Hyster H80FT Operating instructions

Hyster P005 (H80FT, H90FT, H100FT, H110FT, H120FT)
Forklift Service Repair Manual

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
•The Service Manuals are updated on a regular basis, but may not reflect recent design changes to the prod-
uct. 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 expe-
rienced technicians. Failure to properly maintain equipment or to follow instructions 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 exceed the
specifications of the original equipment manufacturer.
•Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to remove parts.
•Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the unit needs
repairs.
•Be sure to follow the WARNING and CAUTION notes in the instructions.
•Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are flammable. Be sure
to follow the necessary safety precautions when handling these fuels and when working on these fuel systems.
•Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the area. Make
sure the area is well ventilated.
NOTE: The following symbols and words indicate safety information in this
manual:
WARNING
Indicates a hazardous situation which, if not avoided, could result in
death or serious injury.
CAUTION
Indicates a hazardous situation which, if not avoided, could result in
minor or moderate injury and property damage.
On the lift truck, the WARNING symbol and word are on orange back-
ground. The CAUTION symbol and word are on yellow background.

Powershift Transmission Table of Contents
TABLE OF CONTENTS
General ............................................................................................................................................................... 1
Serial Number................................................................................................................................................ 1
Charge Pump Repair ......................................................................................................................................... 2
Lift Trucks Manufactured Before July, 2013 ............................................................................................... 2
Remove....................................................................................................................................................... 2
Inspect........................................................................................................................................................ 2
Install......................................................................................................................................................... 2
Lift Trucks Manufactured After July, 2013.................................................................................................. 2
Remove....................................................................................................................................................... 2
Inspect........................................................................................................................................................ 2
Install......................................................................................................................................................... 2
Torque Converter Replace ................................................................................................................................. 4
Remove ........................................................................................................................................................... 4
Install ............................................................................................................................................................. 11
Housings and Chain Drive Repair .................................................................................................................... 17
Remove ........................................................................................................................................................... 17
Clean .............................................................................................................................................................. 24
Inspect ............................................................................................................................................................ 25
Install ............................................................................................................................................................. 25
Clutch Packs Repair........................................................................................................................................... 32
Remove and Disassemble.............................................................................................................................. 32
Transmission, Remove and Disassemble................................................................................................. 32
Clutch Assemblies, Remove and Disassemble......................................................................................... 40
Clean .............................................................................................................................................................. 46
Inspect ............................................................................................................................................................ 46
Assemble and Install ..................................................................................................................................... 47
Clutch Assemblies, Assemble and Install ................................................................................................ 47
Transmission, Assemble and Install ........................................................................................................ 56
Control Valve Repair.......................................................................................................................................... 60
Remove and Disassemble.............................................................................................................................. 60
Clean .............................................................................................................................................................. 63
Inspect ............................................................................................................................................................ 63
Assemble and Install ..................................................................................................................................... 63
MONOTROL® Pedal Repair ............................................................................................................................. 64
Remove and Disassemble.............................................................................................................................. 64
Assemble and Install ..................................................................................................................................... 68
Direction Control Lever ..................................................................................................................................... 69
Remove ........................................................................................................................................................... 69
Install ............................................................................................................................................................. 69
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]
©2013 HYSTER COMPANY i

"THE
QUALITY
KEEPERS"
HYSTER
APPROVED
PARTS

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1300 SRM 1529 General
General
This section has the repair procedures for the transmission.
SERIAL NUMBER
The transmission serial number is located on the
right side of the transmission control valve directly
below the floor plate. See Figure 1.
1. TRANSMISSION SERIAL NUMBER
Figure 1. Transmission Serial Number
Location
Confidential/Proprietary - Do Not Copy or Duplicate 1

Charge Pump Repair 1300 SRM 1529
Charge Pump Repair
LIFT TRUCKS MANUFACTURED BEFORE
JULY, 2013
Remove
NOTE: The charge pump can be removed from the
transmission while it is still in the lift truck but,
for the sake of clarity, the following procedures are
shown with the transmission removed from the lift
truck.
Remove four mounting capscrews, washers, trans-
mission charge pump, and gasket from torque con-
verter housing. Discard gasket. See Figure 2.
Inspect
Inspect the splines on shaft of transmission charge
pump for damage or worn areas that could affect op-
eration of the pump. If the splines are damaged, re-
place the transmission charge pump.
Install
Install new gasket, transmission charge pump,
four washers, and mounting capscrews on torque
converter housing. Tighten capscrews to 19 N•m
(168 lbf in).
Figure 2. Transmission Charge Pump
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
LIFT TRUCKS MANUFACTURED AFTER
JULY, 2013
Remove
NOTE: The charge pump can be removed from the
transmission while it is still in the lift truck but,
for the sake of clarity, the following procedures are
shown with the transmission removed from the lift
truck.
Remove four mounting capscrews, washers, trans-
mission charge pump, and gasket from torque con-
verter housing. Discard gasket. See Figure 3.
Inspect
Inspect the splines on shaft of transmission charge
pump for damage or worn areas that could affect op-
eration of thepump. Ifthesplinesaredamaged,re-
place the transmission charge pump.
Install
Install new gasket, transmission charge pump,
four washers, and mounting capscrews on torque
converter housing. Tighten capscrews in star pat-
tern to 6 N•m (53 lbf in) on first pass. On second
pass, tighten capscrews in star pattern to 19 N•m
(168 lbf in). See Figure 3.
2 Confidential/Proprietary - Do Not Copy or Duplicate

1300 SRM 1529 Charge Pump Repair
NOTE: THE TRANSMISSION IS SHOWN REMOVED FROM LIFT TRUCK FOR CLARITY.
1. CAPSCREW
2. WASHER
3. CHARGE PUMP
4. GASKET
5. TORQUE CONVERTER HOUSING
Figure 3. Transmission Charge Pump
Confidential/Proprietary - Do Not Copy or Duplicate 3

Torque Converter Replace 1300 SRM 1529
Torque Converter Replace
REMOVE
WARNING
Make sure the engine and transmission are
held in position so that they will not fall and
cause an injury and damage to the equipment.
CAUTION
Be careful that you DO NOT damage parts of
thetorqueco
nverter or transmission when
the transmission is separated from the engine.
Keep the transmission and engine in align-
ment until they are completely separated so
parts of the transmission are not damaged.
Useacraneo
r lifting device to separate the
transmission from the engine.
1. Remove engine and transmission as a unit from
lift truck as described in one of the following sec-
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)
See Frame 100 SRM 1120 for lift truck 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)
CAUTION
Usecarewh
en disconnecting the wiring har-
ness connectors from electrical connectors on
the transmission and control valve. The con-
nectors on the transmission and control valve
are easily damaged.
NOTE: When disconnecting wiring harness connec-
tors during disassembly, tag each connector to aid in
connecting the wiring harness during reassembly.
2. Put engine and transmission on solid blocks on a
work surface.
Disconnect transmission wiring harness connec-
tors from control valve and transmission.
Remove transmission wiring harness from trans-
mission. See Figure 4.
WARNING
Make sure that the engine/transmission assem-
bly is stable before attempting to rotate the en-
gine.
Use a flashlight to see the bolts as they are ro-
tated into view through the access hole. DO
NOT use your fingers to check for alignment of
the bolts with the access hole.
3. Move each bolt into view through access hole
of flywheel housing by rotating crankshaft. Re-
move four capscrews that attach flywheel to
torque converter. See Figure 5.
4. Remove access cover from torque converter hous-
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
converter housing to flywheel housing on engine.
Carefully separate transmission from engine.
NOTE: The torque converter cannot be repaired and
must be replaced as a unit, if damaged.
5. Carefully remove torque converter from stator
support.
See Figure 6 for lift trucks manufactured before
July, 2013
See Figure 7 for lift trucks manufactured after
July, 2013
6. Remove plug, suction screen spring, and suction
screen from torque converter housing, and drain
oil from transmission.
See Figure 6 for lift trucks manufactured before
July, 2013
See Figure 7 for lift trucks manufactured after
July, 2013
4 Confidential/Proprietary - Do Not Copy or Duplicate

1300 SRM 1529 Torque Converter Replace
1. GM 2.4L ENGINE
2. CAPSCREW
3. TRANSMISSION WIRING HARNESS
4. TRANSMISSION
5. ACCESS COVER
6. CONTROL VALVE
Figure 4. Engine-Transmission Combination
Confidential/Proprietary - Do Not Copy or Duplicate 5

Torque Converter Replace 1300 SRM 1529
Figure 5. Torque Converter Bolt Access
6 Confidential/Proprietary - Do Not Copy or Duplicate

1300 SRM 1529 Torque Converter Replace
Legend for Figure 5
A. GM 2.4L ENGINE
B. MAZDA ENGINE
C. YANMAR ENGINE
D. GM 4.3L ENGINE
E. CUMMINS 3.3L DIESEL ENGINE
1. ACCESS HOLE 2. FLYWHEEL HOUSING
Confidential/Proprietary - Do Not Copy or Duplicate 7

Torque Converter Replace 1300 SRM 1529
1. TRANSMISSION OIL FILTER
2. DIPSTICK
3. DIPSTICK TUBE
4. TRANSMISSION HOUSING
5. TORQUE CONVERTER HOUSING
6. TRANSMISSION OIL TEMPERATURE SENSOR
7. SUCTION SCREEN
8. SUCTION SCREEN SPRING
9. PLUG
10. CAPSCREW
11. WASHER
12. SMALL ACCESS COVER
13. TORQUE CONVERTER
14. TRANSMISSION CHARGE PUMP
15. STATOR SUPPORT
16. PILOT HUB
Figure 6. Torque Converter Removal, Lift Trucks Manufactured Before July, 2013
8 Confidential/Proprietary - Do Not Copy or Duplicate

1300 SRM 1529 Torque Converter Replace
1. TRANSMISSION OIL FILTER
2. DIPSTICK
3. DIPSTICK TUBE
4. TRANSMISSION HOUSING
5. TORQUE CONVERTER HOUSING
6. TRANSMISSION OIL TEMPERATURE SENSOR
7. SUCTION SCREEN
8. SUCTION SCREEN SPRING
9. PLUG
10. CAPSCREW
11. WASHER
12. SMALL ACCESS COVER
13. TORQUE CONVERTER
14. TRANSMISSION CHARGE PUMP
15. STATOR SUPPORT
16. PILOT HUB
Figure 7. Torque Converter Removal, Lift Trucks Manufactured After July, 2013
7. Remove transmission charge pump. See Charge
Pump Repair.
8. Remove transmission oil filter from torque con-
verter housing.
See Figure 6 for lift trucks manufactured before
July, 2013
See Figure 7 for lift trucks manufactured after
July, 2013
9. If damaged, remove two cap screws and small
access cover from the torque converter housing.
10. Remove dipstick and dipstick tube from torque
converter housing.
See Figure 6 for lift trucks manufactured before
July, 2013
See Figure 7 for lift trucks manufactured after
July, 2013
11. Remove transmission oil temperature sensor
from torque converter housing.
See Figure 6 for lift trucks manufactured before
July, 2013
See Figure 7 for lift trucks manufactured after
July, 2013
Confidential/Proprietary - Do Not Copy or Duplicate 9

Torque Converter Replace 1300 SRM 1529
NOTE: Perform Step 12 through Step 16 only if repair
of the of the transmission chain drive is required. If
the transmission clutch packs are in need of further
repair, see Clutch Packs Repair.
12. Remove two long capscrews and washers from in-
ner face of torque converter housing. See Fig-
ure 9.
13. Remove 15 capscrews from transmission hous-
ing. See Figure 8.
14. Remove two mounting capscrews and harness
bracket from front of torque converter housing.
SeeFigure8.
15. Using a small pry bar in the designated pry
points, remove the torque converter housing
from the transmission housing. See Figure 8.
16. Remove and discard O-rings and gasket. See Fig-
ure 9.
1. PRY POINTS
2. TORQUE CONVERTER HOUSING
3. TRANSMISSION HOUSING
4. HARNESS BRACKET
5. CAPSCREW
Figure 8. Pry Point Location
10 Confidential/Proprietary - Do Not Copy or Duplicate

1300 SRM 1529 Torque Converter Replace
INSTALL
NOTE: Perform Step 1 through Step 4 only if repair
of the transmission chain drive was performed.
1. Install new O-rings and gasket to torque con-
verter housing and transmission housing. See
Figure 9.
2. Install harness bracket and two mounting cap-
screws to front of torque converter housing. See
Figure 8.
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 9.
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 10 for lift trucks manufactured before
July, 2013
See Figure 11 for lift trucks manufactured after
July, 2013
6. Install a new transmission oil filter on torque
converter housing.
7. Install the transmission charge pump. See
Charge Pump Repair.
8. Install suction screen, suction screen spring, and
plug into torque converter housing.
See Figure 10 for lift trucks manufactured before
July, 2013
See Figure 11 for lift trucks manufactured after
July, 2013
1. LONG CAPSCREW
2. WASHER
3. TORQUE CONVERTER HOUSING
4. GASKET
5. TRANSMISSION HOUSING
6. O-RING
7. CAPSCREW
Figure9. TorqueConverterHousing
Confidential/Proprietary - Do Not Copy or Duplicate 11

Torque Converter Replace 1300 SRM 1529
1. TRANSMISSION OIL FILTER
2. DIPSTICK
3. DIPSTICK TUBE
4. TRANSMISSION HOUSING
5. TORQUE CONVERTER HOUSING
6. TRANSMISSION OIL TEMPERATURE SENSOR
7. SUCTION SCREEN
8. SUCTION SCREEN SPRING
9. PLUG
10. CAPSCREW
11. WASHER
12. SMALL ACCESS COVER
13. TORQUE CONVERTER
14. TRANSMISSION CHARGE PUMP
15. STATOR SUPPORT
16. PILOT HUB
Figure 10. Torque Converter Installation, Lift Trucks Manufactured Before July, 2013
12 Confidential/Proprietary - Do Not Copy or Duplicate

1300 SRM 1529 Torque Converter Replace
1. TRANSMISSION OIL FILTER
2. DIPSTICK
3. DIPSTICK TUBE
4. TRANSMISSION HOUSING
5. TORQUE CONVERTER HOUSING
6. TRANSMISSION OIL TEMPERATURE SENSOR
7. SUCTION SCREEN
8. SUCTION SCREEN SPRING
9. PLUG
10. CAPSCREW
11. WASHER
12. SMALL ACCESS COVER
13. TORQUE CONVERTER
14. TRANSMISSION CHARGE PUMP
15. STATOR SUPPORT
16. PILOT HUB
Figure 11. Torque Converter Installation, Lift Trucks Manufactured After July, 2013
9. Install torque converter onto stator support.
Make sure splines are aligned and converter
engages fully.
See Figure 10 for lift trucks manufactured before
July, 2013
See Figure 11 for lift trucks manufactured after
July, 2013
10. Lubricate the pilot hub on the torque converter
with antiseize compound.
See Figure 10 for lift trucks manufactured before
July, 2013
See Figure 11 for lift trucks manufactured after
July, 2013
11. Install transmission oil temperature sensor on
torque converter housing.
See Figure 10 for lift trucks manufactured before
July, 2013
See Figure 11 for lift trucks manufactured after
July, 2013
NOTE: Apply adhesive to entire surface of hole,
20.0 mm (0.79 in.) deep. Also apply adhesive to
lower 20.0 mm (0.79 in.) of dipstick tube.
12. Install dipstick tube and dipstick into torque con-
verter housing.
See Figure 10 for lift trucks manufactured before
July, 2013
See Figure 11 for lift trucks manufactured after
July, 2013
Confidential/Proprietary - Do Not Copy or Duplicate 13

Torque Converter Replace 1300 SRM 1529
13. If removed, install a lifting eye bolt into rear ac-
cess cover bolt hole, and connect a lifting device
to eye bolt.
Align torque converter housing with flywheel
housing. Make sure pilot hub on torque con-
verter engages flywheel.
CAUTION
Be careful that you DO NOT damage parts of
the torque converter or transmission when
the transmission is joined to the engine. Keep
the transmission and engine in alignment un-
til they are completely joined so parts of the
transmission are not damaged. Use a crane or
lifting device to join the transmission to the
engine.
14. Install transmission on engine. Install ten cap-
screws that connect torque converter housing to
flywheel housing. Tighten capscrews to 38 N•m
(28 lbf ft). See Figure 12.
CAUTION
Usecarewh
en connecting the wiring harness
connectors to electrical connectors on the
transmission and control valve. The connec-
tors on the transmission and control valve are
easily damaged.
15. Install transmission wiring harness on transmis-
sion. Connect transmission wiring harness con-
nectors to control valve and transmission. See
Figure 12.
NOTE: Coat the bolt threads that hold the torque con-
verter to flywheel with Loctite™ 242.
16. Rotate engine crankshaft to position the fly-
wheel mounting holes in line with torque con-
verter mounting holes. Install capscrews that
hold torque converter to flywheel through access
hole of flywheel housing. See Figure 13. Tighten
capscrewsto56N•m(41lbfft).
Remove lifting eye bolt, and install access cover
on torque converter housing.
WARNING
Make sure the engine and transmission are
held in position so that they will not fall and
cause an injury and damage to the equipment.
17. Install engine and transmission as a unit into
lift truck as described in one of the following sec-
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)
See Frame 100 SRM 1120 for lift truck 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)
18. Fill transmission to correct level using transmis-
sion fluid and procedure indicated in following
sections:
See Periodic Maintenance 8000 SRM 1150 for
lift truck models:
•S2.0-3.5FT (S40-70FT, S55FTS) (F187)
•H2.0-3.5FT (H40-70FT) (L177)
See Periodic Maintenance 8000 SRM 1207 for
lift truck models:
•S30FT, S35FT, S40FTS (E010)
•H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT,
H40FTS) (F001)
See Periodic Maintenance 8000 SRM 1248 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) (P005)
14 Confidential/Proprietary - Do Not Copy or Duplicate