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Hyster E024 (S135FT, S155FT) Forklift Service Repair

Manual
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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

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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.
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Table of Contents

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

©2015 HYSTER COMPANY i

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Table of Contents

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]

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1300 SRM 1343 Transmission Repair

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

Frame 0100SRM1581 for lift truck models

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Transmission Repair 1300 SRM 1343

1. TORQUE CONVERTER ASSEMBLY 7. OIL BAFFLE

2. INTERNAL SNAP RING 8. SEALING RING
3. PLUG 9. SEAL (OIL BAFFLE)
4. O-RING 10. BEARING
5. EXTERNAL SNAP RING 11. PISTON RING
6. SNAP RING

Figure 1. Torque Converter Assembly

DISASSEMBLE

Refer to Figure 2 and Figure 3.

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1300 SRM 1343 Transmission Repair

NOTE: TORQUE CONVERTER HOUSING FOR LIFT TRUCKS MANUFACTURED BEFORE JUNE 2009
SHOWN.

1. PLUG 9. SNAP RING 19. ADAPTER (FILTER)

2. O-RING 10. RETAINER (SAFETY VALVE) 20. OIL FILTER
3. REGULATOR SPOOL 11. SPRING (SAFETY VALVE) 21. DRAIN PLUG
4. REGULATOR SPRING 12. BALL 22. TORQUE CONVERTER
5. DOWEL PIN 13. SPACER HOUSING
6. RESTRICTION PLUG 14. SCREW 23. STATOR SUPPORT
7. EXPANSION PLUG 15. LOCKWASHER 24. AIR BREATHER
8. GASKET (CONVERTER 16. OIL BAFFLE 25. TUBE (DIPSTICK)
HOUSING TO 17. SUCTION SCREEN 26. DIPSTICK
TRANSMISSION CASE) 18. GASKET

Figure 2. Torque Converter Housing

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Transmission Repair 1300 SRM 1343

NOTE: TORQUE CONVERTER HOUSING FOR LIFT TRUCKS MANUFACTURED AFTER JUNE 2009 SHOWN.

1. TORQUE CONVERTER HOUSING 12. SUCTION SCREEN

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

Figure 3. Torque Converter Housing

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1300 SRM 1343 Transmission Repair

Torque Converter Housing, Disassemble

NOTE: Perform STEP 1 on lift trucks manufactured Before June 2009.

STEP 1.
Remove dipstick and tube.

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1. DIPSTICK
2. TUBE
3. CONVERTER HOUSING

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

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Transmission Repair 1300 SRM 1343

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

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1300 SRM 1343 Transmission Repair

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

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Transmission Repair 1300 SRM 1343

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

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1300 SRM 1343 Transmission Repair

STEP 7.
Remove capscrews, lockwashers, charge pump and
gasket.

NOTE: TORQUE CONVERTER HOUSING FOR

LIFT TRUCKS MANUFACTURED BEFORE JUNE
2009 SHOWN.

1. CAPSCREWS 3. CHARGE PUMP

2. LOCKWASHERS 4. GASKET

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Transmission Repair 1300 SRM 1343

STEP 8.
Remove speed sensor.

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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. bo
Remove control valve assembly. See the Control
Valve Repair section,Remove for procedures.
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NOTE: TRANSMISSION FOR LIFT TRUCKS

MANUFACTURED BEFORE JUNE 2009 SHOWN.
CONTROL VALVE ASSEMBLY IN SAME LOCATION
ON TRANSMISSION FOR LIFT TRUCKS
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MANUFACTURED AFTER JUNE 2009.

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1300 SRM 1343 Transmission Repair

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.

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Transmission Repair 1300 SRM 1343

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.

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1300 SRM 1343 Transmission Repair

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 4. SPACER
2. SPRING 5. O-RING
3. BALL

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Transmission Repair 1300 SRM 1343

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.

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1300 SRM 1343 Transmission Repair

STEP 20.
Remove capscrew, lockwasher, bearing support,
and pin. Remove pump idler gear and bearing as
an assembly. See Idler Gear, Disassemble
procedures.

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1. CAPSCREW
uid

2. LOCKWASHER
3. BEARING SUPPORT
4. PIN
STEP 21.
Remove six socket head screws, lockwashers and
stator support as an assembly. See Stator
Support, Disassemble procedures.
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Transmission Repair 1300 SRM 1343

STEP 22.
Remove capscrew, lockwasher, bearing support
and pin. Remove pump drive gear as an assembly.
See Pump Drive Gear, Disassemble procedures.

1. CAPSCREW
2. LOCKWASHER
3. BEARING SUPPORT
4. PIN

Transmission Case, Disassemble

Refer to Figure 4.

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1300 SRM 1343 Transmission Repair

1. FITTING 7. CLIP
2. O-RING 8. SPRING
3. PLUG 9. SPOOL
4. BAFFLE 10. CASE
5. CAPSCREW 11. SPEED SENSOR PORT PLUG
6. LOCKWASHER

Figure 4. Transmission Case

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Transmission Repair 1300 SRM 1343

NOTE: Perform following step for lift trucks built

Before June 2009.

STEP 1.
Remove and discard gasket from converter
housing to transmission case.

STEP 2.
Remove shims from turbine shaft.

STEP 3.
Using a puller, remove bearing from RANGE 1
and REVERSE 1 shaft.

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1300 SRM 1343 Transmission Repair

STEP 4.
Using a puller, remove bearing from turbine shaft.

STEP 5.
Remove turbine shaft. See Turbine Shaft,
Disassemble procedures.

STEP 6.
Remove RANGE 1 and REVERSE 1 gear
assembly.

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