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