2 Speed Transmision Power Shift PDF

TWO-SPEED
POWERSHIFT
TRANSMISSION
REPAIR
H6.0FT, H7.0FT (H135FT, H155FT) [H006, J006, K006,
L006];
H6.0FT, H7.0FT, H7.0FTS6, H7.0FTS9,
H8.0FTS6 (H135FT, H155FT, H155FTS,
H170FTS) [N006];
S6.0FT, S7.0FT (S135FT, S155FT) [D024, E024, F024,
G024]
PART NO. 1659641 1300 SRM 1343

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.
Table of Contents
TABLE OF CONTENTS
Transmission Repair............................................................................................................................................. 1
Remove.................................................................................................................................................................1
Torque Converter, Remove................................................................................................................................. 1
Disassemble.........................................................................................................................................................2
Torque Converter Housing, Disassemble........................................................................................................4
Transmission Case, Disassemble...................................................................................................................16
FORWARD 1, Disassemble............................................................................................................................20
RANGE 2, Disassemble..................................................................................................................................25
REVERSE 1, Disassemble............................................................................................................................. 28
RANGE 1, Disassemble..................................................................................................................................34
Stator Support, Disassemble......................................................................................................................... 36
Turbine Shaft, Disassemble...........................................................................................................................37
Pump Drive Gear, Disassemble.....................................................................................................................38
Idler Gear, Disassemble................................................................................................................................. 40
Output Shaft, Disassemble............................................................................................................................ 40
Clean and Inspect..............................................................................................................................................42
Housings..........................................................................................................................................................42
Oil Seals and Gaskets.................................................................................................................................... 42
Bearings.......................................................................................................................................................... 43
Gears and Shafts............................................................................................................................................ 43
Assemble............................................................................................................................................................43
RANGE 2, Assemble.......................................................................................................................................43
FORWARD 1, Assemble.................................................................................................................................46
REVERSE 1, Assemble.................................................................................................................................. 50
RANGE 1, Assemble.......................................................................................................................................55
Stator Support, Assemble.............................................................................................................................. 58
Turbine Shaft, Assemble................................................................................................................................59
Pump Drive Gear, Assemble..........................................................................................................................60
Idler Gear, Assemble...................................................................................................................................... 61
Output Shaft, Assemble................................................................................................................................. 62
Torque Converter Housing, Assemble...........................................................................................................63
Transmission Case, Assemble........................................................................................................................66
Torque Converter, Install................................................................................................................................. 81
Install.................................................................................................................................................................82
Control Valve Repair........................................................................................................................................... 83
Remove...............................................................................................................................................................83
Disassemble.......................................................................................................................................................83
Control Valve Assembly................................................................................................................................. 83
Control Valve Body.........................................................................................................................................83
Clean.................................................................................................................................................................. 86
Inspect................................................................................................................................................................86
Assemble............................................................................................................................................................86
Control Valve Body.........................................................................................................................................86
Control Valve Assembly................................................................................................................................. 86
Install.................................................................................................................................................................87
Torque Specification............................................................................................................................................ 89
©2019 HYSTER COMPANY i

"THE
QUALITY
KEEPERS"
HYSTER
APPROVED
PARTS
1300 SRM 1343 Transmission Repair
Transmission Repair
REMOVE Frame 0100SRM1581 for lift truck models
1. For lift truck models S6.0FT, S7.0FT, (S135FT, • H6.0FT, H7.0FT (H135FT, H155FT) (K006)
S155FT) (D024, E024, F024, G024) , remove Frame 0100SRM1948 for lift truck models
the engine and transmission as a combination.
For removal procedures for the engine and • H6.0FT, H7.0FT (H135FT, H155FT) (L006)
transmission combination, see Frame • H6.0FT, H7.0FT, H7.0FTS6, H7.0FTS9,
0100SRM1316. H8.0FTS6 (H135FT, H155FT, H155FTS,
H170FTS) (N006)
2. For lift truck models H6.0FT, H7.0FT
(H135FT, H155FT) (H006, J006, K006, L006) TORQUE CONVERTER, REMOVE
and H6.0FT, H7.0FT, H7.0FTS6, H7.0FTS9, 1. Remove internal snap ring securing plug and
H8.0FTS6 (H135FT, H155FT, H155FTS, O-ring. See Figure 1.
H170FTS) (N006) , there are two different
procedures to remove the transmission from 2. Remove plug and O-ring. Discard O-ring.
the lift truck frame. The first is to remove the
engine and transmission as a combination and 3. Remove internal snap ring from torque
the second is to remove the transmission. For converter assembly.
removal procedures for the engine and
transmission combination or transmission, see 4. Remove external snap ring from turbine shaft
Frame 0100SRM1321 for lift truck models inside torque converter assembly.
• H6.0FT, H7.0FT (H135FT, H155FT) (H006, 5. Slide torque converter off of turbine and stator
J006) shafts.
1
Transmission Repair 1300 SRM 1343
1. TORQUE CONVERTER ASSEMBLY 7. OIL BAFFLE

2. INTERNAL SNAP RING 8. SEALING RING
3. PLUG 9. SEAL (OIL BAFFLE)
4. O-RING 10. BEARING
5. EXTERNAL SNAP RING 11. PISTON RING
6. SNAP RING
Figure 1. Torque Converter Assembly
DISASSEMBLE
Refer to Figure 2 and Figure 3.
2
NOTE: TORQUE CONVERTER HOUSING FOR LIFT TRUCKS MANUFACTURED BEFORE JUNE 2009
SHOWN.
1. PLUG 7. EXPANSION PLUG 14. SCREW 21. DRAIN PLUG

2. O-RING 8. GASKET 15. LOCKWASHER 22. TORQUE CONVERTER
3. REGULATOR (CONVERTER 16. OIL BAFFLE HOUSING
SPOOL HOUSING TO 17. SUCTION SCREEN 23. STATOR SUPPORT
4. REGULATOR TRANSMISSION 18. GASKET 24. AIR BREATHER
SPRING CASE) 19. ADAPTER (FILTER) 25. TUBE (DIPSTICK)
5. DOWEL PIN 9. SNAP RING 20. OIL FILTER 26. DIPSTICK
6. RESTRICTION 10. RETAINER (SAFETY
PLUG VALVE)
11. SPRING (SAFETY
VALVE)
12. BALL
13. SPACER
Figure 2. Torque Converter Housing
3
NOTE: TORQUE CONVERTER HOUSING FOR LIFT TRUCKS MANUFACTURED AFTER JUNE 2009
SHOWN.
1. TORQUE CONVERTER HOUSING 12. SUCTION SCREEN

2. PLUG 13. GASKET
3. O-RING 14. DOWEL PIN
4. SPACER 15. DRAIN PLUG
5. BALL 16. REGULATOR SPOOL
6. REGULATOR SPRING 17. SAFETY SPRING
7. RETAINER (SAFETY VALVE) 18. CAPSCREW
8. SNAP RING 19. WASHER
9. ADAPTER (FILTER) 20. STATOR SUPPORT
10. OIL FILTER 21. LOCKWASHER
11. DIPSTICK TUBE AND BREATHER 22. SCREW
Figure 3. Torque Converter Housing
Torque Converter Housing, Disassemble

NOTE: Perform Step 1 on lift trucks manufactured Before June 2009.
4
STEP 1.
Remove dipstick and tube.
1. DIPSTICK
2. TUBE
3. CONVERTER HOUSING
NOTE: Perform Step 2 on lift trucks manufactured Before June 2009.
STEP 2.
Remove air breather.
1. AIR BREATHER
NOTE: Perform Step 3 on lift trucks manufactured After June 2009.
5
STEP 3.
Remove transmission oil dipstick and breather.
2. DIPSTICK/BREATHER
CAUTION
Disposal of lubricants and fluids must meet local environmental regulations.
NOTE: Place a suitable container below the oil filter to catch remaining oil in filter.
6
STEP 4.
Remove oil filter element and if necessary,
remove filter adapter.
NOTE: Torque converter housing for lift trucks

manufactured Before June 2009 shown. Oil filter
element and filter adapter in same location on
torque converter housing for lift trucks
manufactured After June 2009.
1. FILTER ADAPTER
2. OIL FILTER ELEMENT
7
STEP 5.
Remove pressure regulator valve by removing
plug, O-ring, spool, and spring.
1. PLUG
2. O-RING
3. SPOOL
4. SPRING
CAUTION
Disposal of lubricants and fluids must meet local environmental regulations.
STEP 6.
Drain oil and remove oil suction screen and
gasket.
1. GASKET
2. OIL SUCTION SCREEN
4. DRAIN PLUG
8
STEP 7.
Remove capscrews, lockwashers, charge pump
and gasket.
NOTE: Torque converter housing for lift trucks

manufactured Before June 2009 shown.
1. CAPSCREWS
2. LOCKWASHERS
3. CHARGE PUMP
4. GASKET
9
STEP 8.
Remove speed sensor.
NOTE: Transmission for lift trucks manufactured

Before June 2009 shown. Speed sensor in same
location on transmission for lift trucks
STEP 9.
Remove control valve assembly. See the Control
Valve Repair section,Remove for procedures.

Before June 2009 shown. Control valve assembly
in same location on transmission for lift trucks
10
STEP 10.
Remove output flange assembly.

Before June 2009 shown. Output flange assembly
in same location on transmission for lift trucks
STEP 11.
Remove oil baffle retainer ring.

Before June 2009 shown. Oil baffle retainer ring in
same location on transmission for lift trucks
STEP 12.
Remove oil baffle with oil seal and sealing ring.
11
STEP 13.
Turn the transmission vertically or on output
and remove converter housing to transmission
case socket head bolts.
STEP 14.
Using a lifting device, separate converter
housing from transmission case assembly.
STEP 15.
Remove snap ring and safety valve assembly
from torque converter housing.
12
STEP 16.
Remove retainer, spring, ball, spacer, and O-
ring.
1. RETAINER
2. SPRING
3. BALL
4. SPACER
5. O-RING
STEP 17.
Remove output shaft cup.
1. OUTPUT SHAFT CUP
13
STEP 18.
Remove REVERSE 1 and RANGE 1 gear shaft
cup.
1. REVERSE 1 AND RANGE 1 GEAR SHAFT CUP
STEP 19.
Remove three capscrews and oil baffle.
14
STEP 20.
Remove capscrew, lockwasher, bearing support,
and pin. Remove pump idler gear and bearing
as an assembly. See Idler Gear, Disassemble
procedures.
1. CAPSCREW
2. LOCKWASHER
3. BEARING SUPPORT
4. PIN
STEP 21.
Remove six socket head screws, lockwashers
and stator support as an assembly. See Stator
Support, Disassemble procedures.
15
STEP 22.
Remove capscrew, lockwasher, bearing support
and pin. Remove pump drive gear as an
assembly. See Pump Drive Gear, Disassemble
procedures.
1. CAPSCREW
2. LOCKWASHER
3. BEARING SUPPORT
4. PIN
Transmission Case, Disassemble

Refer to Figure 4.
16
1. FITTING 5. CAPSCREW 9. SPOOL

2. O-RING 6. LOCKWASHER 10. CASE
3. PLUG 7. CLIP 11. SPEED SENSOR PORT PLUG
4. BAFFLE 8. SPRING
Figure 4. Transmission Case
17
NOTE: Perform following step for lift trucks built

Before June 2009.
STEP 1.
Remove and discard gasket from converter
housing to transmission case.
STEP 2.
Remove shims from turbine shaft.
STEP 3.
Using a puller, remove bearing from RANGE 1
and REVERSE 1 shaft.
18
STEP 4.
Using a puller, remove bearing from turbine
shaft.
STEP 5.
Remove turbine shaft. See Turbine Shaft,
Disassemble procedures.
STEP 6.
Remove RANGE 1 and REVERSE 1 gear
assembly.
19
STEP 7.
Using a lifting device, remove RANGE 2 and
FORWARD 1 as an assembly. See RANGE 2,
Disassemble and FORWARD 1, Disassemble
procedures.
STEP 8.
Remove output shaft as an assembly. See
Output Shaft, Disassemble procedures.
STEP 9.
Remove capscrews, lockwashers, and oil baffle.
FORWARD 1, Disassemble
Refer to Figure 5.
20
1. DRUM ASSEMBLY 6. FRICTION DISC 11. PISTON SPRING 16. GEAR (FORWARD 1)
2. PISTON CLUTCH (INNER) 12. SPRING RETAINER 17. SPACER
ASSEMBLY 7. SEPARATOR DISC 13. DISC SPRING 18. SNAP RING
3. PISTON SEAL (OUTER) ASSEMBLY 19. PISTON RING
(INNER) 8. END PLATE 14. RETURN SPRING 20. TURBINE SHAFT AND
4. PISTON SEAL 9. SNAP RING SPACER RANGE 2 GEAR
(OUTER) 10. CLUTCH RING 15. BEARING
5. SHIM SEAL
Figure 5. FORWARD 1 and RANGE 2 Assembly
21
STEP 1.
Remove shaft sealing ring (3).
STEP 2.
Using a puller, remove bearing cone and gear
with outer bearing.
STEP 3.
Remove Spacer.
22
STEP 4.
Remove end-plate retainer ring.
STEP 5.
Remove end plate.
STEP 6.
Remove inner (friction) and outer (separator)
discs.
23
STEP 7.
Using a puller, remove forward low inner
bearing.
STEP 8.
Remove inner bearing snap ring.
WARNING
The spring has a force of 2400 N (540 lb) when properly seated, ensure spring cannot cause injury when
the snap ring is removed.
STEP 9.
Using a hydraulic press, compress spring and
spring retainer, and remove spring retainer
snap ring.
24
STEP 10.
Remove spring and spring retainer.
STEP 11.
Remove spring retainer.
STEP 12.
Remove piston, and discard inner and outer
piston seals.
RANGE 2, Disassemble
Refer to Figure 5.
25
STEP 1.
Using a puller, remove bearing cone.
WARNING
STEP 2.
Using a hydraulic press, compress piston
return disc springs, and remove return spring
snap ring.
STEP 3.
Remove piston return disc springs.
26
STEP 4.
STEP 5.
Remove end-plate.
STEP 6.
clutch discs.
27
STEP 7.
Remove spacer returning springs.
STEP 8.
piston seals.
REVERSE 1, Disassemble
Refer to Figure 6.
28
1. DRUM ASSEMBLY 5. SEAL RING 9. SNAP RING 13. GEAR ASSEMBLY

2. PISTON CLUTCH 6. FRICTION DISC 10. CLUTCH RING (RANGE 1)
ASSEMBLY (INNER) SEAL 14. GEAR ASSEMBLY
3. PISTON SEAL 7. SEPARATOR DISC 11. PISTON SPRING (REVERSE 1)
(INNER) (OUTER) 12. SPRING RETAINER 15. BEARING ASSEMBLY
4. PISTON SEAL 8. END PLATE
(OUTER)
Figure 6. REVERSE 1 and RANGE 1 Assembly
29
STEP 1.
Remove sealing rings (3).
STEP 2.
Using a puller, remove cone bearing.
STEP 3.
Remove REVERSE 1 gear outer bearing snap
ring.
30
STEP 4.
Using a puller, remove REVERSE 1 gear.
STEP 5.
STEP 6.
Remove end plate.
31
STEP 7.
Remove the inner (friction) and outer
(separator) clutch discs.
STEP 8.
Using a puller, remove REVERSE 1 gear inner
bearing.
STEP 9.
Remove REVERSE 1 gear inner bearing snap
ring.
WARNING
32
STEP 10.
spring retainer and remove snap ring.
STEP 11.
Remove spring and spring retainer.
STEP 12.
Remove spring retainer.
33
STEP 13.
piston seals.
RANGE 1, Disassemble
Refer to Figure 6.
STEP 1.
STEP 2.
Remove end-plate.
34
STEP 3.
clutch disc.
STEP 4.
Using a puller, remove RANGE 1 gear inner
bearing.
WARNING
STEP 5.
spring retainer and remove snap ring.
35
STEP 6.
Remove spring and spring retainers (2).
STEP 7.
piston seals.
Stator Support, Disassemble

STEP 1.
Remove stator support bearing snap ring.
36
STEP 2.
Remove stator support sealing ring.
STEP 3.
Using a puller, remove stator support bearing.
Turbine Shaft, Disassemble

STEP 1.
Remove turbine shaft bearing cup.
37
STEP 2.
Remove turbine shaft sealing ring.
STEP 3.
Using a puller, remove turbine shaft bearing.
Pump Drive Gear, Disassemble

Refer to Figure 7.
38
1. PUMP DRIVE IDLER GEAR 5. BEARING SUPPORT

2. SNAP RING 6. CAPSCREW
3. BEARING 7. LOCKWASHER
4. PIN 8. PUMP DRIVE GEAR
Figure 7. Pump Drive Idler Gear and Pump Drive Gear Assembly
STEP 1.
Remove pump drive bearing snap ring.
39
STEP 2.
Remove pump drive bearing.
Idler Gear, Disassemble

Refer to Figure 7.
STEP 1.
Remove idler gear bearing inner snap ring.
STEP 2.
Remove idler gear bearing.
Output Shaft, Disassemble

Refer to Figure 8.
40
1. OUTPUT SHAFT 5. COVER

2. BEARING 6. OUTPUT FLANGE
3. OUTPUT GEAR 7. PLUG
4. OIL SEAL
Figure 8. Output Shaft Assembly
STEP 1.
Using a puller, remove output gear and
bearing.
41
STEP 2.
Turn shaft and using a puller remove bearing.
CLEAN AND INSPECT The importance of careful and thorough inspection

of all parts cannot be over stressed. Replacement of
all parts showing indication of wear or stress will
WARNING eliminate costly and avoidable failures at a later
To prevent serious eye injury, always wear safe date.
eye protection when performing vehicle
maintenance or service. Housings
Clean interior and exterior of housings, bearing
caps, etc., thoroughly. Cast parts may be cleaned in
WARNING hot solution tanks with mild alkali solution
To avoid personal injury when cleaning parts, work providing these parts do not have ground or
in a well-ventilated area, wear protective clothing polished surfaces. Parts should remain in solution
(face shield or safety glasses and protective long enough to be thoroughly cleaned and heated.
gloves), and follow chemical manufacturer's This will aid the evaporation of the cleaning
recommendations for safe usage. solution and rinse water. Parts cleaned in solution
tanks must be thoroughly rinsed with clean water to
Solvent cleaners can be flammable, poisonous,
remove all traces of alkali. Cast parts may also be
and cause burns. Examples of solvent cleaners are
cleaned with steam cleaner.
carbon tetrachloride, emulsion-type cleaners, and
petroleum-based cleaners. To avoid serious Inspect housings, covers and bearing caps to ensure
personal injury when using solvent cleaners, that they are thoroughly clean and that mating
carefully follow manufacturer's instructions and surfaces, bearing bores, etc., are free from nicks or
these procedures: burrs. Check all parts carefully for evidence of
Wear safe eye protection. cracks or conditions which would cause subsequent
•
oil leaks or failures.
• Wear clothing that protects skin.
• Work in a well-ventilated area. Oil Seals and Gaskets
• DO NOT use gasoline or solvents that Replacement of spring load oil seals, O-rings, metal
contain gasoline. Gasoline can explode. sealing rings, gaskets, and snap rings is more
• Use hot solution tanks or alkaline solutions economical when the unit is disassembled than
correctly. Carefully follow manufacturer's premature overhaul to replace these parts at a
instructions. future time. Further loss of lubricant through a
worn seal may result in failure of other more
Clean all parts thoroughly using solvent type
expensive parts of the assembly. Sealing members
cleaning fluid. It is recommended that parts be
should be handled carefully, particularly when
immersed in cleaning fluid and moved up and down
being installed. Cutting, scratching, or curling
slowly until all old lubricant and foreign material is
under of lips of seals seriously impairs its efficiency.
dissolved and parts are thoroughly cleaned.
42
When assembling new metal type sealing rings, Bearings may be rotated slowly by hand to facilitate
these should be lubricated with a coat of chassis drying process.
grease to stabilize rings in their grooves for ease of
NOTE: DO NOT replace a bearing cone or cup
assembly of mating members. Lubricate all O-rings
individually without replacing the mating cup or
and seals with recommended type Automatic
cone at the same time.
Transmission Fluid before assembly.
Carefully inspect all rollers: cages and cups for
Bearings wear, chipping, or nicks to determine fitness of
bearings for further use. After inspection, dip
bearings in Automatic Transmission Fluid and wrap
WARNING in clean lint-free cloth or paper to protect them until
Compressed air can move particles so that they installed.
cause injury to the user or to other personnel.
Make sure that the path of the compressed air is Gears and Shafts
away from all personnel. Wear protective goggles If Magna-Flux process is available, use process to
or a face shield to prevent injury to the eyes. check parts. Examine teeth on all gears carefully for
wear, pitting, chipping, nicks, cracks, or scores. If
NOTE: DO NOT spin the bearings when drying.
gear teeth show spots where case hardening is worn
Remove bearings from cleaning fluid and strike flat through or cracked, replace with new gear. Small
against a block of wood to dislodge solidified nicks may be removed with suitable hone. Inspect
particles of lubricant. Immerse again in cleaning shafts and quills to make certain they are not
fluid to flush out particles. Repeat above operation sprung, bent or spline-twisted, and that shafts are
until bearings are thoroughly clean. Dry bearings true.
using moisture-free compressed air. Be careful to
direct air stream across bearing to avoid spinning. ASSEMBLE
RANGE 2, Assemble
Refer to Figure 5.
NOTE: Ring must be sized before installing piston clutch in clutch drum. Sizing is best accomplished by
rotating piston while holding a round object against the new inner and outer seal ring.
STEP 1.
Install new piston clutch inner and outer
sealing rings. Rotate piston until seal ring is
flush with outer diameter of piston. Install
piston clutch in clutch drum. Use caution as not
to damage newly installed seal rings.
43
STEP 2.
Install return disc spring spacer.
STEP 3.
Install piston return disc springs.
WARNING
the snap ring is installed.
STEP 4.
return disc springs, and install return spring
snap ring.
44
STEP 5.
Install one outer disc. Install one inner disc.
Alternate outer and inner disc until proper
amount are installed. First disc next to the
piston is outer (separator), last disc installed is
inner (friction).
STEP 6.
Install end-plate.
STEP 7.
Install end-plate retainer ring.
WARNING
Hot parts. Wear protective clothing and gloves to prevent burns.
CAUTION
DO NOT use an open flame to warm bearings. Using an open flame could cause damage to bearing.
45
STEP 8.
Warm bearing cone to 120°C (248°F), and
install bearing cone on shaft.
FORWARD 1, Assemble
Refer to Figure 5.
STEP 1.
STEP 2.
Install piston return spring spacer.
46
STEP 3.
Install piston return spring and piston return
spring retainer.
WARNING
STEP 4.
return spring, and install piston return spring
snap ring.
STEP 5.
inner (friction).
47
STEP 6.
Install end-plate.
STEP 7.
STEP 8.
Install inner bearing snap ring.
48
STEP 9.
Install inner bearing.
STEP 10.
Install spacer.
CAUTION
DO NOT force this operation, could cause damage to seal rings.
STEP 11.
Install new clutch sealing ring and install
forward low clutch gear and bearing as an
assembly. Align splines on forward low with
internal teeth of inner (friction) discs.
WARNING
Hot Parts. Wear protective clothing and gloves to prevent burns.
49
CAUTION
STEP 12.
STEP 13.
Install shaft sealing rings (3).
REVERSE 1, Assemble
Refer to Figure 6.
50
STEP 1.
STEP 2.
Install spring retainer.
STEP 3.
Install spring and spring retainer.
WARNING
51
STEP 4.
return spring, and install piston return spring
snap ring.
STEP 5.
inner (friction).
STEP 6.
Install end-plate.
52
STEP 7.
STEP 8.
Install REVERSE 1 gear inner bearing snap
ring.
WARNING
CAUTION
STEP 9.
Warm REVERSE 1 gear inner bearing to
120°C (248°F), and install inner bearing on
shaft.
53
CAUTION
DO NOT force this operation, could cause damage to seal rings.
STEP 10.
Install new clutch sealing ring and install
REVERSE 1 gear and bearing as an assembly.
Align splines on forward low with internal
teeth of inner (friction) discs.
STEP 11.
Install outer bearing. Sealed side up.
STEP 12.
Install REVERSE 1 gear outer bearing snap
ring.
WARNING
54
CAUTION
STEP 13.
STEP 14.
Install sealing rings.
RANGE 1, Assemble
Refer to Figure 6.
55
STEP 1.
STEP 2.
Install spring and spring retainers.
WARNING
STEP 3.
return spring, and install piston spring snap
ring.
56
STEP 4.
inner (friction).
STEP 5.
Install end-plate.
STEP 6.
WARNING
CAUTION
57
STEP 7.
Warm RANGE 1 gear inner bearing to
120°C (248°F), and install bearing on shaft.
Stator Support, Assemble
WARNING
CAUTION
STEP 1.
Warm stator support bearing to 120°C (248°F),
and install bearing on shaft.
58
STEP 2.
Install stator support sealing ring. Use grease
to center seal in groove.
STEP 3.
Install stator support bearing snap ring.
Turbine Shaft, Assemble
WARNING
CAUTION
59
STEP 1.
Warm turbine shaft bearing to 120°C (248°F),
and install bearing on shaft.
STEP 2.
Install turbine shaft sealing ring.
STEP 3.
Install turbine shaft bearing cup.
Pump Drive Gear, Assemble

Refer to Figure 7.
60
STEP 1.
Install pump drive bearing and bearing
support.
STEP 2.
Install pump drive bearing retaining ring.
Idler Gear, Assemble

Refer to Figure 7.
STEP 1.
Install idler gear bearing.
61
STEP 2.
Install idler gear bearing inner retainer rings
(2).
Output Shaft, Assemble

Refer to Figure 8.
WARNING
CAUTION
STEP 1.
install on output shaft.
62
STEP 2.
Warm gear to 120°C (248°F), and install gear
on output shaft.
STEP 3.
install on output shaft.
Torque Converter Housing, Assemble

STEP 1.
Install output shaft cup.
1. OUTPUT SHAFT CUP
63
STEP 2.
Install REVERSE 1 and RANGE 1 gear shaft
cup.
1. REVERSE 1 AND RANGE 1 GEAR SHAFT CUP
STEP 3.
Install O-ring, spacer, ball, spring, and
retainer.
1. RETAINER
2. SPRING
3. BALL
4. SPACER
5. O-RING
64
STEP 4.
Install safety valve and snap ring.
STEP 5.
Install oil baffle, and tighten capscrews to
25 N•m (18 lbf ft).
NOTE: Make sure that the pin for the bearing support is in the right hole.
65
STEP 6.
Install pump drive gear assembly, bearing
support, pin, lockwasher, and capscrew. See
Pump Drive Gear, Assemble procedures.
Tighten capscrew to 122 N•m (90 lbf ft).
1. CAPSCREW
2. LOCKWASHER
3. BEARING SUPPORT
4. PIN
Transmission Case, Assemble

Refer to Figure 4.
66
STEP 1.
Install oil baffle, and tighten screw to
25 N•m (18 lbf ft).
STEP 2.
Install output shaft assembly. See Output
Shaft, Assemble procedures.
STEP 3.
Install REVERSE 1 and RANGE 1 shaft
assembly. See RANGE 1, Assemble procedures.
67
STEP 4.
Install FORWARD 1 and RANGE 2 shaft
assembly. See FORWARD 1, Assemble and
RANGE 2, Assemble procedures.
STEP 5.
Install RANGE 1 gear. Align splines on
RANGE 1 gear with internal teeth of inner
(friction) discs.
STEP 6.
Tap RANGE 1 gear bearing into position.
68
STEP 7.
Install RANGE 1 gear bearing snap ring.
WARNING
CAUTION
STEP 8.
Warm RANGE 1 gear shaft bearing to
120°C (248°F), and install bearing on shaft.
CAUTION
DO NOT force this operation, could cause damage friction disc.
69
STEP 9.
Install turbine shaft in RANGE 2. Align splines
on RANGE 2 gear with internal teeth of inner
(friction) discs.
NOTE: Perform the following step for lift trucks

built Before June 2009.
NOTE: A light coat of grease will hold gasket and
O-rings into place.
STEP 10.
Install a new gasket and two O-rings between
transmission case and converter housing.
STEP 11.
Align dowels and install converter housing on
transmission case.
70
STEP 12.
Install remaining socket head bolts to
transmission case and converter housing and
tighten to 38 N•m (28 lbf ft).
STEP 13.
Install oil suction screen and gasket.
1. GASKET
2. OIL SUCTION SCREEN
4. DRAIN PLUG
71
STEP 14.
Install pressure regulator valve by installing
spring, spool, O-ring, and plug.
1. PLUG
2. O-RING
3. SPOOL
4. SPRING
72
STEP 15.
If necessary, install filter adapter. Install new
oil filter element. Tighten oil filter element
hand tight. Turn addition 1/4 turn.
1. FILTER ADAPTER
2. OIL FILTER ELEMENT
STEP 16.
Install turbine shaft bearing cap.
73
STEP 17.
Measure depth from stator support to cup.
NOTE: Pre-load bearing to 0.025 to 0.101 mm (0.0009 to 0.0039 in.). The formula used to calculate shim
thickness is A - B + D = C. See drawing below.
STEP 18.
Measure depth from stator support to outer
ring.
74
STEP 19.
Install shims.
STEP 20.
Install stator support, see Stator Support,
Assemble procedures, and tighten capscrews to
25 N•m (18 lbf ft).
NOTE: Make sure that the pin for the bearing support is in the right hole.
75
STEP 21.
Install capscrew, lockwasher, bearing support,
pin, and pump drive idler gear assembly. See
Pump Drive Gear, Assemble procedures.
Tighten capscrew to 122 N•m (90 lbf ft).
1. CAPSCREW
2. LOCKWASHER
3. BEARING SUPPORT
4. PIN
STEP 22.
Install oil baffle with oil seal and seal ring.
76
STEP 23.
Install oil baffle retainer ring.
STEP 24.
Install output flange assembly.
NOTE: Make sure to install guide studs prior to installing control valve assembly onto transmission case.
STEP 25.
Using guide studs, install new control valve
assembly onto transmission case. See Control
Valve Assemble procedures.
NOTE: A light coat of grease will hold gasket into place.
77
STEP 26.
Install new charging pump gasket.
STEP 27.
Install charging pump to converter housing.
Install capscrews and lockwashers. Tighten
capscrew to 25 N•m (18 lbf ft).
1. CAPSCREWS
2. LOCKWASHERS
3. CHARGE PUMP
4. GASKET
78
STEP 28.
Install speed sensor, and tighten to
6.9 N•m (61 lbf in).
NOTE: Perform Step 29 for lift trucks manufactured Before June 2009.
STEP 29.
Install air breather.
1. AIR BREATHER
NOTE: Perform Step 30 for lift trucks manufactured Before June 2009.
79
STEP 30.
Install dipstick and tube.
1. DIPSTICK
2. TUBE
NOTE: Perform Step 31 for lift trucks manufactured After June 2009.
80
STEP 31.
Install dipstick and breather.
1. CONVERTER 2. DIPSTICK/
HOUSING BREATHER
TORQUE CONVERTER, INSTALL 3. Install the internal snap ring into the inner
groove inside of the torque converter assembly.
CAUTION 4. Install new O-ring onto plug.

When installing the torque converter, be careful
not to damage the oil seal or stator seal ring. 5. Install plug and O-ring into torque converter
assembly.
1. Slide torque converter onto turbine and stator
shafts. See Figure 9. 6. Install external snap ring securing plug and O-
ring.
2. Install external snap ring onto turbine shaft.
81
1. TORQUE CONVERTER ASSEMBLY 7. OIL BAFFLE

2. INTERNAL SNAP RING 8. SEALING RING
3. PLUG 9. SEAL (OIL BAFFLE)
4. O-RING 10. BEARING
5. EXTERNAL SNAP RING 11. PISTON RING
6. SNAP RING
Figure 9. Torque Converter Assembly
INSTALL Frame 0100SRM1321 for lift truck models

1. For lift truck models S6.0FT, S7.0FT, (S135FT, • H6.0FT, H7.0FT (H135FT, H155FT) (H006,
S155FT) (D024, E024, F024, G024) , install the J006)
engine and transmission as a combination. For Frame 0100SRM1581 for lift truck models
install procedures for the engine and
• H6.0FT, H7.0FT (H135FT, H155FT) (K006)
transmission combination, see Frame
0100SRM1316. Frame 0100SRM1948for lift truck models
• H6.0FT, H7.0FT (H135FT, H155FT) (L006)
2. For lift truck models H6.0FT, H7.0FT
(H135FT, H155FT) (H006, J006, K006, L006, • H6.0FT, H7.0FT, H7.0FTS6, H7.0FTS9,
N006) there are two different procedures to H8.0FTS6 (H135FT, H155FT, H155FTS,
H170FTS) (N006)
install the transmission to the lift truck frame.
The first is to install the engine and
transmission as a combination and the second
is to install the transmission. For install
procedures for the engine and transmission
combination and the transmission, see
82
1300 SRM 1343 Control Valve Repair
Control Valve Repair

NOTE: Refer to Figure 10 and Figure 11 during the 7. Remove the remaining 10 mounting capscrews,
Control Valve Repair procedure. washers, and control valve assembly from the
transmission case.
See Figure 10 for lift truck models
• S6.0FT, S7.0FT (S135FT, S155FT) (D024, NOTE: When the control valve assembly is being
E024) and H6.0FT, H7.0FT (H135FT, removed from the transmission. The control valve
H155FT) (H006, J006) manufactured before gasket may still be attached to the transmission
October 2009. case.
See Figure 11 for lift truck models 8. Remove and discard control valve gasket.
• S6.0FT, S7.0FT (S135FT, S155FT) (D024,
E024, F024, G024) and H6.0FT, H7.0FT DISASSEMBLE
(H135FT, H155FT) (J006, K006, L006) and
H6.0FT, H7.0FT, H7.0FTS6, H7.0FTS9, Control Valve Assembly
H8.0FTS6 (H135FT, H155FT, H155FTS,
NOTE: Make sure that the area around the valve is
H170FTS) (N006) , manufactured after
October 2009. clean and that no dirt can fall into the valve during
disassembly.
REMOVE 1. Remove control valve top cover and gasket from
control valve body, and discard gasket.
CAUTION 2. Remove control valve body and gasket from
Ensure the area around the control valve assembly bottom plate, and discard gasket.
is clean and that foreign material cannot enter the
control valve during removal. Foreign material may 3. Remove bottom plate.
cause damage to equipment.
Control Valve Body
1. Shut off engine.
1. Remove hydraulic inching valve, shim, inching
2. Disconnect the negative battery cable from spool, piston, and O-rings from sleeve. Discard
battery. O-rings.
3. Disconnect the right hand chassis harness from 2. Remove two setscrews for each of the three
the transmission harness. solenoids. Remove solenoids.
NOTE: When disconnecting wiring harness 3. Remove plug and O-ring and remove shuttle
connectors during removal, tag each connector to spool. Discard O-ring.
aid in connecting the wiring harness during
installation. 4. Remove plug and O-ring and remove spring,
spacer, and selector spool. Discard O-ring.
4. Disconnect the control valve electrical
connectors and move the transmission harness 5. Remove plug, O-ring, regulator spool, plug, and
out of the way. spring. Discard O-ring.
5. Disconnect the brake supply hose from the 6. Remove plug, O-ring, check valve spring, ball,
control valve body, and install a plug in brake accumulator dump spool and pin, and spring.
supply hose. Discard O-ring.
6. Loosen the 4 capscrews marked 11, 12, 13 and 7. Remove spring housing, O-ring, spacer, outer
14 in Figure 12 until you feel that the load is spring, accumulator spring, inner spring, stop
relieved from the bolt. DO NOT remove pin, retainer, rest spring, and accumulator
them. spool. Discard O-ring.
83
Control Valve Repair 1300 SRM 1343
8. Remove plug, O-ring, selector spring and

spacer.
1. HYDRAULIC 8. SOLENOIDS 15. CHECK VALVE 22. INNER 29. WASHERS

INCHING 9. PLUG SPRING SPRING 30. TOP COVER
VALVE 10. SHUTTLE 16. PIN 23. STOP PIN 31. GASKET
2. SHIM SPOOL 17. BALL 24. RETAINER 32. CONTROL VALVE
3. INCHING 11. SPRING 18. ACCUMULATO 25. REST SPRING BODY
SPOOL 12. SPACER R DUMP 26. ACCUMULATO 33. BOTTOM PLATE
4. PISTON 13. SELECTOR SPOOL R SPOOL 34. BRAKE SUPPLY
5. SLEEVE SPOOL 19. SPRING 27. SELECTOR HOSE
6. O-RING 14. REGULATOR HOUSING SPRING 35. TRANSMISSION
7. SETSCREWS SPOOL 20. OUTER 28. CAPSCREWS HARNESS
SPRING
21. ACCUMULATO
R SPRING
Figure 10. Control Valve Assembly for Lift Truck Models and Manufactured Before October 2009S6.0FT,
S7.0FT (S135FT, S155FT) (D024, E024) H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006)
84
Figure 11. Control Valve Assembly for Lift Truck Models , and , Manufactured After October 2009S6.0FT,
S7.0FT (S135FT, S155FT) (D024, E024, F024, G024) H6.0FT, H7.0FT (H135FT, H155FT) (J006, K006, L006)
and H6.0FT, H7.0FT, H7.0FTS6, H7.0FTS9, H8.0FTS6 (H135FT, H155FT, H155FTS, H170FTS) (N006)
85
Legend for Figure 11.
1. HYDRAULIC 5. SETSCREWS 10. SELECTOR 14. ACCUMULATO 19. TOP COVER

INCHING 6. SOLENOIDS SPOOL R SPRING 20. WASHERS
VALVE 7. PLUG 11. REGULATOR 15. INNER 21. CAPSCREWS
2. INCHING 8. SPRING SPOOL SPRING 22. CONTROL VALVE
SPOOL 9. SPACER 12. ACCUMULATO 16. STOP PIN BODY
3. PISTON R SPOOL 17. GASKET
4. O-RING 13. OUTER 18. BOTTOM
SPRING PLATE
CLEAN INSPECT
Inspect the all parts including solenoids for wear or
WARNING damage. If parts are damaged, replace.
Compressed air used for cleaning purposes will Inspect bores of the control valve body for wear or
not exceed 30 psi (207 kPa), can move particles so damage. If body is damaged, replace.
that they cause injury to the user or to other
personnel. Make sure that the path of the ASSEMBLE
compressed air is away from all personnel. Wear
personal protective equipment (safety glasses, Control Valve Body
face shield, and gloves) to prevent injury. 1. Install spacer, selector spring, plug and new O-
ring.
WARNING 2. Install accumulator spool, rest spring, retainer,

Cleaning solvents maybe be flammable and toxic stop pin, spacer, inner spring, accumulator
and cause severe skin irritation. Wear protective spring, outer spring, and new O-ring and
safety glasses, goggles and gloves and use in a spring housing.
well-ventilated area. Avoid contact with skin, eyes
and clothes and DO NOT breath vapors. DO NOT 3. Install spring, pin, accumulator dump spool,
use near open flame or excessive heat. If you ball, and check valve spring, and new O-ring
become dizzy while using cleaning solvent, get and plug.
fresh air immediately and get medical aid. If
contact with eyes is made, wash your eyes with 4. Install spring, plug, regulator spool, plug and
water and get medical aid immediately. Carefully new O-ring.
follow manufactures instructions.
5. Install selector spool, spacer, spring, and new
1. Clean all parts, except solenoids assemblies, in O-ring and plug.
solvent.
6. Install shuttle spool, and new O-ring and plug.
NOTE: Parts should remain in solution long enough
7. Install three solenoids and setscrews.
to be thoroughly cleaned and heated to aid the
evaporation of the cleaning solution and rinse
8. Install new O-rings onto sleeve. Install piston,
water.
inching spool, and shim into sleeve. Install
2. Cast parts may be cleaned in hot solution tanks sleeve into hydraulic inching valve.
with mild alkali solution if parts do not have
ground or polished surfaces. 9. Install hydraulic inching valve.
3. Parts cleaned in solution tanks must be Control Valve Assembly

thoroughly rinsed with clean water to remove
1. Install new control valve gasket and bottom
all traces of alkali. Cast parts may also be
plate.
cleaned with steam cleaner.
2. Install new control valve gasket on top of
bottom plate.
86
3. Install control valve body onto new control 2. Install the control valve assembly onto the
valve gasket and bottom plate. transmission case.
4. Install new control valve gasket onto control 3. Once the control valve assembly is aligned into
valve body. the correct position. Install the 10 long
remaining capscrews and washers, and tighten
5. Install top cover onto new control valve gasket all 14 capscrews to
and control valve body. 20 to 25 N•m (15 to 18 lbf ft). See Figure 12 for
correct torque sequence.
6. Install four short capscrews and washers into
top cover. See (items 11, 12, 13, 14) in
Figure 12.
INSTALL
1. Install two guide bolts and align new control
valve gasket onto transmission case.
87
Figure 12. Torque Sequence
4. Remove plug from brake supply hose, and 6. Connect the transmission harness to the right
install the brake supply hose to the control hand chassis harness.
valve body.
7. Connect the negative battery cable to the
5. Connect the electrical connectors as tagged battery.
during removal onto the solenoid valve
assemblies.
88
1300 SRM 1343 Torque Specification
Torque Specification
Oil Baffle Capscrew
25 N•m (18 lbf ft)
Pump Drive Gear Assembly Capscrew

122 N•m (90 lbf ft)
Converter Housing to Transmission Case Socket

Heads
38 N•m (28 lbf ft)
Drive Pump Idler Gear Assembly Capscrew

122 N•m (90 lbf ft)
Stator Support Capscrews

25 N•m (18 lbf in)
Charge Pump to Converter Housing Capscrews

25 N•m (18 lbf ft)
Control Valve Mounting Capscrews

20 to 25 N•m (15 to 18 lbf ft)
89
TECHNICAL PUBLICATIONS
1300 SRM 1343 11/19 (9/15)(3/14)(9/13)(3/13)(7/12)

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What safety precautions should be taken when working on transmission repairs?

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What are the steps to disassemble the control valve body?

TWO-SPEED

PART NO. 1659641 1300 SRM 1343

©2019 HYSTER COMPANY i

1. TORQUE CONVERTER ASSEMBLY 7. OIL BAFFLE

Figure 1. Torque Converter Assembly

1. PLUG 7. EXPANSION PLUG 14. SCREW 21. DRAIN PLUG

Figure 2. Torque Converter Housing

1. TORQUE CONVERTER HOUSING 12. SUCTION SCREEN

Figure 3. Torque Converter Housing

Torque Converter Housing, Disassemble

NOTE: Perform Step 2 on lift trucks manufactured Before June 2009.

NOTE: Perform Step 3 on lift trucks manufactured After June 2009.

NOTE: Torque converter housing for lift trucks

NOTE: Torque converter housing for lift trucks

NOTE: Transmission for lift trucks manufactured

NOTE: Transmission for lift trucks manufactured

NOTE: Transmission for lift trucks manufactured

NOTE: Transmission for lift trucks manufactured

1. OUTPUT SHAFT CUP

1. REVERSE 1 AND RANGE 1 GEAR SHAFT CUP

Transmission Case, Disassemble

1. FITTING 5. CAPSCREW 9. SPOOL

Figure 4. Transmission Case

NOTE: Perform following step for lift trucks built

Figure 5. FORWARD 1 and RANGE 2 Assembly

1. DRUM ASSEMBLY 5. SEAL RING 9. SNAP RING 13. GEAR ASSEMBLY

Figure 6. REVERSE 1 and RANGE 1 Assembly

Stator Support, Disassemble

Turbine Shaft, Disassemble

Pump Drive Gear, Disassemble

1. PUMP DRIVE IDLER GEAR 5. BEARING SUPPORT

Idler Gear, Disassemble

Output Shaft, Disassemble

1. OUTPUT SHAFT 5. COVER

Figure 8. Output Shaft Assembly

CLEAN AND INSPECT The importance of careful and thorough inspection

Stator Support, Assemble

Turbine Shaft, Assemble

Pump Drive Gear, Assemble

Idler Gear, Assemble

Output Shaft, Assemble

Torque Converter Housing, Assemble

1. OUTPUT SHAFT CUP

1. REVERSE 1 AND RANGE 1 GEAR SHAFT CUP

Transmission Case, Assemble

NOTE: Perform the following step for lift trucks

NOTE: A light coat of grease will hold gasket into place.

CAUTION 4. Install new O-ring onto plug.

1. TORQUE CONVERTER ASSEMBLY 7. OIL BAFFLE

Figure 9. Torque Converter Assembly

INSTALL Frame 0100SRM1321 for lift truck models

Control Valve Repair

8. Remove plug, O-ring, selector spring and

1. HYDRAULIC 8. SOLENOIDS 15. CHECK VALVE 22. INNER 29. WASHERS

Legend for Figure 11.