Hyster Fortis S60FT Operating instructions

Hyster E024 (S135FT, S155FT) Forklift Service Repair
Manual

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

SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• The Service Manuals are updated on a regular basis, but may not reflect recent design changes to the
product. Updated technical service information may be available from your local authorized Hyster®
dealer. Service Manuals provide general guidelines for maintenance and service and are intended for
use by trained and experienced technicians. Failure to properly maintain equipment or to follow in-
structions contained in the Service Manual could result in damage to the products, personal injury,
property damage or death.
• 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 ex-
ceed 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 flamma-
ble. 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.

©2015 HYSTER COMPANY
TABLE OF CONTENTS
Transmission Repair ............................................................................................................................................... 1
Remove ................................................................................................................................................................ 1
Torque Converter, Remove .................................................................................................................................1
Disassemble .........................................................................................................................................................2
Torque Converter Housing, Disassemble ......................................................................................................5
Transmission Case, Disassemble .................................................................................................................16
FORWARD 1, Disassemble .......................................................................................................................... 20
RANGE 2, Disassemble ................................................................................................................................26
REVERSE 1, Disassemble ............................................................................................................................28
RANGE 1, Disassemble ................................................................................................................................34
Stator Support, Disassemble ........................................................................................................................36
Turbine Shaft, Disassemble .........................................................................................................................37
Pump Drive Gear, Disassemble ................................................................................................................... 38
Idler Gear, Disassemble ............................................................................................................................... 41
Output Shaft, Disassemble .......................................................................................................................... 42
Clean and Inspect ............................................................................................................................................. 44
Housings ........................................................................................................................................................44
Oil Seals and Gaskets ...................................................................................................................................44
Bearings ........................................................................................................................................................ 44
Gears and Shafts .......................................................................................................................................... 45
Assemble ............................................................................................................................................................45
RANGE 2, Assemble .....................................................................................................................................45
FORWARD 1, Assemble ............................................................................................................................... 48
REVERSE 1, Assemble .................................................................................................................................52
RANGE 1, Assemble .....................................................................................................................................57
Stator Support, Assemble .............................................................................................................................60
Turbine Shaft, Assemble ..............................................................................................................................61
Pump Drive Gear, Assemble ........................................................................................................................ 62
Idler Gear, Assemble .................................................................................................................................... 62
Output Shaft, Assemble ............................................................................................................................... 63
Torque Converter Housing, Assemble .........................................................................................................64
Transmission Case, Assemble ......................................................................................................................67
Torque Converter, Install ................................................................................................................................. 80
Install .................................................................................................................................................................81
Control Valve Repair .............................................................................................................................................82
Remove .............................................................................................................................................................. 82
Disassemble .......................................................................................................................................................82
Control Valve Assembly ............................................................................................................................... 82
Control Valve Body .......................................................................................................................................82
Clean ..................................................................................................................................................................86
Inspect ............................................................................................................................................................... 86
Assemble ............................................................................................................................................................86
Control Valve Body .......................................................................................................................................86
Control Valve Assembly ............................................................................................................................... 87
Install .................................................................................................................................................................87
Torque Specification ..............................................................................................................................................89
Table of Contents
i

This section is for the following models:
H6.0FT, H7.0FT (H135FT, H155FT) [H006, J006, K006, L006];
S6.0FT, S7.0FT (S135FT, S155FT) [D024, E024, F024, G024]
Table of Contents
ii

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

1. TORQUE CONVERTER ASSEMBLY
2. INTERNAL SNAP RING
3. PLUG
4. O-RING
5. EXTERNAL SNAP RING
6. SNAP RING
7. OIL BAFFLE
8. SEALING RING
9. SEAL (OIL BAFFLE)
10. BEARING
11. PISTON RING
Figure 1. Torque Converter Assembly
DISASSEMBLE
Refer to Figure 2 and Figure 3.
Transmission Repair 1300 SRM 1343
2

NOTE: TORQUE CONVERTER HOUSING FOR LIFT TRUCKS MANUFACTURED BEFORE JUNE 2009
SHOWN.
1. PLUG
2. O-RING
3. REGULATOR SPOOL
4. REGULATOR SPRING
5. DOWEL PIN
6. RESTRICTION PLUG
7. EXPANSION PLUG
8. GASKET (CONVERTER
HOUSING TO
TRANSMISSION CASE)
9. SNAP RING
10. RETAINER (SAFETY VALVE)
11. SPRING (SAFETY VALVE)
12. BALL
13. SPACER
14. SCREW
15. LOCKWASHER
16. OIL BAFFLE
17. SUCTION SCREEN
18. GASKET
19. ADAPTER (FILTER)
20. OIL FILTER
21. DRAIN PLUG
22. TORQUE CONVERTER
HOUSING
23. STATOR SUPPORT
24. AIR BREATHER
25. TUBE (DIPSTICK)
26. DIPSTICK
Figure 2. Torque Converter Housing
1300 SRM 1343 Transmission Repair
3

NOTE: TORQUE CONVERTER HOUSING FOR LIFT TRUCKS MANUFACTURED AFTER JUNE 2009 SHOWN.
1. TORQUE CONVERTER HOUSING
2. PLUG
3. O-RING
4. SPACER
5. BALL
6. REGULATOR SPRING
7. RETAINER (SAFETY VALVE)
8. SNAP RING
9. ADAPTER (FILTER)
10. OIL FILTER
11. DIPSTICK TUBE AND BREATHER
12. SUCTION SCREEN
13. GASKET
14. DOWEL PIN
15. DRAIN PLUG
16. REGULATOR SPOOL
17. SAFETY SPRING
18. CAPSCREW
19. WASHER
20. STATOR SUPPORT
21. LOCKWASHER
22. SCREW
Figure 3. Torque Converter Housing
Transmission Repair 1300 SRM 1343
4

Torque Converter Housing, Disassemble
NOTE: Perform STEP 1 on lift trucks manufactured Before June 2009.
STEP 1.
Remove dipstick and tube.
1. DIPSTICK
2. TUBE
3. CONVERTER HOUSING
NOTE: Perform STEP 2 on lift trucks manufactured Before June 2009.
1300 SRM 1343 Transmission Repair
5

STEP 2.
Remove air breather.
1. AIR BREATHER
2. CONVERTER HOUSING
NOTE: Perform STEP 3 on lift trucks manufactured After June 2009.
STEP 3.
Remove transmission oil dipstick and breather.
1. CONVERTER HOUSING
2. DIPSTICK/BREATHER
Transmission Repair 1300 SRM 1343
6

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.
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
3. CONVERTER HOUSING
1300 SRM 1343 Transmission Repair
7

STEP 5.
Remove pressure regulator valve by removing
plug, O-ring, spool, and spring.
1. PLUG
2. O-RING
3. SPOOL
4. SPRING
5. CONVERTER HOUSING
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
3. CONVERTER HOUSING
4. DRAIN PLUG
Transmission Repair 1300 SRM 1343
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
1300 SRM 1343 Transmission Repair
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
MANUFACTURED AFTER JUNE 2009.
STEP 9.
Remove control valve assembly. See the Control
Valve Repair section,Remove for procedures.
NOTE: TRANSMISSION FOR LIFT TRUCKS
MANUFACTURED BEFORE JUNE 2009 SHOWN.
CONTROL VALVE ASSEMBLY IN SAME LOCATION
ON TRANSMISSION FOR LIFT TRUCKS
MANUFACTURED AFTER JUNE 2009.
Transmission Repair 1300 SRM 1343
10

STEP 10.
Remove output flange assembly.
NOTE: TRANSMISSION FOR LIFT TRUCKS
MANUFACTURED BEFORE JUNE 2009 SHOWN.
OUTPUT FLANGE ASSEMBLY IN SAME LOCATION
ON TRANSMISSION FOR LIFT TRUCKS
MANUFACTURED AFTER JUNE 2009.
STEP 11.
Remove oil baffle retainer ring.
NOTE: TRANSMISSION FOR LIFT TRUCKS
MANUFACTURED BEFORE JUNE 2009 SHOWN.
OIL BAFFLE RETAINER RING IN SAME LOCATION
ON TRANSMISSION FOR LIFT TRUCKS
MANUFACTURED AFTER JUNE 2009.
1300 SRM 1343 Transmission Repair
11

STEP 12.
Remove oil baffle with oil seal and sealing ring.
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.
Transmission Repair 1300 SRM 1343
12

STEP 15.
Remove snap ring and safety valve assembly from
torque converter housing.
STEP 16.
Remove retainer, spring, ball, spacer, and O-ring.
1. RETAINER
2. SPRING
3. BALL
4. SPACER
5. O-RING
1300 SRM 1343 Transmission Repair
13

STEP 17.
Remove output shaft cup.
1. OUTPUT SHAFT CUP
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.
Transmission Repair 1300 SRM 1343
14