TWO-SPEED
POWERSHIFT
TRANSMISSION
TROUBLESHOOTING AND REPAIRS
H6.00-7.00XL (H135-155XL, H135-155XL
2
) [F006, G006];
S6.00-7.00XL (S135-155XL, S135-155XL
2
) [B024, C024]
PART NO. 897107 1300 SRM 325
Two-Speed Powershift Transmission Table of Contents
TABLE OF CONTENTS
General ............................................................................................................................................................... 1
Transmission Repair .......................................................................................................................................... 1
Transmission and Torque Converter, Remove ............................................................................................. 1
Transmission, Disassemble ........................................................................................................................... 3
Reverse-Low Clutch, Disassemble ................................................................................................................ 6
Reverse-High Clutch, Disassemble............................................................................................................... 9
Forward-Low Clutch, Disassemble ............................................................................................................... 12
Forward-High Clutch, Disassemble ............................................................................................................. 15
Clean and Inspect .......................................................................................................................................... 17
Forward Low and High Clutches Assembly ..................................................................................................... 18
Forward Clutches, Assemble ........................................................................................................................ 20
Reverse-Low Clutch, Assemble ..................................................................................................................... 26
Reverse Clutches, Assemble.......................................................................................................................... 28
Transmission, Assemble ................................................................................................................................ 35
Torque Converter, Install .............................................................................................................................. 42
Control Valve Repair .......................................................................................................................................... 43
Remove ........................................................................................................................................................... 43
Disassemble ................................................................................................................................................... 44
Assemble ........................................................................................................................................................ 45
Install ............................................................................................................................................................. 47
MONOTROL Pedal ............................................................................................................................................ 47
Remove and Disassemble .............................................................................................................................. 47
Assemble and Install ..................................................................................................................................... 47
Stall Test ............................................................................................................................................................. 50
Linkage Adjustments......................................................................................................................................... 51
Linkage for Inching Pedal H6.00-7.00XL (H135-155XL, H135-155XL
2
) (F006, G006) ............................. 51
Linkage for Inching Pedal S6.00-7.00XL (S135-155XL, S135-155XL
2
) (B024, C024) ............................... 54
Linkage for Range Lever - Early Model H6.00-7.00XL (H135-155XL) (F006) Trucks .............................. 57
Linkage for Direction Control Lever - Early Model H6.00-7.00XL (H135-155XL) (F006) Trucks ............ 57
Linkage for Range Lever - Later Model H6.00-7.00XL (H135-155XL, H135-155XL
2
) (F006, G006)
Trucks ............................................................................................................................................................. 59
Linkage for Direction Control Lever - Later Model H6.00-7.00XL (H135-155XL, H135-155XL
2
)
(F006, G006) Trucks ...................................................................................................................................... 61
Linkage for Range Lever S6.00-7.00XL (S135-155XL, S135-155XL
2
) (B024, C024) ................................. 63
Linkage for Direction Control Lever S6.00-7.00XL (S135-155XL, S135-155XL
2
) (B024, C024) ............... 63
Oil Pressure Check ............................................................................................................................................ 65
System Pressure Check Port ......................................................................................................................... 65
Torque Converter Check Port ....................................................................................................................... 65
Clutch Pressure Check Port .......................................................................................................................... 65
Inching Pressure ............................................................................................................................................ 66
Solenoid Check Ports (MONOTROL Control Only) ..................................................................................... 66
Lubrication Pressure Check Ports ................................................................................................................ 66
Specifications...................................................................................................................................................... 67
Troubleshooting.................................................................................................................................................. 67
This section is for the following models:
H6.00-7.00XL (H135-155XL, H135-155XL
2
) [F006, G006];
S6.00-7.00XL (S135-155XL, S135-155XL
2
) [B024, C024]
©2003 HYSTER COMPANY i
1300 SRM 325 Transmission Repair
General
This section has the repair procedures and a troubleshooting table for the two-speed powershift transmission
(Hyster T-40).
Transmission Repair
TRANSMISSION AND TORQUE
CONVERTER, REMOVE
1. Remove the floor plates. Remove the mount for
the seat. Remove the drive shaft.
2. Disconnect the linkages at the cranks on the
crossmember for the pedals. Make sure the links
are on top of the transmission. Put tags for iden-
tification on the wires at the transmission and
disconnect the wires. Disconnect the oil lines at
the transmission.
3. Remove the access cover in the torque converter
housing. See Figure 1 and Figure 2. Remove the
four capscrews that hold the drive plate to the
flywheel. Rotate the engine flywheel manually
to have access to the capscrews. Push the torque
converter toward the transmission.
1. TORQUE CONVERTER HOUSING
2. TRANSMISSION
3. TRANSMISSION FILTER
4. CONTROL VALVE
5. REVERSE SOLENOID
6. FORWARD SOLENOID
7. DIPSTICK
Figure 1. Hyster T-40 Transmission
1
Transmission Repair 1300 SRM 325
Figure 2. Two-Speed Powershift Transmission (Hyster T-40)
2
1300 SRM 325 Transmission Repair
Legend for Figure 2
1. TRANSMISSION PUMP
2. FRONT COVER
3. INPUT SHAFT
4. COUNTERSHAFT
5. OUTPUT SHAFT
6. FORWARD SIFT
7. REVERSE-LOW CLUTCH ASSEMBLY
8. REVERSE-HIGH CLUTCH ASSEMBLY
9. FORWARD-LOW CLUTCH ASSEMBLY
10. FORWARD-HIGH CLUTCH ASSEMBLY
11. MANIFOLD BLOCK
4. Put blocks under the engine to hold it in position.
Put straps around the transmission and connect
a lifting device to the straps. Make sure the lift-
ing device is holding the weight of the transmis-
sion. Remove the capscrews that hold the engine
mounts (on the torque converter housing) to the
frame. Remove the capscrews that hold the en-
gine mounts to the torque converter housing. Re-
move the mounts.
5. Lower the transmission and engine a small
amount using the lifting device. Make sure no
parts of the engine touch the firewall.
6. Remove the capscrews that hold the torque con-
verter housing to the engine adapter. Move the
transmission from the engine and lift it from
the lift truck. Make sure the torque converter
does not fall from the transmission. Remove the
torque converter from the transmission.
7. Remove the plug from the transmission cover
and drain the oil from the transmission.
TRANSMISSION, DISASSEMBLE
STEP 1.
Remove the torque converter housing from the trans-
mission. Remove the transmission pump only for in-
spection or replacement. If the transmission pump is
worn or damaged, it must be replaced as an assem-
bly.
1. TORQUE CONVERTER HOUSING
2. TRANSMISSION PUMP
3
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Hyster B024 (S7.00XL) Forklift Service Manual
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Description
This manual contains maintenance and repair procedures for the Hyster B024 (S7.00XL) Forklift.
- Covers the following models:
- Hyster B024 (S7.00XL) Forklift Service Repair Factory Manual
Service Repair Factory Manual Covers:
- Two-speed powershift transmission repair
- Alternator with regulator
- Brake system
- Capacities and specifications
- Cooling system
- Diagrams
- Differential
- Drive axle
- Frame
- Gm 4.3l v-6 engine
- Hydraulic gear pumps
- Hydraulic system
- Instrument panel indicators and senders
- Lift cylinders (old mast)
- Main control valve
- Masts
- Metric and inch (sae) fasteners
- Microprocessor spark timing system (msts)
- Periodic maintenance
- Perkins diesel engine-1000 series (ar, yg, yh)
- Steering axle
- Steering control unit
- Three-speed manual transmission
- Tilt cylinders
- Two-speed powershift transmission-description and operation
Hyster B024 (S7.00XL) Forklift Service Repair Factory Manual is written step by step in details, so you become very easy to repair by yourself. It can save your expenses.
Do not hesitate, after your payment, you will immediately get the manual.
File Format:
- Compatible: All Versions of Windows & Mac
- Language: English
- Requirements: Adobe Reader
Hyster B024 (S7.00XL) Forklift Service Manual
