable gas when they are being charged. Keep fire and sparks
away from the area. Make sure the area is well ventilated.
NOTE: The following symbols and words indicate safety information in this
manual:
WARNING
Indicates a condition that can cause immediate death or injury!
CAUTION
Indicates a condition that can cause property damage!
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 ............................................................................................................................................................. 7
Front Cover Housing and Chain Drive Repair................................................................................................. 12
Remove ........................................................................................................................................................... 12
Clean .............................................................................................................................................................. 19
Inspect ............................................................................................................................................................ 19
Install ............................................................................................................................................................. 19
Clutch Packs Repair .......................................................................................................................................... 25
Remove and Disassemble .............................................................................................................................. 25
Transmission, Remove and Disassemble ................................................................................................. 25
Clutch Assemblies, Remove and Disassemble ......................................................................................... 36
Clean .............................................................................................................................................................. 42
Inspect ............................................................................................................................................................ 42
Assemble and Install ..................................................................................................................................... 43
Clutch Assemblies, Assemble and Install ................................................................................................ 43
Transmission, Assemble and Install ........................................................................................................ 51
Control Valve Repair.......................................................................................................................................... 56
Clean .............................................................................................................................................................. 57
Inspect ............................................................................................................................................................ 57
MONOTROL® Pedal Repair .............................................................................................................................. 60
Direction Control Lever ..................................................................................................................................... 64
Remove ........................................................................................................................................................... 64
Install ............................................................................................................................................................. 64
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]
©2007 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) 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
NOTE: The charge pump can be removed from the
transmission while it is still in the lift truck but,
for the sake of clarity, the following procedures are
shown with the transmission removed from the lift
truck.
Remove four mounting capscrews, washers, trans-

mission charge pump, and gasket from the torque
converter housing. Discard the gasket. See Figure 2.
INSPECT
Inspect the splines on the shaft of the transmission
charge pump for damage or worn areas that could
affect the operation of the pump. If the splines are
damaged, replace the transmission charge pump.
NOTE: THE TRANSMISSION IS SHOWN REMOVED
INSTALL FROM THE LIFT TRUCK FOR CLARITY.
Install new gasket, transmission charge pump, four A. EARLY LIFT TRUCK MODELS EXCEPT
mounting capscrews, and washers in the torque H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT
(H80, 90, 100, 110, 120FT) (N005) MODELS
converter housing. Tighten capscrews to 19 N•m B. NEWER LIFT TRUCK MODELS
(168 lbf in).
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 WARNING
Make sure that the engine/transmission assem-
WARNING bly is stable before attempting to rotate the en-
Make sure the engine and transmission are gine.
held in position so that they will not fall and
cause an injury and damage to the equipment. Use a flashlight to see the bolts as they are ro-
tated into view through the access hole. Do not
use your fingers to check for alignment of the
CAUTION bolts with the access hole.
Be careful that you do not damage parts of
the torque converter or transmission when 3. Move each bolt into view through the access hole
the transmission is separated from the engine. of the flywheel housing by rotating the crank-
Keep the transmission and engine in align- shaft. Remove the four capscrews that attach the
ment until they are completely separated so flywheel to the torque converter. See Figure 4.
parts of the transmission are not damaged.
Use a crane or lifting device to separate the 4. Remove the access cover from the torque con-
transmission from the engine. verter housing. Install a lifting eye bolt into the
rear access cover bolt hole, and connect a lifting
1. Remove the engine and transmission as a unit device to the eye bolt. Remove the 10 capscrews
from the lift truck. See the section Frame 100 that hold the torque converter housing to the fly-
SRM 1243 for S4.0, 4.5, 5.5FT, S5.5FTS, (S80, wheel housing on the engine. Carefully separate
100, 120FT; S80, 100FTBCS; S120FTS; S120FT- the transmission from the engine.
PRS) (G004) and H4.0FT5/FT6; H4.5FTS5,
H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) NOTE: The torque converter cannot be repaired and
(N005) lift trucks, and Frame 100 SRM 1120 must be replaced as a unit, if damaged.
for S30FT, S35FT, S40FTS (E010); H1.6FT, 5. Carefully remove the torque converter from the
H1.8FT, 2.0FTS (H30FT, H35FT, H40FTS) stator support. See Figure 5.
(F001); S2.0-3.5FT (S40-70FT, S55FTS) (F187);
H2.0-3.5FT (H40-70FT) (L177) lift trucks. 6. Remove the plug, suction screen spring, and suc-
tion screen from the torque converter housing,
CAUTION and drain the oil from the transmission.
Use care when disconnecting the wiring har- 7. Remove the transmission charge pump and
ness connectors from electrical connectors on transmission oil filter from the torque converter
the transmission and control valve. The con- housing.
nectors on the transmission and control valve
are easily damaged. NOTE: Step 8, Step 9, and the NOTE below ap-
ply to early lift truck models except H4.0FT5/FT6;
NOTE: When disconnecting wiring harness connec- H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110,
tors during disassembly, tag each connector to aid in 120FT) (N005) models.
connecting the wiring harness during reassembly.
8. Remove the dipstick from the dipstick tube,
2. Put the engine and transmission on solid blocks and disconnect the vent tube assembly from the
on a work surface. Disconnect the connectors of transmission housing.
the transmission wiring harness from the control
valve and transmission. Remove the transmis- NOTE: The dipstick tube must be removed before the
sion wiring harness from the transmission. See torque converter housing can be removed from the
Figure 3. front cover housing.
9. Remove the dipstick tube from the torque con-

verter housing.

Torque Converter Replace 1300 SRM 1129
A. EARLY LIFT TRUCK MODELS EXCEPT B. NEWER LIFT TRUCK MODELS

(H80, 90, 100, 110, 120FT) (N005) 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

Figure 4. Torque Converter Bolt Access

Legend for Figure 4

A. GM 2.4L ENGINE ON ENGINE AND TRANSMISSIONS SHOWN
B. MAZDA ENGINE IN ILLUSTRATIONS A THROUGH D, EXCEPT
C. YANMAR ENGINE WHEN D IS USED ON H4.0FT5/FT6; H4.5FTS5,
D. GM 4.3L ENGINE H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT)
E. ILLUSTRATES NEW DIPSTICK AND BREATHER (N005) LIFT TRUCK MODELS
LOCATION AND NEW FITTING DESIGN USED F. CUMMINS 4.5L DIESEL ENGINE
1. ACCESS HOLE 2. FLYWHEEL HOUSING

(H80, 90, 100, 110, 120FT) (N005) 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

10. If damaged, remove the small access cover from

the torque converter housing.
NOTE: Perform Step 11 only if repair of the of the

transmission chain drive is required. If the trans-
mission clutch packs are in need of further repair,
see Clutch Packs Repair.
11. Remove 12 capscrews from the transmission

housing and four mounting capscrews from the
front of the torque converter housing. Using
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.
INSTALL
1. Install new O-rings and gasket and using four
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.
2. If removed, install the small access cover on the A. EARLY LIFT TRUCK MODELS EXCEPT
torque converter housing. Tighten capscrews to H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT
7.9 N•m (69 lbf in). See Figure 8. (H80, 90, 100, 110, 120FT) (N005) MODELS
NOTE: The information in Step 3 and Step 4 applies
only to early lift truck models except for H4.0FT5/ 1. PRY POINTS
FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 3. FRONT COVER HOUSING
110, 120FT) (N005) models. 4. TRANSMISSION HOUSING
3. Clean the surface of the dipstick tube and dip- Figure 6. Pry Point Location
stick hole in the torque converter housing. Apply
adhesive (Hyster P/N 264159) to the entire sur- 8. Install the torque converter onto the input shaft
face of the hole in the housing. Insert the dipstick and stator support of the transmission. Make
tube until the collar bottoms on the housing and sure the splines are aligned and the converter
orient the tab against the housing flange. engages fully.
4. Install the dipstick into the dipstick tube, and 9. Lubricate the pilot hub on the torque converter
connect the vent tube assembly to the transmis- with antiseize compound. See Figure 8.
sion housing.
10. If removed, install a lifting eye bolt into the rear
5. Install a new transmission oil filter on the torque access cover bolt hole, and connect a lifting de-
converter housing. vice to the eye bolt. Align the torque converter
housing with the flywheel housing. Make sure
6. Install the transmission charge pump on the the pilot hub on the torque converter engages the
torque converter housing. Tighten capscrews to flywheel.
19 N•m (168 lbf in).
7. Install the suction screen, suction screen spring,

and plug into the torque converter housing.


(H80, 90, 100, 110, 120FT) (N005) MODELS
1. CAPSCREW 4. GASKET
2. WASHER 5. FRONT COVER HOUSING
Figure 7. Torque Converter Housing
CAUTION CAUTION
Be careful that you do not damage parts of Use care when connecting the wiring harness
the torque converter or transmission when connectors to electrical connectors on the
the transmission is joined to the engine. Keep transmission and control valve. The connec-
the transmission and engine in alignment un- tors on the transmission and control valve are
til they are completely joined so parts of the easily damaged.
transmission are not damaged. Use a crane or
lifting device to join the transmission to the 12. Install the transmission wiring harness on the
engine. transmission. Connect the connectors of the
transmission wiring harness to the control valve
11. Install the transmission to the engine. Install and transmission. See Figure 9.
the capscrews that connect the torque converter
housing to the flywheel housing. Tighten the
capscrews to 38 N•m (28 lbf ft). See Figure 9.


(H80, 90, 100, 110, 120FT) (N005) 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
13. Rotate the engine crankshaft to position the through the access hole of the flywheel housing.
flywheel mounting holes in line with the torque See Figure 10. Tighten the capscrews to 56 N•m
converter mounting holes. Install the capscrews (41 lbf ft). Remove the lifting eye bolt, and install
that hold the torque converter to the flywheel, the access cover on the torque converter housing.
after coating the threads with Loctite™ 242,


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


Front Cover Housing and Chain Drive Repair 1300 SRM 1129
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
8000 SRM 1207 for S30FT, S35FT, S40FTS
into the lift truck. See the section Frame 100
(E010); H1.6FT, H1.8FT, 2.0FTS (H30FT,
SRM 1243 for S4.0, 4.5, 5.5FT, S5.5FTS, (S80,
H35FT, H40FTS) (F001) lift trucks, and Pe-
100, 120FT; S80, 100FTBCS; S120FTS; S120FT-
riodic Maintenance 8000 SRM 1248 for S4.0,
4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT; S80,
H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT)
100FTBCS; S120FTS; S120FTPRS) (G004) and
(N005) lift trucks, and Frame 100 SRM 1120
for S30FT, S35FT, S40FTS (E010); H1.6FT,
(H80, 90, 100, 110, 120FT) (N005) lift trucks.
H1.8FT, 2.0FTS (H30FT, H35FT, H40FTS)
(F001); S2.0-3.5FT (S40-70FT, S55FTS) (F187);
H2.0-3.5FT (H40-70FT) (L177) lift trucks.
Front Cover Housing and Chain Drive Repair

REMOVE H1.8FT, 2.0FTS (H30FT, H35FT, H40FTS)
(F001); S2.0-3.5FT (S40-70FT, S55FTS) (F187);
WARNING H2.0-3.5FT (H40-70FT) (L177) lift trucks.
Make sure the engine and transmission are
held in position so that they will not fall and CAUTION
cause an injury and damage to the equipment. To prevent possible damage to the transmis-
sion assembly when placing the assembly on a
CAUTION work surface, place blocks under the back side
of the transmission housing for additional sup-
Keep the transmission and engine in alignment
port.
until they are completely separated so parts of
the transmission are not damaged. Use a crane
or lifting device to separate the transmission CAUTION
from the engine. Use care when disconnecting the wiring har-
ness connectors from electrical connectors on
1. Remove the engine and transmission as a unit
the transmission and control valve. The con-
from the lift truck. See the section Frame 100
SRM 1243 for S4.0, 4.5, 5.5FT, S5.5FTS, (S80,
are easily damaged.
PRS) (G004) and H4.0FT5/FT6; H4.5FTS5, NOTE: When disconnecting wiring harness connec-
H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) tors during disassembly, tag each connector to aid in
(N005) lift trucks, and Frame 100 SRM 1120 connecting the wiring harness during reassembly.

1300 SRM 1129 Front Cover Housing and Chain Drive Repair
2. Put the engine and transmission on solid blocks valve and transmission. Remove the transmis-
on a work surface. Disconnect the connectors of sion wiring harness from the transmission. See
the transmission wiring harness from the control Figure 11.

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



6. Remove the dipstick from the dipstick tube, and
WARNING disconnect the tube assembly from the transmis-
Make sure that the engine/transmission assem- sion housing.
bly is stable before attempting to rotate the en-
gine. NOTE: The dipstick tube must be removed before the
torque converter housing can be removed from the
Use a flashlight to see the bolts as they are ro- front cover housing.
tated into view through the access hole. Do not
use your fingers to check for alignment of the 7. Remove the dipstick tube from the torque con-
bolts with the access hole. verter housing.
3. Move each bolt into view through the access hole 8. Remove the plug, suction screen spring, and suc-
of the flywheel housing by rotating the crank- tion screen from the torque converter housing
shaft. Remove the four capscrews that attach the and drain the oil from the transmission.
flywheel to the torque converter. See Figure 12.
9. Remove the transmission charge pump from the
4. Remove the access cover from the torque con- torque converter housing.
verter housing. Install a lifting eye bolt into the
rear access cover bolt hole, and connect a lifting 10. Remove the four mounting capscrews from the
device to the eye bolt. Remove the 10 capscrews front of the torque converter housing. Loosen
that hold the torque converter housing to the fly- the remaining 12 capscrews on the transmission
wheel housing. Carefully separate the transmis- housing and using a small pry bar, remove the
sion from the engine. torque converter housing from the front cover
housing. See Figure 14. Discard the O-rings on
5. Carefully remove the torque converter from the the front cover housing and the gasket.
stator support. See Figure 13.
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) models.


(H80, 90, 100, 110, 120FT) (N005) 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: 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.
12. Remove the two snubbers from the front cover

housing. Carefully pull the driving and driven
sprockets, chain, and bearings from the front
cover housing as an assembly. Remove and dis-
card the O-ring from the driving sprocket.
13. Remove the stator support from the front cover

housing. Remove and discard the sealing ring
and O-ring from the stator support.
14. Remove the plug, regulator compression spring,

and regulator spool from the front cover housing.
15. Remove the baffle from the front cover housing.
16. The front cover housing is held in alignment with

the transmission housing with dowel pins. Re-
move three mounting capscrews from the front of
A. EARLY LIFT TRUCK MODELS EXCEPT the front cover housing. Remove the remaining
H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT 12 capscrews from the transmission housing. To
(H80, 90, 100, 110, 120FT) (N005) MODELS
B. NEWER LIFT TRUCK MODELS separate the front cover housing from the trans-
mission housing, use a small pry bar to loosen
1. PRY POINTS the front cover housing. See Figure 14. Remove
2. TORQUE CONVERTER HOUSING the front cover housing from the transmission
3. FRONT COVER HOUSING
4. TRANSMISSION HOUSING housing. Discard the O-rings on the transmis-
sion housing and the gasket.
Figure 14. Pry Point Location

Figure 15. Chain Drive


(H80, 90, 100, 110, 120FT) (N005) MODELS
1. SNUBBER 12. STATOR SUPPORT
2. PUMP DRIVE CHAIN 13. SEALING RING
3. BEARING 14. FRONT COVER HOUSING
4. DRIVEN SPROCKET 15. TRANSMISSION HOUSING
5. OIL SEAL 16. BAFFLE
6. ANGULAR CONTACT BEARING 17. PLUG
7. BUSHING 18. REGULATOR COMPRESSION SPRING
8. O-RING 19. REGULATOR SPOOL
9. DRIVING SPROCKET 20. FRONT COVER HOUSING MOUNTING
10. CAPSCREW CAPSCREWS
11. LOCKWASHER
CLEAN INSTALL
1. Install new O-rings and gasket on the trans-
WARNING mission housing. The front cover housing is
Cleaning solvents can be flammable and toxic held in alignment with the transmission hous-
and can cause skin irritation. When using ing with dowel pins. Install the front cover
cleaning solvents, always follow the solvent housing on the transmission housing. Install
manufacturer’s recommended safety proce- 12 capscrews through the transmission housing
dures. and front cover housing. Install the three front
cover housing capscrews and tighten to 38 N•m
Compressed air can move particles so they
(28 lbf ft) See Figure 16.
cause injury to the user or to other personnel.
Make sure the path of the compressed air is 2. Install the baffle in the front cover housing. See
away from all personnel. Wear protective gog- Figure 16.
gles or a face shield to prevent injury to the
eyes. 3. Install the regulator spool, regulator compres-
sion spring, and plug into the front cover hous-
1. Clean the snubbers with warm, soapy water and ing.
dry with compressed air.
4. Install the new sealing ring and O-ring on the
2. Clean bearings, chain, stator support, and gears stator support. Install the stator support on the
with solvent and dry with compressed air front cover housing. See Figure 16. Tighten the
capscrews to 38 N•m (28 lbf ft).
INSPECT
5. On a lint-free cloth, place the driving sprocket
1. Inspect the snubbers for cracks or wear. If dam- on the right side and the driven sprocket on the
aged or worn, replace both snubbers. left side, and place the chain around both sprock-
2. Inspect the chain, gears, and stator support for ets (see Figure 16.). Install the bearings on the
damage. If damage is present, replace the dam- sprockets. Carefully place the driving and driven
aged component. Inspect the driving and driven sprockets, chain, and bearings assembly on the
gears for damage or wear to the gear teeth. If front cover. Install two snubbers on the front
the gear teeth are worn or damaged, replace the cover housing.
gear. Inspect the splines on the input shaft for
damage, and if damaged, replace the input clutch
pack. See Clutch Packs Repair.

Figure 16. Chain Drive


(H80, 90, 100, 110, 120FT) (N005) MODELS
1. SNUBBER 12. STATOR SUPPORT
2. PUMP DRIVE CHAIN 13. SEALING RING
3. BEARING 14. FRONT COVER HOUSING
4. DRIVEN SPROCKET 15. TRANSMISSION HOUSING
5. OIL SEAL 16. BAFFLE
6. ANGULAR CONTACT BEARING 17. PLUG
7. BUSHING 18. REGULATOR COMPRESSION SPRING
8. O-RING 19. REGULATOR SPOOL
9. DRIVING SPROCKET 20. FRONT COVER HOUSING MOUNTING
10. CAPSCREW CAPSCREWS
11. LOCKWASHER
6. Install the new oil seal into rear of the torque to the front cover housing. Install 12 capscrews
converter housing as noted during removal. from the back of the transmission housing.
See Figure 17. Tighten 16 capscrews on the
7. Install the new O-rings and gasket on the front transmission housing and front cover housing to
cover housing. Using the front four mounting 38 N•m (28 lbf ft).
capscrews, install the torque converter housing
Figure 17. Torque Converter Housing Installation


(H80, 90, 100, 110, 120FT) (N005) 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
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) 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


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


1300 SRM 1129 Clutch Packs Repair

18. Install the engine and transmission as a unit given in the section Periodic Maintenance
into the lift truck. See the section Frame 100 8000 SRM 1150 for S2.0-3.5FT (S40-70FT,
SRM 1243 for S4.0, 4.5, 5.5FT, S5.5FTS, (S80, S55FTS) (F187); H2.0-3.5FT (H40-70FT)
100, 120FT; S80, 100FTBCS; S120FTS; S120FT- (L177) lift trucks, Periodic Maintenance
PRS) (G004) and H4.0FT5/FT6; H4.5FTS5, 8000 SRM 1207 for S30FT, S35FT, S40FTS
H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (E010); H1.6FT, H1.8FT, 2.0FTS (H30FT,
(N005) lift trucks, and Frame 100 SRM 1120 H35FT, H40FTS) (F001) lift trucks, and Pe-
for S30FT, S35FT, S40FTS (E010); H1.6FT, riodic Maintenance 8000 SRM 1248 for S4.0,
H1.8FT, 2.0FTS (H30FT, H35FT, H40FTS) 4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT; S80,
(F001); S2.0-3.5FT (S40-70FT, S55FTS) (F187); 100FTBCS; S120FTS; S120FTPRS) (G004) and
H2.0-3.5FT (H40-70FT) (L177) lift trucks. H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT
(H80, 90, 100, 110, 120FT) (N005) lift trucks.
19. Fill the transmission to the correct level using
the correct transmission fluid and procedure
Clutch Packs Repair

REMOVE AND DISASSEMBLE H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT)
Transmission, Remove and Disassemble for S30FT, S35FT, S40FTS (E010); H1.6FT,
WARNING (F001); S2.0-3.5FT (S40-70FT, S55FTS) (F187);
H2.0-3.5FT (H40-70FT) (L177) lift trucks.
Make sure the engine and transmission are
held in position so that they will not fall and
cause an injury and damage to the equipment. CAUTION
To prevent possible damage to the transmis-
sion assembly when placing the assembly on a
CAUTION
work surface, place blocks under the back side
Be careful that you do not damage parts of of the transmission housing for additional sup-
the torque converter or transmission when port.
the transmission is separated from the engine.
Keep the transmission and engine in align-
ment until they are completely separated so CAUTION
parts of the transmission are not damaged. Use care when disconnecting the wiring har-
Use a crane or lifting device to separate the ness connectors from electrical connectors on
transmission from the engine. the transmission and control valve. The con-
1. Remove the engine and transmission as a unit are easily damaged.
SRM 1243 for S4.0, 4.5, 5.5FT, S5.5FTS, (S80, NOTE: When disconnecting wiring harness connec-
100, 120FT; S80, 100FTBCS; S120FTS; S120FT- tors during disassembly, tag each connector to aid in
PRS) (G004) and H4.0FT5/FT6; H4.5FTS5, connecting the wiring harness during reassembly.

Clutch Packs Repair 1300 SRM 1129
2. Put the engine and transmission on solid blocks of the transmission wiring harness from the con-
on a work surface. Disconnect the two connectors trol valve and transmission. Remove the trans-
of the chassis wiring harness from the transmis- mission wiring harness from the transmission.
sion wiring harness. Disconnect the connectors See Figure 20.

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

6. On the two-speed transmission, remove the idler

WARNING gear and two bearings. See Figure 22.
Make sure that the engine/transmission assem-
bly is stable before attempting to rotate the en- NOTE: The procedure for removal of the output gear
gine. is the same for both transmissions.
Use a flashlight to see the bolts as they are ro- 7. Remove the bolt, three washers, and yoke from
tated into view through the access hole. Do not the back of the transmission. See Figure 22.
use your fingers to check for alignment of the
bolts with the access hole. 8. Remove the spacer from the yoke.
3. Move each bolt into view through the access hole NOTE: Note the position of the oil seal during re-
of the flywheel housing by rotating the crank- moval to aid in installation.
shaft. Remove the four capscrews that attach the 9. Remove the oil seal from the back of the trans-
flywheel to the torque converter. See Figure 21. mission.
4. Remove the access cover from the torque con- 10. Remove the bearings, snap ring, special nut, and
verter housing. Install a lifting eye bolt into the output gear from the transmission.
rear access cover bolt hole, and connect a lifting
device to the eye bolt. Remove the 10 capscrews 11. Disassembly of the clutch assemblies follows.
that hold the torque converter housing to the fly- The procedures are the same for removal and
wheel housing. Carefully separate the transmis- disassembly of the clutch pack assemblies for
sion from the engine. both the 1- and 2-speed transmissions. See Fig-
ure 23, Figure 24, and Figure 25.
5. Remove the torque converter housing and the
front cover housing from the transmission hous-
ing. See Front Cover Housing and Chain Drive
Repair, Remove, Step 4 through Step 16.




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 CLUTCH PACK
8. SPACER

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 oil grooves is worn away or the discs are dam-

aged. Discard a friction disc that has a thickness
WARNING less than 2.2 mm (0.087 in.).
Cleaning solvents can be flammable and toxic 4. The conical plate and separator plates must not
and can cause skin irritation. When using be bent, have damaged surfaces, or have large
cleaning solvents, always follow the solvent blue areas from too much heat. If any of the
manufacturer’s recommended safety proce- above conditions exist, replace the damaged com-
dures. ponent.
Clean all metal parts with cleaning solvent and place 5. Check the "H" 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 3.2 mm (0.126 in.), replace the conical plate.
any other foreign matter that would affect the per-
formance of the parts. 6. Check the "t" dimension of the conical plate as
shown in Figure 26. If the dimension is less than
INSPECT 2.4 mm (0.094 in.), replace the conical plate.
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
have spline damage.
3. Inspect the friction discs for burned lining or bent

surfaces. Check for small holes in the lining. Re-
Figure 26. Conical Plate Inspection
place the friction discs if one-half the depth of the

7. Inspect the bearings for wear or damage. If the threaded areas. If the hardware is not in usable
bearings are damaged, replace them. condition, replace the hardware.
8. Inspect the piston for damage. Make sure that

the sealing surfaces are good. Make sure the ori- CAUTION
fice is clean. The dowel pins are used to properly align the
housings for proper mating to each other. If the
9. Check for grooves or other damage on the ma- alignment is not correct, damage to the trans-
chined surfaces of the clutch pack shafts and mission assembly could occur.
transmission housing. Check the mounting and
sealing surfaces in the housing for damage. If 11. Inspect dowel pins and dowel pin holes. If any
there is evidence of any damage, replace the dowel pin is damaged at all, replace the dowel
housing or transmission. If the clutch pack shaft pin. If a dowel pin hole is damaged, replace the
is damaged, replace the clutch pack. housing.
10. Inspect all hardware and mounting surfaces for 12. Check the fit of bearings in the transmission
the presence of rust, sealing compounds, and us- housings. If the bearings fit too loosely into the
able condition. If the hardware is to be reused, housings, this could mean that the bores are
clean all rust and sealing compounds from the oversized. Replace housings as necessary.
ASSEMBLE AND INSTALL

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 6. Install the front cover housing and the torque
converter housing on the transmission. See
NOTE: The procedure for installation of the output Front Cover Housing and Chain Drive Repair,
gear is the same for both transmissions. Install, Step 1 through Step 15.
1. Install the bearing, output gear, special nut, snap
ring, and bearing on the transmission. See Fig- CAUTION
ure 27. Use care when connecting the wiring harness
connectors to electrical connectors on the
2. Install the oil seal into the back of the transmis-
transmission and control valve. The connec-
sion as noted during removal.
tors on the transmission and control valve are
3. Install the spacer in the yoke. easily damaged.
4. Install the yoke, three washers, and bolt in the 7. Install the transmission wiring harness on the
back of the transmission. Tighten the bolt to transmission. Connect the connectors of the
38 N•m (28 lbf ft). See Figure 27. transmission wiring harness to the control valve
and transmission. Connect the two connectors of
5. On the 2-speed transmission, install the two the chassis wiring harness to the transmission
bearings and idler gear. See Figure 27. wiring harness. See Figure 28.

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
8. Rotate the engine crankshaft to position the (F001); S2.0-3.5FT (S40-70FT, S55FTS) (F187);
flywheel mounting holes in line with the torque H2.0-3.5FT (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 8000 SRM 1207 for S30FT, S35FT, S40FTS
into the lift truck. See the section Frame 100 (E010); H1.6FT, H1.8FT, 2.0FTS (H30FT,
SRM 1243 for S4.0, 4.5, 5.5FT, S5.5FTS, (S80, H35FT, H40FTS) (F001) lift trucks, and Pe-
100, 120FT; S80, 100FTBCS; S120FTS; S120FT- riodic Maintenance 8000 SRM 1248 for S4.0,
PRS) (G004) and H4.0FT5/FT6; H4.5FTS5, 4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT; S80,
H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) 100FTBCS; S120FTS; S120FTPRS) (G004) and
(N005) lift trucks, and Frame 100 SRM 1120 H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT
for S30FT, S35FT, S40FTS (E010); H1.6FT, (H80, 90, 100, 110, 120FT) (N005) lift trucks.


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


Control Valve Repair 1300 SRM 1129

Control Valve Repair

REMOVE AND DISASSEMBLE plugs so that the compressed springs do not
cause injury.
CAUTION 5. Remove the plug for the proportional supply reg-
Use care when disconnecting the wiring har- ulator spool. Discard the O-ring. Remove the
nesses from the connectors. The connectors spring and proportional supply regulator spool
are easily damaged. from the control valve body.
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
of the transmission. See Figure 31.
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- A. EARLY LIFT TRUCK MODELS EXCEPT
tent to complete any repairs that are required. H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT
(H80, 90, 100, 110, 120FT) (N005) MODELS
NOTE: Disassemble the control valve in a clean, con-
tamination-free area. 1. TORQUE CONVERTER HOUSING
2. HARNESS STANDOFF
4. Remove two pressure transducers, two fittings, 3. TRANSMISSION WIRING HARNESS
capscrew, lockwasher, and clip from the control
valve body. See Figure 32. Figure 30. Transmission Assembly
WARNING
There are compressed springs under the plugs
in the control valve. Carefully remove the

1300 SRM 1129 Control Valve Repair
8. Remove the socket head screws and forward pro-

portional valve from the control valve body. Re-
peat for the reverse proportional valve.
9. Remove the socket head screws and transmission

enable valve from the control valve body.
CLEAN
WARNING
Cleaning solvents can be flammable and toxic
and can cause skin irritation. When using
cleaning solvents, always follow the solvent
manufacturer’s recommended safety proce-
dures.
Compressed air can move particles so they

cause injury to the user or to other personnel.
Make sure the path of the compressed air is
away from all personnel. Wear protective gog-
gles or a face shield to prevent injury to the
eyes.
CAUTION
Do not allow cleaning solvent to come in con-
tact with rubber or plastic components as it
can damage those components.
Clean all metal components in solvent and dry with

compressed air.
A. EARLY LIFT TRUCK MODELS EXCEPT INSPECT
(H80, 90, 100, 110, 120FT) (N005) MODELS
B. NEWER LIFT TRUCK MODELS 1. Make sure there are no scratches or damage on
the spools or in the bores of the control valve
1. TRANSMISSION ASSEMBLY body. If the control valve body bores are dam-
2. GASKET aged, replace the control valve.
3. CONTROL VALVE ASSEMBLY
4. LOCKWASHER 2. Inspect the control valve body for the presence of
5. CAPSCREW
6. TRANSMISSION INPUT SPEED SENSOR (TISS) burrs. Burrs may be removed using a fine file,
7. TRANSMISSION OUTPUT SPEED SENSOR emery cloth, or crocus cloth.
(TOSS)
3. Check that the springs are not bent or damaged.
Figure 31. Control Valve Removal Make sure the spools move freely in their bores.
6. Remove the plug for the torque converter reg- 4. Inspect the connectors on the proportional and
ulator spool. Discard the O-ring. Remove the solenoid valves and, if they are damaged, replace
spring and torque converter regulator spool from the damaged proportional or solenoid valves.
the control valve body.
7. Remove the plug for the supply spool. Discard

the O-ring. Remove the spring and supply spool
from the control valve body.

Control Valve Repair 1300 SRM 1129
Figure 32. Control Valve Arrangement

1300 SRM 1129 Control Valve Repair

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
ASSEMBLE AND INSTALL that hold the control valve on the transmission.
Do not tighten at this time.
NOTE: Lubricate the parts of the control valve with
clean transmission oil during assembly. 9. Tighten capscrews to 13.3 N•m (118 lbf in) in
the sequence shown in Figure 33. Retighten cap-
1. Install the transmission enable valve and socket screws to 19 N•m (168 lbf in) in the sequence
head screws into the control valve body. Tighten shown in Figure 33.
socket head screws to 3 to 4 N•m (27 to 35 lbf in).
See Figure 32.
CAUTION
2. Install the reverse proportional valve, forward Use care when connecting the wiring har-
proportional valve, and socket head capscrews nesses to the connectors. The connectors are
into the control valve body. Tighten socket head easily damaged.
screws to 3 to 4 N•m (27 to 35 lbf in).
10. Install the cable connector in the standoff and
3. Install the supply spool and spring into the connect the wiring harness connectors to the
control valve body. Install the plug with a new transmission and control valve as tagged during
O-ring. removal. See Figure 30.
4. Install the torque converter regulator spool and
spring into the control valve body. Install the
plug and new O-ring.
5. Install the proportional supply regulator spool

and spring into the control valve body. Install
the plug and new O-ring.
6. Install the clip, lockwasher, capscrew, two fit-

tings, and two pressure transducers into the con-
trol valve body.
7. Install the transmission input speed sensor (tiss)

and two capscrews in the transmission. Install
the transmission output speed sensor (toss) and
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- Figure 33. Control Valve Mounting Screw
mission. See Figure 31. Install the capscrews Tightening Sequence

MONOTROL® Pedal Repair 1300 SRM 1129
MONOTROL® Pedal Repair

REMOVE AND DISASSEMBLE 2. Remove three capscrews that hold the throttle
base to the cowl, and remove the pedal assembly
1. Remove five screws, dash panel, and kick plate from the lift truck. See Figure 35.
SRM 1243 for S4.0, 4.5, 5.5FT, S5.5FTS, (S80,
H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(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

1. CAPSCREW
complete the repair of the MONOTROL pedal.
2. HYDRAULIC LEVER ASSEMBLY
4. Remove the connector from the connector holder
Figure 34. Hydraulic Lever Relocation
on the throttle base. Remove the outer and inner
springs from the throttle base and MONOTROL
pedal assembly.

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
5. Remove the e-clip and throttle base from the and springs from the pedal frame. If any metal
throttle pedal shaft. Remove the roll pin and the inserts in the pedal pad are damaged, replace as
throttle pedal shaft from the MONOTROL pedal necessary. See Figure 37.
assembly. Discard the roll pin.
7. Remove two hex head screws, lockwashers, nuts,
NOTE: Tag wires prior to removing from mi- and microswitch from the pedal pad. Repeat for
croswitches to aid in connecting. remaining microswitch and remove the wiring
harness from the pedal frame.
6. Remove u-clip, foam lock seal, and wiring har-
ness from the pedal frame. Remove four pan 8. If damaged, remove the stop screw and nut from
head screws, lockwashers, washers, pedal pad, the pedal frame.

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; S120FT-
bolts. Using the three capscrews that hold the PRS) (G004) and H4.0FT5/FT6; H4.5FTS5,
throttle base to the cowl, install the pedal assem- H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT)
bly on the lift truck. Tighten the bolts to 19 to (N005) 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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66
TECHNICAL PUBLICATIONS
1300 SRM 1129 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.

• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair

• 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];

©2007 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

Remove four mounting capscrews, washers, trans-

Figure 2. Transmission Charge Pump

2 Confidential/Proprietary - Do Not Copy or Duplicate

Torque Converter Replace

9. Remove the dipstick tube from the torque con-

Confidential/Proprietary - Do Not Copy or Duplicate 3

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

Figure 3. Engine-Transmission Combination

4 Confidential/Proprietary - Do Not Copy or Duplicate

Figure 4. Torque Converter Bolt Access

Confidential/Proprietary - Do Not Copy or Duplicate 5

Legend for Figure 4

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

Figure 5. Torque Converter Removal

6 Confidential/Proprietary - Do Not Copy or Duplicate

10. If damaged, remove the small access cover from

NOTE: Perform Step 11 only if repair of the of the

11. Remove 12 capscrews from the transmission

7. Install the suction screen, suction screen spring,

Confidential/Proprietary - Do Not Copy or Duplicate 7

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

Figure 7. Torque Converter Housing

8 Confidential/Proprietary - Do Not Copy or Duplicate

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

Figure 8. Torque Converter Installation

Confidential/Proprietary - Do Not Copy or Duplicate 9

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

Figure 9. Engine-Transmission Combination

10 Confidential/Proprietary - Do Not Copy or Duplicate

Figure 10. Torque Converter Bolt Access

Confidential/Proprietary - Do Not Copy or Duplicate 11

Legend for Figure 10

Front Cover Housing and Chain Drive Repair

12 Confidential/Proprietary - Do Not Copy or Duplicate

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

Figure 11. Engine-Transmission Combination

Confidential/Proprietary - Do Not Copy or Duplicate 13

Figure 12. Torque Converter Bolt Access

14 Confidential/Proprietary - Do Not Copy or Duplicate

Legend for Figure 12

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

Confidential/Proprietary - Do Not Copy or Duplicate 15

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

Figure 13. Torque Converter Housing Removal