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) [P005]

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

Company, its subsidiaries and/or vendors. Copying or distribution of any sections of
this manual marked "Confidential/Proprietary" is prohibited.

PART NO. 4043132 1300 SRM 1529

 SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and
that the load being lifted is balanced. Make sure the crane, cables, and chains have the capacity
to support the weight of the load.

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

• Wear safety glasses.

• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric
lift trucks. Disconnect the battery ground cable on internal combustion lift trucks.

• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT
TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance section.

• Keep the unit clean and the working area clean and orderly.

• Use the correct tools for the job.

• Keep the tools clean and in good condition.

• Always use HYSTER APPROVED parts when making repairs. Replacement parts must meet
or exceed the specifications of the original equipment manufacturer.

• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force
to remove parts.

• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the
unit needs repairs.

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

• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are
flammable. Be sure to follow the necessary safety precautions when handling these fuels and
when working on these fuel systems.

• Batteries generate flammable gas when they are being charged. Keep fire and sparks away from
the area. Make sure the area is well ventilated.

NOTE: The following symbols and words indicate safety information in this
manual:

WARNING
Indicates a hazardous situation which, if not avoided, could result in
death or serious injury.

CAUTION
Indicates a hazardous situation which, if not avoided, could result in
minor or moderate injury and property damage.

On the lift truck, the WARNING symbol and word are on orange back-
ground. The CAUTION symbol and word are on yellow background.
Powershift Transmission Table of Contents

TABLE OF CONTENTS

General ............................................................................................................................................................... 1
Serial Number................................................................................................................................................ 1
Charge Pump Repair ......................................................................................................................................... 1
Remove ........................................................................................................................................................... 1
Inspect ............................................................................................................................................................ 1
Install ............................................................................................................................................................. 1
Torque Converter Replace ................................................................................................................................. 2
Remove ........................................................................................................................................................... 2
Install ............................................................................................................................................................. 7
Housings and Chain Drive Repair .................................................................................................................... 13
Remove ........................................................................................................................................................... 13
Clean .............................................................................................................................................................. 20
Inspect ............................................................................................................................................................ 20
Install ............................................................................................................................................................. 20
Clutch Packs Repair........................................................................................................................................... 25
Remove and Disassemble .............................................................................................................................. 25
Transmission, Remove and Disassemble ................................................................................................. 25
Clutch Assemblies, Remove and Disassemble ......................................................................................... 33
Clean .............................................................................................................................................................. 39
Inspect ............................................................................................................................................................ 39
Assemble and Install ..................................................................................................................................... 40
Clutch Assemblies, Assemble and Install ................................................................................................ 40
Transmission, Assemble and Install ........................................................................................................ 49
Control Valve Repair.......................................................................................................................................... 53
Remove and Disassemble .............................................................................................................................. 53
Clean .............................................................................................................................................................. 54
Inspect ............................................................................................................................................................ 54
Assemble and Install ..................................................................................................................................... 56
MONOTROL® Pedal Repair ............................................................................................................................. 56
Remove and Disassemble .............................................................................................................................. 56
Assemble and Install ..................................................................................................................................... 58
Direction Control Lever ..................................................................................................................................... 61
Remove ........................................................................................................................................................... 61
Install ............................................................................................................................................................. 61

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) [P005]

©2011 HYSTER COMPANY i

"THE
QUALITY
KEEPERS"

HYSTER
APPROVED
PARTS
1300 SRM 1529 Charge Pump Repair

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.

1. TRANSMISSION SERIAL NUMBER

Figure 1. Transmission Serial Number

Location

Charge Pump Repair

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

Confidential/Proprietary - Do Not Copy or Duplicate 1

Torque Converter Replace 1300 SRM 1529

Legend for Figure 2

NOTE: THE TRANSMISSION IS SHOWN REMOVED

FROM LIFT TRUCK FOR CLARITY.
1. CAPSCREW
2. CHARGE PUMP
3. GASKET
4. TORQUE CONVERTER HOUSING

Figure 2. Transmission Charge Pump

Torque Converter Replace

REMOVE See Frame 100 SRM 1120 for lift truck models:
• S30FT, S35FT, S40FTS (E010)
WARNING • H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT,
H40FTS) (F001)
Make sure the engine and transmission are
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
held in position so that they will not fall and
• H2.0-3.5FT (H40-70FT) (L177)
cause an injury and damage to the equipment.

CAUTION
CAUTION
Use care when disconnecting the wiring har-
Be careful that you DO NOT damage parts of
ness connectors from electrical connectors on
the torque converter or transmission when
the transmission and control valve. The con-
the transmission is separated from the engine.
nectors on the transmission and control valve
Keep the transmission and engine in align-
are easily damaged.
ment until they are completely separated so
parts of the transmission are not damaged. NOTE: When disconnecting wiring harness connec-
Use a crane or lifting device to separate the tors during disassembly, tag each connector to aid in
transmission from the engine. connecting the wiring harness during reassembly.
1. Remove engine and transmission as a unit from 2. Put engine and transmission on solid blocks on a
lift truck as described in one of the following sec- work surface.
tions:
Disconnect transmission wiring harness connec-
See Frame 100 SRM 1243 for lift truck models: tors from control valve and transmission.
• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT;
S80, 100FTBCS; S120FTS; S120FTPRS) Remove transmission wiring harness from trans-
(G004) mission. See Figure 3.
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005)

2 Confidential/Proprietary - Do Not Copy or Duplicate

1300 SRM 1529 Torque Converter Replace

1. GM 2.4L ENGINE 4. TRANSMISSION

2. CAPSCREW 5. ACCESS COVER
3. TRANSMISSION WIRING HARNESS 6. CONTROL VALVE

Figure 3. Engine-Transmission Combination

Confidential/Proprietary - Do Not Copy or Duplicate 3

Torque Converter Replace 1300 SRM 1529

8. Remove transmission oil filter from torque con-

WARNING verter housing. See Figure 5.
Make sure that the engine/transmission assem-
bly is stable before attempting to rotate the en- 9. If damaged, remove two cap screws and small
gine. access cover from the torque converter housing.

Use a flashlight to see the bolts as they are ro- 10. Remove dipstick and dipstick tube from torque
tated into view through the access hole. DO converter housing. See Figure 5.
NOT use your fingers to check for alignment of
the bolts with the access hole. 11. Remove transmission oil temperature sensor
from torque converter housing. See Figure 5.
3. Move each bolt into view through access hole
of flywheel housing by rotating crankshaft. Re- NOTE: Perform Step 12 through Step 16 only if repair
move four capscrews that attach flywheel to of the of the transmission chain drive is required. If
torque converter. See Figure 4. the transmission clutch packs are in need of further
repair, see Clutch Packs Repair.
4. Remove access cover from torque converter hous-
ing. Install a lifting eye bolt into rear access 12. Remove two long capscrews and washers from in-
cover bolt hole, and connect a lifting device to ner face of torque converter housing. See Fig-
eye bolt. Remove ten capscrews that hold torque ure 7.
converter housing to flywheel housing on engine. 13. Remove fifteen capscrews from transmission
Carefully separate transmission from engine. housing. See Figure 6.
NOTE: The torque converter cannot be repaired and 14. Remove two mounting capscrews and harness
must be replaced as a unit, if damaged. bracket from front of torque converter housing.
5. Carefully remove torque converter from stator See Figure 6.
support. See Figure 5. 15. Using a small pry bar in the designated pry
6. Remove plug, suction screen spring, and suction points, remove the torque converter housing
screen from torque converter housing, and drain from the transmission housing. See Figure 6.
oil from transmission. See Figure 5. 16. Remove and discard O-rings and gasket. See Fig-
7. Remove transmission charge pump. See Charge ure 7.
Pump Repair,Remove.

Legend for Figure 4

A. GM 2.4L ENGINE D. GM 4.3L ENGINE
B. MAZDA ENGINE E. CUMMINS 3.3L DIESEL ENGINE
C. YANMAR ENGINE
1. ACCESS HOLE 2. FLYWHEEL HOUSING

4 Confidential/Proprietary - Do Not Copy or Duplicate

1300 SRM 1529 Torque Converter Replace

Figure 4. Torque Converter Bolt Access

Confidential/Proprietary - Do Not Copy or Duplicate 5

Torque Converter Replace 1300 SRM 1529

Figure 5. Torque Converter Removal

6 Confidential/Proprietary - Do Not Copy or Duplicate

1300 SRM 1529 Torque Converter Replace

Legend for Figure 5

1. TRANSMISSION OIL FILTER 9. PLUG
2. DIPSTICK 10. CAPSCREW
3. DIPSTICK TUBE 11. WASHER
4. TRANSMISSION HOUSING 12. SMALL ACCESS COVER
5. TORQUE CONVERTER HOUSING 13. TORQUE CONVERTER
6. TRANSMISSION OIL TEMPERATURE SENSOR 14. TRANSMISSION CHARGE PUMP
7. SUCTION SCREEN 15. STATOR SUPPORT
8. SUCTION SCREEN SPRING 16. PILOT HUB

INSTALL 10. Lubricate the pilot hub on the torque converter

with antiseize compound. See Figure 8.
NOTE: Perform Step 1 through Step 4 only if repair
of the transmission chain drive was performed. 11. Install transmission oil temperature sensor on
torque converter housing. See Figure 8.
1. Install new O-rings and gasket to torque con-
verter housing and transmission housing. See
Figure 7.

2. Install harness bracket and two mounting cap-

screws to front of torque converter housing. See
Figure 6.

3. Using fifteen capscrews, install transmission

housing to torque converter housing. Tighten
capscrews to 38 N•m (28 lbf ft).

4. Install two washers and long capscrews into face

of torque converter housing. Tighten capscrews
to 38 N•m (28 lbf ft). See Figure 7.

5. If removed, install small access cover and two

capscrews on torque converter housing. Tighten
capscrews to 7.9 N•m (69 lbf in). See Figure 8.

6. Install a new transmission oil filter on torque

converter housing.

7. Install the transmission charge pump. See

Charge Pump Repair,Install. 1. PRY POINTS
2. TORQUE CONVERTER HOUSING
8. Install suction screen, suction screen spring, and 3. TRANSMISSION HOUSING
plug into torque converter housing. See Figure 8. 4. HARNESS BRACKET
5. CAPSCREW
9. Install torque converter onto stator support.
Make sure splines are aligned and converter Figure 6. Pry Point Location
engages fully. See Figure 8.

Confidential/Proprietary - Do Not Copy or Duplicate 7

Torque Converter Replace 1300 SRM 1529

1. LONG CAPSCREW 5. TRANSMISSION HOUSING

2. WASHER 6. O-RING
3. TORQUE CONVERTER HOUSING 7. CAPSCREW
4. GASKET

Figure 7. Torque Converter Housing

Legend for Figure 8

1. TRANSMISSION OIL FILTER 9. PLUG
2. DIPSTICK 10. CAPSCREW
3. DIPSTICK TUBE 11. WASHER
4. TRANSMISSION HOUSING 12. SMALL ACCESS COVER
5. TORQUE CONVERTER HOUSING 13. TORQUE CONVERTER
6. TRANSMISSION OIL TEMPERATURE SENSOR 14. TRANSMISSION CHARGE PUMP
7. SUCTION SCREEN 15. STATOR SUPPORT
8. SUCTION SCREEN SPRING 16. PILOT HUB

8 Confidential/Proprietary - Do Not Copy or Duplicate

1300 SRM 1529 Torque Converter Replace

Figure 8. Torque Converter Installation

Confidential/Proprietary - Do Not Copy or Duplicate 9

Torque Converter Replace 1300 SRM 1529

NOTE: Apply adhesive to entire surface of hole, Remove lifting eye bolt, and install access cover
20.0 mm (0.79 in.) deep. Also apply adhesive to on torque converter housing.
lower 20.0 mm (0.79 in.) of dipstick tube.

12. Install dipstick tube and dipstick into torque con- WARNING
verter housing. See Figure 8. Make sure the engine and transmission are
held in position so that they will not fall and
13. If removed, install a lifting eye bolt into rear ac- cause an injury and damage to the equipment.
cess cover bolt hole, and connect a lifting device
to eye bolt. 17. Install engine and transmission as a unit into
lift truck as described in one of the following sec-
Align torque converter housing with flywheel tions:
housing. Make sure pilot hub on torque con-
verter engages flywheel. See Frame 100 SRM 1243 for lift truck models:
• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT;
S80, 100FTBCS; S120FTS; S120FTPRS)
CAUTION (G004)
Be careful that you DO NOT damage parts of • H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-
the torque converter or transmission when 5.5FT (H80, 90, 100, 110, 120FT) (N005, P005)
the transmission is joined to the engine. Keep
the transmission and engine in alignment un- See Frame 100 SRM 1120 for lift truck models:
til they are completely joined so parts of the • S30FT, S35FT, S40FTS (E010)
transmission are not damaged. Use a crane or • H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT,
lifting device to join the transmission to the H40FTS) (F001)
engine. • S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)
14. Install transmission on engine. Install ten cap-
screws that connect torque converter housing to 18. Fill transmission to correct level using transmis-
flywheel housing. Tighten capscrews to 38 N•m sion fluid and procedure indicated in following
(28 lbf ft). See Figure 9. sections:

See Periodic Maintenance 8000 SRM 1150 for

CAUTION lift truck models:
Use care when connecting the wiring harness • S2.0-3.5FT (S40-70FT, S55FTS) (F187)
connectors to electrical connectors on the • H2.0-3.5FT (H40-70FT) (L177)
transmission and control valve. The connec-
tors on the transmission and control valve are See Periodic Maintenance 8000 SRM 1207 for
easily damaged. lift truck models:
• S30FT, S35FT, S40FTS (E010)
15. Install transmission wiring harness on transmis- • H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT,
sion. Connect transmission wiring harness con- H40FTS) (F001)
nectors to control valve and transmission. See
Figure 9. See Periodic Maintenance 8000 SRM 1248 for
lift truck models:
NOTE: Coat the bolt threads that hold the torque con- • S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT;
verter to flywheel with Loctite™ 242. S80, 100FTBCS; S120FTS; S120FTPRS)
(G004)
16. Rotate engine crankshaft to position the fly- • H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-
wheel mounting holes in line with torque con- 5.5FT (H80, 90, 100, 110, 120FT) (P005)
verter mounting holes. Install capscrews that
hold torque converter to flywheel through access
hole of flywheel housing. See Figure 10. Tighten
capscrews to 56 N•m (41 lbf ft).

10 Confidential/Proprietary - Do Not Copy or Duplicate

1300 SRM 1529 Torque Converter Replace

1. GM 2.4L ENGINE 4. TRANSMISSION

2. CAPSCREW 5. ACCESS COVER
3. TRANSMISSION WIRING HARNESS 6. CONTROL VALVE

Figure 9. Engine-Transmission Combination

Confidential/Proprietary - Do Not Copy or Duplicate 11

Torque Converter Replace 1300 SRM 1529

Figure 10. Torque Converter Bolt Access

12 Confidential/Proprietary - Do Not Copy or Duplicate

1300 SRM 1529 Housings and Chain Drive Repair

Legend for Figure 10

A. GM 2.4L ENGINE D. GM 4.3L ENGINE
B. MAZDA ENGINE E. CUMMINS 3.3L DIESEL ENGINE
C. YANMAR ENGINE
1. ACCESS HOLE 2. FLYWHEEL HOUSING

Housings and Chain Drive Repair

REMOVE work surface, place blocks under the back side
of the transmission housing for additional sup-
WARNING port.
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. Use care when disconnecting the wiring har-
ness connectors from electrical connectors on
CAUTION the transmission and control valve. The con-
nectors on the transmission and control valve
Keep the transmission and engine in alignment
are easily damaged.
until they are completely separated so parts of
the transmission are not damaged. Use a crane NOTE: When disconnecting wiring harness connec-
or lifting device to separate the transmission tors during disassembly, tag each connector to aid in
from the engine. connecting the wiring harness during reassembly.
1. Remove engine and transmission as a unit from 2. Put engine and transmission on solid blocks on
lift truck as described in one of the following sec- a work surface. Disconnect transmission wiring
tions: connectors from control valve and transmission.
Remove transmission wiring harness from trans-
See Frame 100 SRM 1243 for lift truck models:
mission. See Figure 11.
• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT;
S80, 100FTBCS; S120FTS; S120FTPRS)
(G004) WARNING
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0- Make sure that the engine/transmission assem-
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005) bly is stable before attempting to rotate the en-
gine.
See Frame 100 SRM 1120 for lift truck models:
• S30FT, S35FT, S40FTS (E010) Use a flashlight to see the bolts as they are ro-
• H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, tated into view through the access hole. DO
H40FTS) (F001) NOT use your fingers to check for alignment of
• S2.0-3.5FT (S40-70FT, S55FTS) (F187) the bolts with the access hole.
• H2.0-3.5FT (H40-70FT) (L177)
3. Move each bolt into view through access hole
of flywheel housing by rotating crankshaft. Re-
CAUTION move four capscrews that attach flywheel to
To prevent possible damage to the transmis- torque converter. See Figure 12.
sion assembly when placing the assembly on a

Confidential/Proprietary - Do Not Copy or Duplicate 13

Housings and Chain Drive Repair 1300 SRM 1529

1. GM 2.4L ENGINE 5. CAPSCREW

2. CAPSCREW 6. ACCESS COVER
3. TRANSMISSION WIRING HARNESS 7. CONTROL VALVE
4. TRANSMISSION

Figure 11. Engine-Transmission Combination

14 Confidential/Proprietary - Do Not Copy or Duplicate

1300 SRM 1529 Housings and Chain Drive Repair

Figure 12. Torque Converter Bolt Access

Confidential/Proprietary - Do Not Copy or Duplicate 15

Housings and Chain Drive Repair 1300 SRM 1529

Legend for Figure 12

A. GM 2.4L ENGINE D. GM 4.3L ENGINE
B. MAZDA ENGINE E. CUMMINS 3.3L DIESEL ENGINE
C. YANMAR ENGINE
1. ACCESS HOLE 2. FLYWHEEL HOUSING

4. Remove access cover from torque converter hous- 9. Remove fifteen capscrews from transmission
ing. Install a lifting eye bolt into rear access housing. See Figure 15.
cover bolt hole, and connect a lifting device to
eye bolt. Remove ten capscrews that hold torque 10. Remove two mounting capscrews and harness
converter housing to flywheel housing. Carefully bracket from front of torque converter housing.
separate transmission from the engine. See Figure 15.

5. Carefully remove torque converter from stator 11. Using a small pry bar in the designated pry
support. See Figure 13. points, remove the torque converter housing
from the transmission housing. See Figure 15.
6. Remove plug, suction screen spring, and suction
screen from torque converter housing and drain 12. Remove and discard O-rings and gasket. See Fig-
oil from the transmission. See Figure 13. ure 14.

7. Remove transmission charge pump. See Charge NOTE: While performing Step 13, note position of oil
Pump Repair,Remove. seal to aid in installation of new oil seal.

8. Remove two long capscrews and washers from in- 13. Remove and discard oil seal from rear of torque
ner face of torque converter housing. See Fig- converter housing. See Figure 16.
ure 14.

Legend for Figure 13

1. TRANSMISSION OIL FILTER 9. PLUG
2. DIPSTICK 10. CAPSCREW
3. DIPSTICK TUBE 11. WASHER
4. TRANSMISSION HOUSING 12. SMALL ACCESS COVER
5. TORQUE CONVERTER HOUSING 13. TORQUE CONVERTER
6. TRANSMISSION OIL TEMPERATURE SENSOR 14. TRANSMISSION CHARGE PUMP
7. SUCTION SCREEN 15. STATOR SUPPORT
8. SUCTION SCREEN SPRING 16. PILOT HUB

16 Confidential/Proprietary - Do Not Copy or Duplicate

1300 SRM 1529 Housings and Chain Drive Repair

Figure 13. Torque Converter Housing Removal

Confidential/Proprietary - Do Not Copy or Duplicate 17

Housings and Chain Drive Repair 1300 SRM 1529

1. LONG CAPSCREW 5. TRANSMISSION HOUSING

2. WASHER 6. O-RING
3. TORQUE CONVERTER HOUSING 7. CAPSCREW
4. GASKET

Figure 14. Torque Converter Housing

Legend for Figure 15
1. PRY POINTS
2. TORQUE CONVERTER HOUSING
3. TRANSMISSION HOUSING
4. HARNESS BRACKET
5. CAPSCREW

Figure 15. Pry Point Location

18 Confidential/Proprietary - Do Not Copy or Duplicate

1300 SRM 1529 Housings and Chain Drive Repair

1. SNUBBER 9. DRIVING SPROCKET

2. PUMP DRIVE CHAIN 10. CAPSCREW
3. BEARING 11. LOCKWASHER
4. DRIVEN SPROCKET 12. STATOR SUPPORT
5. OIL SEAL 13. SEALING RING
6. ANGULAR CONTACT BEARING 14. TRANSMISSION HOUSING
7. BUSHING 15. BAFFLE
8. O-RING

Figure 16. Chain Drive

14. Remove two snubbers from transmission hous- 18. Remove four capscrews, lockwashers, and stator
ing. See Figure 16. support from transmission housing. Remove and
discard sealing ring and O-ring from stator sup-
15. Carefully remove pump drive chain, driven port. See Figure 16.
sprocket, driving sprocket, and bearings from
transmission housing. See Figure 16. 19. Remove baffle from transmission housing. See
Figure 16.
16. Remove bearing from driven sprocket. See Fig-
ure 16. 20. Remove O-rings from transmission housing and
discard. See Figure 16.
17. Remove angular contact bearing, bushing, and
O-ring from driving sprocket. Discard O-ring.
See Figure 16.

Confidential/Proprietary - Do Not Copy or Duplicate 19

Housings and Chain Drive Repair 1300 SRM 1529

CLEAN 4. Install stator support, lockwashers, and cap-

screws on transmission housing. See Figure 16.
WARNING Tighten capscrews to 38 N•m (28 lbf ft).
Cleaning solvents can be flammable and toxic 5. On a lint-free cloth, place driving sprocket on
and can cause skin irritation. When using right side, driven sprocket on left side, and place
cleaning solvents, always follow the solvent chain around both sprockets (see Figure 16).
manufacturer’s recommended safety proce- Install bearings on sprockets. The angular bear-
dures. ing should be installed onto driving sprocket
with thinner shoulder of outer race towards
Compressed air can move particles so they
the sprocket and wider shoulder of outer race
cause injury to the user or to other personnel.
(side marked with part number) towards torque
Make sure the path of the compressed air is
converter housing. Carefully place driving and
away from all personnel. Wear protective gog-
driven sprockets, chain, and bearings assembly
gles or a face shield to prevent injury to the
on transmission. Install two snubbers on trans-
eyes.
mission housing. See Figure 16.
1. Clean snubbers with warm, soapy water and dry
6. Install new oil seal into rear of torque converter
with compressed air.
housing as noted during removal.
2. Clean bearings, chain, stator support, and gears
7. Install new O-rings and gasket on torque con-
with solvent and dry with compressed air
verter housing. See Figure 17.
INSPECT 8. Using fifteen capscrews, install transmission
1. Inspect snubbers for cracks or wear. If damaged housing to torque converter housing. Tighten
or worn, replace both snubbers. capscrews to 38 N•m (28 lbf ft). See Figure 17.

2. Inspect chain, sprockets, and stator support for 9. Install two washers and long capscrews into face
damage. If damage is present, replace damaged of torque converter housing. Tighten capscrews
component. to 38 N•m (28 lbf ft). See Figure 17.

3. Inspect driving and driven gears for damage or 10. Install harness bracket and two mounting cap-
wear to gear teeth. If gear teeth are worn or screws to front of torque converter housing. See
damaged, replace gear. Figure 15.

4. Inspect splines on the input shaft for damage.If 11. Install suction screen, suction screen spring,
damaged, replace input clutch pack. See Clutch and plug into torque converter housing. See
Packs Repair. Figure 18.

12. Install torque converter onto input shaft and

INSTALL stator support of the transmission. Make sure
1. Install new O-rings on transmission housing. splines are aligned and converter engages fully.
See Figure 16. See Figure 18.

2. Install the baffle in transmission housing. See 13. Lubricate the pilot hub on the torque converter
Figure 16. with antiseize compound. See Figure 18.

3. Install new sealing ring and O-ring on the stator 14. Install the transmission charge pump. See
support. See Figure 16. Charge Pump Repair, Install.

20 Confidential/Proprietary - Do Not Copy or Duplicate

1300 SRM 1529 Housings and Chain Drive Repair

1. LONG CAPSCREW 5. TRANSMISSION HOUSING

2. WASHER 6. O-RING
3. TORQUE CONVERTER HOUSING 7. CAPSCREW
4. GASKET

Figure 17. Torque Converter Housing Installation

15. If removed, install a lifting eye bolt into rear ac- 17. Install transmission wiring harness on transmis-
cess cover bolt hole, and connect a lifting device sion. Connect transmission wiring harness con-
to eye bolt. Align torque converter housing with nectors to control valve and transmission. See
flywheel housing. Make sure pilot hub on torque Figure 19.
converter engages flywheel.
NOTE: Coat the bolt threads that hold the torque con-
16. Install transmission to engine. Install ten cap- verter to flywheel with Loctite™ 242.
screws that connect torque converter housing to
flywheel housing. Tighten capscrews to 38 N•m 18. Rotate engine crankshaft to position the fly-
(28 lbf ft). See Figure 19. wheel mounting holes in line with torque con-
verter mounting holes. Install capscrews that
hold torque converter to flywheel through access
CAUTION hole of flywheel housing. See Figure 20. Tighten
Use care when connecting the wiring harness capscrews to 56 N•m (41 lbf ft).
connectors to electrical connectors on the
transmission and control valve. The connec- Remove lifting eye bolt, and install access cover
tors on the transmission and control valve are on torque converter housing.
easily damaged.

Confidential/Proprietary - Do Not Copy or Duplicate 21

Housings and Chain Drive Repair 1300 SRM 1529

1. TRANSMISSION OIL FILTER 6. TRANSMISSION OIL 12. SMALL ACCESS COVER

2. DIPSTICK TEMPERATURE SENSOR 13. TORQUE CONVERTER
3. DIPSTICK TUBE 7. SUCTION SCREEN 14. TRANSMISSION CHARGE
4. TRANSMISSION HOUSING 8. SUCTION SCREEN SPRING PUMP
5. TORQUE CONVERTER 9. PLUG 15. STATOR SUPPORT
HOUSING 10. CAPSCREW 16. PILOT HUB
11. WASHER

Figure 18. Torque Converter Housing Removal

22 Confidential/Proprietary - Do Not Copy or Duplicate

1300 SRM 1529 Housings and Chain Drive Repair

1. GM 2.4L ENGINE 5. CAPSCREW

2. CAPSCREW 6. ACCESS COVER
3. TRANSMISSION WIRING HARNESS 7. CONTROL VALVE
4. TRANSMISSION

Figure 19. Engine-Transmission Combination

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Housings and Chain Drive Repair 1300 SRM 1529

Figure 20. Torque Converter Bolt Access

24 Confidential/Proprietary - Do Not Copy or Duplicate

1300 SRM 1529 Clutch Packs Repair

Legend for Figure 20

A. GM 2.4L ENGINE C. YANMAR ENGINE E. CUMMINS 3.3L DIESEL
B. MAZDA ENGINE D. GM 4.3L ENGINE ENGINE
1. ACCESS HOLE 2. FLYWHEEL HOUSING

19. Install engine and transmission as a unit into See Periodic Maintenance 8000 SRM 1150 for
lift truck as described in one of the following sec- lift truck models:
tions: • S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)
See Frame 100 SRM 1243 for lift truck models:
• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; See Periodic Maintenance 8000 SRM 1207 for
S80, 100FTBCS; S120FTS; S120FTPRS) lift truck models:
(G004) • S30FT, S35FT, S40FTS (E010)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0- • H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT,
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005) H40FTS) (F001)

See Frame 100 SRM 1120 for lift truck models: See Periodic Maintenance 8000 SRM 1248 for
• S30FT, S35FT, S40FTS (E010) lift truck models:
• H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, • S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT;
H40FTS) (F001) S80, 100FTBCS; S120FTS; S120FTPRS)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187) (G004)
• H2.0-3.5FT (H40-70FT) (L177) • H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-
5.5FT (H80, 90, 100, 110, 120FT) (P005)
20. Fill transmission to the correct level using trans-
mission fluid and procedure indicated in the fol-
lowing sections:

Clutch Packs Repair

REMOVE AND DISASSEMBLE 1. Remove engine and transmission as a unit from
lift truck as described in one of the following sec-
Transmission, Remove and Disassemble tions:

See Frame 100 SRM 1243 for lift truck models:

WARNING • S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT;
Make sure the engine and transmission are S80, 100FTBCS; S120FTS; S120FTPRS)
held in position so that they will not fall and (G004)
cause an injury and damage to the equipment. • H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005)
CAUTION See Frame 100 SRM 1120 for lift truck models:
Be careful that you do not damage parts of • S30FT, S35FT, S40FTS (E010)
the torque converter or transmission when • H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT,
the transmission is separated from the engine. H40FTS) (F001)
Keep the transmission and engine in align- • S2.0-3.5FT (S40-70FT, S55FTS) (F187)
ment until they are completely separated so • H2.0-3.5FT (H40-70FT) (L177)
parts of the transmission are not damaged.
Use a crane or lifting device to separate the
transmission from the engine.

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Clutch Packs Repair 1300 SRM 1529

3. Move each bolt into view through access hole

CAUTION of flywheel housing by rotating crankshaft. Re-
To prevent possible damage to the transmis- move four capscrews that attach flywheel to
sion assembly when placing the assembly on a torque converter. See Figure 22.
work surface, place blocks under the back side
of the transmission housing for additional sup- 4. Remove access cover from torque converter hous-
port. ing. Install a lifting eye bolt into rear access
cover bolt hole, and connect a lifting device to
eye bolt. Remove ten capscrews that hold torque
CAUTION converter housing to flywheel housing. Carefully
Use care when disconnecting the wiring har- separate transmission from engine.
ness connectors from electrical connectors on
the transmission and control valve. The con- 5. Remove torque converter housing from transmis-
nectors on the transmission and control valve sion housing. See Housings and Chain Drive Re-
are easily damaged. pair, Remove.

NOTE: When disconnecting wiring harness connec- 6. Remove idler gear and two bearings. See Fig-
tors during disassembly, tag each connector to aid in ure 23.
connecting the wiring harness during reassembly.
7. Remove bolt, stato seal, and yoke from back of
2. Put engine and transmission on solid blocks on a transmission housing. See Figure 23.
work surface.
8. Remove spacer from yoke. See Figure 23.
Disconnect two connectors of chassis wiring har-
ness from transmission wiring harness. NOTE: Note the position of the oil seal during re-
moval to aid in installation.
Disconnect transmission wiring harness connec-
tors from control valve and transmission. Re- 9. Remove oil seal from back of transmission hous-
move transmission wiring harness from trans- ing. See Figure 23.
mission. See Figure 21. 10. Remove bearing, snap ring, special nut, output
gear, and bearing from transmission housing.
WARNING See Figure 23.
Make sure that the engine/transmission assem-
11. Removal and disassembly of clutch assemblies
bly is stable before attempting to rotate the en-
follows. The procedures are the same for for-
gine.
ward, reverse, and high clutch pack assemblies.
Use a flashlight to see the bolts as they are ro- See Figure 24, Figure 25, and Figure 26.
tated into view through the access hole. DO
NOT use your fingers to check for alignment of
the bolts with the access hole.

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1300 SRM 1529 Clutch Packs Repair

1. GM 2.4L ENGINE 4. TRANSMISSION

2. CAPSCREW 5. ACCESS COVER
3. TRANSMISSION WIRING HARNESS 6. CONTROL VALVE

Figure 21. Engine-Transmission Combination

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Clutch Packs Repair 1300 SRM 1529

Figure 22. Torque Converter Bolt Access

28 Confidential/Proprietary - Do Not Copy or Duplicate

1300 SRM 1529 Clutch Packs Repair

Legend for Figure 22

A. GM 2.4L ENGINE D. GM 4.3L ENGINE
B. MAZDA ENGINE E. CUMMINS 3.3L DIESEL ENGINE
C. YANMAR ENGINE
1. ACCESS HOLE 2. FLYWHEEL HOUSING

1. BEARING 8. OIL SEAL

2. IDLER GEAR 9. YOKE
3. SNAP RING 10. STATO SEAL
4. SPECIAL NUT 11. BOLT
5. OUTPUT GEAR 12. REVERSE GEAR
6. TRANSMISSION HOUSING 13. FORWARD CLUTCH PACK
7. SPACER 14. HIGH FORWARD CLUTCH PACK

Figure 23. Output Gear Removal

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Clutch Packs Repair 1300 SRM 1529

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. Forward Clutch Pack

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1300 SRM 1529 Clutch Packs Repair

1. SEAL 8. SNAP RING

2. BEARING 9. CONICAL PLATE
3. GEAR ASSEMBLY DRUM 10. FRICTION DISK
4. PISTON SEAL 11. SEPARATOR PLATE
5. PISTON 12. PRESSURE PLATE
6. SPRING 13. OUTPUT GEAR
7. SPRING GUIDE 14. BACK PLATE

Figure 25. Reverse Clutch Pack

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Clutch Packs Repair 1300 SRM 1529

1. SEAL 8. SNAP RING

2. BEARING 9. CONICAL PLATE
3. GEAR ASSEMBLY DRUM 10. FRICTION DISK
4. PISTON SEAL 11. SEPARATOR PLATE
5. PISTON 12. PRESSURE PLATE
6. SPRING 13. BACK PLATE
7. SPRING GUIDE 14. OUTPUT GEAR

Figure 26. High Clutch Pack

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1300 SRM 1529 Clutch Packs Repair

Clutch Assemblies, Remove and Disassemble

STEP 1.
Pull forward clutch (low gear), reverse clutch and for-
ward clutch (high gear) assemblies straight out from
transmission housing.

1. FORWARD CLUTCH (LOW GEAR)

2. REVERSE CLUTCH
3. FORWARD CLUTCH (HIGH GEAR)
4. TRANSMISSION INPUT SPEED SENSOR (TISS)
5. TRANSMISSION OUTPUT SPEED SENSOR
(TOSS)

STEP 2.
Remove shaft seal and bearing from forward (low)
clutch pack input shaft. Discard shaft seal. Remove
bearing from forward (high) and reverse gear packs.

1. FORWARD CLUTCH (HIGH GEAR)

2. FORWARD CLUTCH (LOW GEAR)
3. REVERSE CLUTCH
4. BEARING
5. SHAFT SEAL

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Clutch Packs Repair 1300 SRM 1529

STEP 3.
Remove snap ring from output gear. Remove output
gear from input shaft

1. FORWARD CLUTCH (HIGH GEAR)

2. FORWARD CLUTCH (LOW GEAR)
3. REVERSE CLUTCH
4. OUTPUT GEAR
5. SNAP RING

NOTE: Before removing seal bearing, note position of seal on bearing.

STEP 4.
Remove seal from output gear. Remove seal bearing,
snap ring, and bearing from output gear.

1. SEAL BEARING
2. SNAP RING
3. SEAL
4. OUTPUT GEAR
5. BEARING

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1300 SRM 1529 Clutch Packs Repair

STEP 5.

Remove snap ring, back plate and pressure plate

from gear assembly drum.

1. SNAP RING
2. BACK PLATE
3. PRESSURE PLATE
4. GEAR ASSEMBLY DRUM

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Clutch Packs Repair 1300 SRM 1529

STEP 6.
Remove friction disks and separator plates alternately until all have been removed from gear assembly drum

1. FRICTION DISK 2. SEPARATOR PLATE 3. GEAR ASSEMBLY DRUM

STEP 7.
Remove conical plate from gear assembly drum.

1. CONICAL PLATE
2. GEAR ASSEMBLY DRUM

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1300 SRM 1529 Clutch Packs Repair

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 piston only if there is a problem with piston or piston seals.

STEP 8.
Using spring compression tool, Hyster P/N 867890
and a press, place spring compression tool on spring
guide with opening of the tool above opening of snap
ring, and compress large and small springs just
enough to allow removal of snap ring from spring
guide. Slowly release press to decompress springs.

1. SPRING COMPRESSION TOOL

2. SPRING GUIDE

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Clutch Packs Repair 1300 SRM 1529

STEP 9.
Remove snap ring, spring guide, large spring, and
small spring from input shaft.

1. SNAP RING
2. SPRING GUIDE
3. LARGE SPRING
4. SMALL SPRING
5. INPUT SHAFT

STEP 10.
Remove piston from gear assembly drum and piston
seal from piston. Discard piston seal.

1. PISTON
2. PISTON SEAL
3. GEAR ASSEMBLY DRUM
4. SHAFT SEAL

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1300 SRM 1529 Clutch Packs Repair

STEP 11.
Remove shaft seals and bearing from input shaft.
Discard shaft seals.

1. SHAFT SEALS
2. BEARING
3. INPUT SHAFT

CLEAN grooves is worn away or discs are damaged.

Discard a friction disc that has a thickness less
WARNING 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 damaged compo-
dures. nent.
Clean all metal parts with cleaning solvent and place 5. Check "H" dimension of conical plate as shown
on a lint-free cloth to dry. Ensure that the cleaning in Figure 27. If dimension is less than 3.2 mm
and assembly environment is free of dust, dirt, and (0.126 in.), replace conical plate.
any other foreign matter that would affect the per-
formance of the parts. 6. Check "t" dimension of conical plate as shown
in Figure 27. If dimension is less than 2.4 mm
INSPECT (0.094 in.), replace conical plate.
1. Inspect gear teeth on clutch assemblies and all
other gears for wear or damage. If the gear teeth
are worn or damaged, replace damaged compo-
nent.

2. Check all parts that have splines for damage to

splines. Check for notches worn in splines. Re-
place clutch pack or gears that have spline dam-
age.

3. Inspect friction discs for burned lining or bent

surfaces. Check for small holes in the lining.
Figure 27. Conical Plate Inspection
Replace friction discs if one-half depth of oil

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Clutch Packs Repair 1300 SRM 1529

7. Inspect bearings for wear or damage. If bearings

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

ASSEMBLE AND INSTALL

Clutch Assemblies, Assemble and Install

STEP 1.
Install bearing and new shaft seals on input shaft.

1. SHAFT SEALS
2. BEARING
3. INPUT SHAFT

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1300 SRM 1529 Clutch Packs Repair

NOTE: Perform STEP 2 through STEP 5 only if piston was removed.

STEP 2.
Lubricate all parts with clean transmission oil. In-
stall shaft seal on shaft and piston seal on piston.

1. PISTON SEAL
2. PISTON

STEP 3.
Install piston into gear assembly drum.

1. PISTON
2. PISTON SEAL
3. GEAR ASSEMBLY DRUM
4. SHAFT SEAL

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Clutch Packs Repair 1300 SRM 1529

STEP 4.
Install 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

42 Confidential/Proprietary - Do Not Copy or Duplicate

1300 SRM 1529 Clutch Packs Repair

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

1. SPRING COMPRESSION TOOL

2. SPRING GUIDE

Confidential/Proprietary - Do Not Copy or Duplicate 43

Clutch Packs Repair 1300 SRM 1529

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

STEP 6.
Install conical plate into gear assembly drum.

1. CONICAL PLATE
2. GEAR ASSEMBLY DRUM

44 Confidential/Proprietary - Do Not Copy or Duplicate

1300 SRM 1529 Clutch Packs Repair

STEP 7.
Install separator plates and friction disks alternately until all have been installed in gear assembly drum.

1. FRICTION DISK 2. SEPARATOR PLATE 3. GEAR ASSEMBLY DRUM

Confidential/Proprietary - Do Not Copy or Duplicate 45

Clutch Packs Repair 1300 SRM 1529

STEP 8.

Install pressure plate, back plate and snap ring

in gear assembly drum. Using a dial indicator or
feeler gauge, check clearance between snap ring
and pressure plate. There must be 2.7±0.2 mm
(0.106±0.008 in.) of clearance. If clearance is not
correct, see Parts Manual for correct pressure plate.

1. SNAP RING
2. BACK PLATE
3. PRESSURE PLATE
4. GEAR ASSEMBLY DRUM

NOTE: Make sure seal on seal bearing is in correct position as noted during removal.

STEP 9.
Install seal onto output gear. Install bearing, snap
ring, and seal bearing into output gear.

1. SEAL BEARING
2. SNAP RING
3. SEAL
4. OUTPUT GEAR
5. BEARING

46 Confidential/Proprietary - Do Not Copy or Duplicate

1300 SRM 1529 Clutch Packs Repair

STEP 10.
Install output gear on input shaft. Install bearing
and snap ring in output gear.

1. SNAP RING
2. BEARING
3. OUTPUT GEAR

STEP 11.
Install bearing and shaft seal on input shaft for
Forward (low) gear pack. Install bearing to Forward
(high) and Reverse gear packs.

1. SHAFT SEAL
2. BEARING
3. INPUT SHAFT

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Clutch Packs Repair 1300 SRM 1529

STEP 12.
Install reverse clutch assembly in transmission hous-
ing. DO NOT damage seal rings on end of clutch
shaft.

Check gap between TOSS and TISS sensors and re-

verse gear. The allowable gap for TOSS sensor is 0.8
to 1.8 mm (0.031 to 0.071 in.). The allowable gap for
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 forward clutch assemblies (high and low) in
transmission housing. DO NOT damage seal rings
on end of clutch shaft.

1. REVERSE CLUTCH
2. FORWARD CLUTCH
3. TISS SENSOR
4. TOSS SENSOR

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1300 SRM 1529 Clutch Packs Repair

Transmission, Assemble and Install 4. Install yoke, stato seal, and bolt in back of trans-
mission. Tighten bolt to 38 N•m (28 lbf ft). See
1. Install bearing, output gear, special nut, snap Figure 28.
ring, and bearing on transmission. See Fig-
ure 28. 5. Install two bearings and idler gear. See Fig-
ure 28.
2. Install oil seal into back of transmission as noted
during removal. 6. Install torque converter housing on transmis-
sion. See Housings and Chain Drive Repair,
3. Install spacer in yoke. Install.

1. BEARING 8. SPACER
2. IDLER GEAR 9. YOKE
3. SNAP RING 10. STATO SEAL
4. SPECIAL NUT 11. BOLT
5. OUTPUT GEAR 12. REVERSE GEAR
6. TRANSMISSION HOUSING 13. FORWARD CLUTCH PACK (LOW)
7. OIL SEAL 14. FORWARD CLUTCH PACK (HIGH)

Figure 28. Output Gear Installation

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Clutch Packs Repair 1300 SRM 1529

See Frame 100 SRM 1120 for lift truck models:

CAUTION • S30FT, S35FT, S40FTS (E010)
Use care when connecting the wiring harness • H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT,
connectors to electrical connectors on the H40FTS) (F001)
transmission and control valve. The connec- • S2.0-3.5FT (S40-70FT, S55FTS) (F187)
tors on the transmission and control valve are • H2.0-3.5FT (H40-70FT) (L177)
easily damaged.
10. Fill transmission to the correct level using trans-
7. Install transmission wiring harness on transmis- mission fluid and procedure indicated in the fol-
sion. Connect transmission wiring harness con- lowing sections:
nectors to control valve and transmission. Con-
nect two chassis wiring harness connectors to See Periodic Maintenance 8000 SRM 1150 for
transmission wiring harness. See Figure 29. lift truck models:
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
NOTE: Coat the bolt threads that hold the torque con- • H2.0-3.5FT (H40-70FT) (L177)
verter to flywheel with Loctite™ 242.
See Periodic Maintenance 8000 SRM 1207 for
8. Rotate engine crankshaft to position the fly- lift truck models:
wheel mounting holes in line with torque con- • S30FT, S35FT, S40FTS (E010)
verter mounting holes. Install capscrews that • H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT,
hold torque converter to flywheel through access H40FTS) (F001)
hole of flywheel housing. See Figure 30. Tighten
capscrews to 56 N•m (41 lbf ft). See Periodic Maintenance 8000 SRM 1248 for
lift truck models:
Remove lifting eye bolt, and install access cover • S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT;
on torque converter housing. S80, 100FTBCS; S120FTS; S120FTPRS)
(G004)
9. Install engine and transmission as a unit into • H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-
lift truck as described in one of the following sec- 5.5FT (H80, 90, 100, 110, 120FT) (P005)
tions:

See Frame 100 SRM 1243 for lift truck models:

• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT;
S80, 100FTBCS; S120FTS; S120FTPRS)
(G004)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005)

50 Confidential/Proprietary - Do Not Copy or Duplicate

1300 SRM 1529 Clutch Packs Repair

1. GM 2.4L ENGINE 5. CAPSCREW

2. CAPSCREW 6. ACCESS COVER
3. TRANSMISSION WIRING HARNESS 7. CONTROL VALVE
4. TRANSMISSION

Figure 29. Engine-Transmission Combination

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Clutch Packs Repair 1300 SRM 1529

Figure 30. Torque Converter Bolt Access

52 Confidential/Proprietary - Do Not Copy or Duplicate

1300 SRM 1529 Control Valve Repair

Legend for Figure 30

A. GM 2.4L ENGINE C. YANMAR ENGINE E. CUMMINS 3.3L DIESEL
B. MAZDA ENGINE D. GM 4.3L ENGINE ENGINE
1. ACCESS HOLE 2. FLYWHEEL HOUSING

Control Valve Repair

REMOVE AND DISASSEMBLE 2. Remove capscrews and lockwashers from control
valve and transmission. See Figure 32.
CAUTION
Use care when disconnecting the wiring har-
nesses from the connectors. The connectors
are easily damaged.

1. Clean area around control valve. Put identifica-

tion tags on wire harness connectors and connec-
tors on transmission and control valve. Discon-
nect wiring harness connectors from transmis-
sion and control valve connectors. Remove ca-
ble connector from standoff located on torque con-
verter housing. See Figure 31.

1. TRANSMISSION ASSEMBLY
2. GASKET
3. CONTROL VALVE ASSEMBLY
4. LOCKWASHER
1. TORQUE CONVERTER HOUSING 5. CAPSCREW
2. HARNESS STANDOFF 6. TRANSMISSION INPUT SPEED SENSOR (TISS)
3. TRANSMISSION WIRING HARNESS 7. TRANSMISSION OUTPUT SPEED SENSOR
(TOSS)
Figure 31. Transmission Assembly
Figure 32. Control Valve Removal

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Control Valve Repair 1300 SRM 1529

3. Remove control valve assembly and gasket from plugs so that the compressed springs do not
transmission. Discard gasket. Put a cover on cause injury.
top of the transmission to keep dirt out of the
transmission. See Figure 32. 7. Remove plug for proportional supply regulator
spool. Discard O-ring. See Figure 34.
4. Remove capscrew, lock washer and the transmis-
sion input speed sensor (TISS) from transmis- 8. Remove spring and proportional supply regula-
sion. See Figure 33. tor spool from control valve body. See Figure 34.

9. Remove plug for torque converter regulator

spool. Discard O-ring. See Figure 34.

10. Remove the spring and torque converter regula-

tor spool from control valve body. See Figure 34.

11. Remove plug for supply spool. Discard O-ring.

See Figure 34.

12. Remove the spring and supply spool from the con-
trol valve body. See Figure 34.

13. Remove socket head screws and forward propor-

tional valve from control valve body. Repeat for
reverse proportional valve. See Figure 34.

14. Remove socket head screws and transmission en-

able valve from control valve body. See Figure 34.

CLEAN

WARNING
Cleaning solvents can be flammable and toxic
1. TRANSMISSION ASSEMBLY and can cause skin irritation. When using
2. TRANSMISSION OUTPUT SPEED SENSOR cleaning solvents, always follow the solvent
(TOSS) manufacturer’s recommended safety proce-
3. TRANSMISSION INPUT SPEED SENSOR (TISS)
4. LOCK WASHER dures.
5. CAPSCREW
Compressed air can move particles so they
Figure 33. Transmission Speed Sensor cause injury to the user or to other personnel.
Make sure the path of the compressed air is
5. Remove capscrew, lock washer and the transmis- away from all personnel. Wear protective gog-
sion output speed sensor (TOSS) from transmis- gles or a face shield to prevent injury to the
sion. See Figure 33. eyes.
NOTE: Disassemble control valve only to extent re-
quired for repairs. CAUTION
DO NOT allow cleaning solvent to come in con-
NOTE: Disassemble the control valve in a clean, con- tact with rubber or plastic components as it
tamination-free area. can damage those components.
6. Remove two pressure transducers and two fit- Clean all metal components in solvent and dry with
tings from control valve body. See Figure 34. compressed air.

WARNING INSPECT
There are compressed springs under the plugs
1. Make sure there are no scratches or damage on
in the control valve. Carefully remove the
the spools or in the bores of the control valve body.

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1300 SRM 1529 Control Valve Repair

If the control valve body bores are damaged, re- 3. Check that the springs are not bent or damaged.
place the control valve. Make sure the spools move freely in their bores.

2. Inspect the control valve body for the presence of 4. Inspect the connectors on the proportional and
burrs. Burrs may be removed using a fine file, solenoid valves and, if they are damaged, replace
emery cloth, or crocus cloth. the damaged proportional or solenoid valves.

1. CONTROL VALVE BODY 7. FORWARD PROPORTIONAL VALVE

2. PRESSURE TRANSDUCER 8. SOCKET HEAD SCREW
3. FITTING 9. TORQUE CONVERTER REGULATOR SPOOL
4. PROPORTIONAL SUPPLY REGULATOR SPOOL 10. REVERSE PROPORTIONAL VALVE
5. SPRING 11. TRANSMISSION ENABLE VALVE
6. PLUG 12. SUPPLY SPOOL

Figure 34. Control Valve Arrangement

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MONOTROL® Pedal Repair 1300 SRM 1529

ASSEMBLE AND INSTALL Figure 32. Install capscrews that hold control
valve on transmission. DO NOT tighten at this
NOTE: Lubricate the parts of the control valve with time. See Figure 34.
clean transmission oil during assembly.
10. Tighten capscrews to 13.3 N•m (118 lbf in) in
1. Install transmission enable valve and socket the sequence shown in Figure 35. Retighten cap-
head screws onto control valve body. Tighten screws to 19 N•m (168 lbf in) in sequence shown
socket head screws to 3 to 4 N•m (27 to 35 lbf in). in Figure 35.
See Figure 34.

2. Install reverse proportional valve, forward pro- CAUTION

portional valve, and socket head screws onto con- Use care when connecting the wiring har-
trol valve body. Tighten socket head screws to 3 nesses to the connectors. The connectors are
to 4 N•m (27 to 35 lbf in). See Figure 34. easily damaged.
3. Install supply spool and spring into control valve 11. Install cable connector in standoff and connect
body. Install new O-ring on plug. Install plug wiring harness connectors to transmission and
into control valve body. See Figure 34. control valve as tagged during removal. See Fig-
ure 31.
4. Install torque converter regulator spool and
spring into control valve body. Install new
O-ring on plug. Install plug into control valve
body. See Figure 34.

5. Install proportional supply regulator spool and

spring into control valve body. Install new O-ring
on plug. Install plug into control valve body. See
Figure 34.

6. Install two fittings and two pressure transducers

into control valve body. See Figure 34.

7. Install transmission input speed sensor (tiss)

and capscrew in transmission. Tighten cap-
screws to 6.9 N•m (61 lbf in). See Figure 34.

8. Install the transmission output speed sensor

(toss) and capscrew in the transmission. Tighten
capscrews to 6.9 N•m (61 lbf in). See Figure 34.
Figure 35. Control Valve Mounting Screw
9. Install a new control valve gasket on transmis- Tightening Sequence
sion. Install control valve on transmission. See

MONOTROL® Pedal Repair

REMOVE AND DISASSEMBLE See Frame 100 SRM 1120 for lift truck models:
• S30FT, S35FT, S40FTS (E010)
1. Remove five screws, dash panel, and kick plate • H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT,
from lift truck. H40FTS) (F001)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
See Frame 100 SRM 1243 for lift truck models:
• H2.0-3.5FT (H40-70FT) (L177)
• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT;
S80, 100FTBCS; S120FTS; S120FTPRS) Remove three capscrews and swing hydraulic
(G004) lever assembly toward operator’s seat. Dis-
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0- connect two cable assemblies from the pedal
5.5FT (H80, 90, 100, 110, 120FT) (P005) assembly. See Figure 36.

56 Confidential/Proprietary - Do Not Copy or Duplicate

1300 SRM 1529 MONOTROL® Pedal Repair

from throttle base and MONOTROL pedal as-

sembly.

5. Remove e-clip and throttle base from throttle

pedal shaft. Remove roll pin and throttle pedal
shaft from MONOTROL pedal assembly. Dis-
card roll pin.

NOTE: Tag wires prior to removing from mi-

croswitches to aid in connecting.

6. Remove u-clip, foam lock seal, and wiring har-

ness from pedal frame. Remove four pan head
screws, lockwashers, washers, pedal pad, and
springs from pedal frame. If any metal inserts
in pedal pad are damaged, replace as necessary.
See Figure 39.

1. CAPSCREW
2. HYDRAULIC LEVER ASSEMBLY

Figure 36. Hydraulic Lever Relocation

2. Remove three capscrews that hold throttle base

to cowl, and remove pedal assembly from lift
truck. See Figure 37.

3. Remove two pan head screws, lockwashers, and

accelerator position sensor from throttle base.
See Figure 38.

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. CAPSCREWS

complete the repair of the MONOTROL pedal. 2. PEDAL ASSEMBLY
3. COWL
4. Remove connector from connector holder on
throttle base. Remove outer and inner springs Figure 37. MONOTROL Pedal Removal

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MONOTROL® Pedal Repair 1300 SRM 1529

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 38. MONOTROL Pedal Bracket Disassembly

7. Remove two hex head screws, lockwashers, nuts, screws with Loctite™ 222. Install two lockwash-
and microswitch from pedal pad. Repeat for re- ers and nuts on hex head screws. DO NOT
maining microswitch and remove wiring harness tighten nuts at this time. Repeat for the other
from pedal frame. microswitch.

8. If damaged, remove stop screw and nut from 3. Put wires through hole in pedal frame. The white
pedal frame. banded wire is for reverse microswitch, and the
blue banded wire is for forward microswitch.
ASSEMBLE AND INSTALL Adjust each microswitch in its mount so that the
measurement between the edge of the mount
1. If removed, install stop screw and nut on pedal and the base of the microswitch equals 0.0 to
frame. See Figure 39. 0.5 mm (0.0 to 0.02 in.). Tighten the mounting
nuts of each microswitch as adjustment is com-
2. Install microswitch and two hex head screws in
pleted. See Figure 40.
pedal pad. Coat exposed threads of hex head

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1300 SRM 1529 MONOTROL® Pedal Repair

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 39. MONOTROL Pedal Disassembly

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MONOTROL® Pedal Repair 1300 SRM 1529

6. Install throttle pedal shaft and new roll pin in

the MONOTROL pedal assembly. Install throt-
tle base and e-clip on throttle pedal shaft. See
Figure 38.

CAUTION
Use care when installing the connector in its
holder as the connector can be easily damaged.

7. Install inner and outer springs on throttle base

and MONOTROL pedal assembly. Install con-
nector in connector holder on throttle base.

8. Install actuator and magnet in the throttle base.

Install accelerator position sensor, lockwashers,
and two pan head screws in the throttle base.
Tighten screws to 2.25 N•m (19 lbf in).

9. Apply adhesive compound to three mounting

bolts. Using three capscrews that hold the throt-
tle base to the cowl, install the pedal assembly
on lift truck. Tighten the bolts to 19 to 25 N•m
(168 to 221 lbf in). See Figure 37.

1. MICROSWITCH MOUNT
2. MICROSWITCH BASE

Figure 40. Microswitch Adjustment

4. Install wiring harness in the pedal frame. In-

stall foam lock seal and u-clip. Install pedal pad
and springs in the pedal frame. Coat threads of
four pan head screws with Loctite 222. Install
pan head screws, lockwashers, and washers in
the pedal pad. Tighten pan head screws to 2.25
to 2.50 N•m (19 to 32 lbf in).

5. Using an ohmmeter, check for continuity be- 1. WIRING HARNESS CONNECTOR

2. WIRING HARNESS
tween pins 3 and 4 of the MONOTROL wiring
harness connector with the MONOTROL pedal Figure 41. Microswitch Continuity Check
in the reverse position, and between pins 1 and
2 with the pedal in the forward position. See
Figure 41.

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1300 SRM 1529 Direction Control Lever

10. Connect two cable assemblies to pedal assembly. See Frame 100 SRM 1120 for lift truck models:
Swing hydraulic lever assembly toward cowl and • S30FT, S35FT, S40FTS (E010)
install three capscrews. See Figure 36. Install • H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT,
dashboard on the lift truck. H40FTS) (F001)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
SeeFrame 100 SRM 1243 for lift truck models: • H2.0-3.5FT (H40-70FT) (L177)
• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT;
S80, 100FTBCS; S120FTS; S120FTPRS) 11. Depress the MONOTROL pedal until it stops.
(G004) Unscrew stop screw until it contacts metal floor
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0- plate. Tighten nut to 10 N•m (89 lbf in).
5.5FT (H80, 90, 100, 110, 120FT) (P005)

Direction Control Lever

REMOVE of lever enough to free tab of interior lock of the
display panel. See B, Figure 42.
NOTE: There is no repair of the direction control
lever. 3. Repeat above steps on the opposite side of direc-
tion control lever. Remove direction control lever
1. Insert a small, flat-blade screwdriver with a from display panel.
3.175 mm (0.125 in.) or less, wide blade into
opening on display panel on an outward angle INSTALL
enough to compress spring tab on direction con-
trol lever. See A, Figure 42. Slide the direction control lever into opening on left
side of display panel until locking tabs are engaged
2. Pry spring tab toward body of direction control in display panel.
lever and, at the same time, pull on the handle

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Direction Control Lever 1300 SRM 1529

NOTE: DISPLAY PANEL SHOWN OUTSIDE OF LIFT TRUCK FOR CLARITY.

A. STEP 1 B. STEP 2
1. DIRECTION CONTROL LEVER 3. DISPLAY PANEL
2. FLAT-BLADE SCREWDRIVER

Figure 42. Direction Control Lever Removal

62 Confidential/Proprietary - Do Not Copy or Duplicate

 TECHNICAL PUBLICATIONS

1300 SRM 1529 10/11 Printed in United Kingdom