Transmissão H90 - (11-2018) - US-EN

ONE AND TWO SPEED
TRANSMISSIONS
REPAIR
H4.0FT5, H4.0FT6, H4.5FTS5, H4.5FT6, H5.0FT,
H5.5FT (H80-120FT) [R005, S005, U005];S4.0, 4.5,
5.5FT, S5.5FTS (S80, 100, 120FT; S80, 100FTBCS;
S120FTS; S120FTPRS) [H004, J004]
PART NO. 4047207 1300 SRM 1569

SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• 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.
Table of Contents
TABLE OF CONTENTS
General .....................................................................................................................................................................1
Serial Number ..................................................................................................................................................... 1
Charge Pump Repair ...............................................................................................................................................1
Lift Trucks Manufactured Before July, 2013 .....................................................................................................1
Remove ............................................................................................................................................................. 1
Inspect ..............................................................................................................................................................2
Install ............................................................................................................................................................... 2
Lift Trucks Manufactured After July, 2013 .......................................................................................................2
Remove ............................................................................................................................................................. 2
Inspect ..............................................................................................................................................................3
Install ............................................................................................................................................................... 3
Torque Converter Replace ...................................................................................................................................... 3
Remove .................................................................................................................................................................3
Install ................................................................................................................................................................... 9
Housings and Chain Drive Repair ....................................................................................................................... 14
Remove ...............................................................................................................................................................15
Clean .................................................................................................................................................................. 23
Inspect ................................................................................................................................................................23
Install ................................................................................................................................................................. 23
Clutch Packs Repair- 1 Speed Transmission .......................................................................................................28
Remove and Disassemble ..................................................................................................................................29
Transmission, Remove and Disassemble ..................................................................................................... 29
Clutch Assemblies, Remove and Disassemble ............................................................................................. 35
Clean .................................................................................................................................................................. 41
Inspect ................................................................................................................................................................41
Assemble and Install .........................................................................................................................................42
Clutch Assemblies, Assemble and Install .................................................................................................... 42
Transmission, Assemble and Install ............................................................................................................ 50
Clutch Packs Repair- 2 Speed Transmission .......................................................................................................53
Transmission, Remove and Disassemble ..................................................................................................... 54
Clutch Assemblies, Remove and Disassemble ............................................................................................. 61
Clean .................................................................................................................................................................. 68
Inspect ................................................................................................................................................................68
Clutch Assemblies, Assemble and Install .................................................................................................... 69
Transmission, Assemble and Install ............................................................................................................ 78
Control Valve Repair .............................................................................................................................................80
Clean .................................................................................................................................................................. 84
Inspect ................................................................................................................................................................84
MONOTROL® Pedal Repair .................................................................................................................................85
Direction Control Lever ........................................................................................................................................ 90
Remove ...............................................................................................................................................................90
Install ................................................................................................................................................................. 90
©2018 HYSTER COMPANY i

Table of Contents
This section is for the following models:
H4.0FT5, H4.0FT6, H4.5FTS5, H4.5FT6, H5.0FT, H5.5FT (H80-120FT) [R005,

S005, U005];
S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; S80, 100FTBCS; S120FTS;
S120FTPRS) [H004, J004]
ii
1300 SRM 1569 General
General
NOTE: 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
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,
transmission charge pump, and gasket from torque
converter housing. Discard gasket. See Figure 2.
Figure 2. Transmission Charge Pump
1
Charge Pump Repair 1300 SRM 1569
Legend for Figure 2. converter housing. Tighten capscrews to

NOTE: THE TRANSMISSION IS SHOWN REMOVED 19 N•m (168 lbf in).
FROM LIFT TRUCK FOR CLARITY.
LIFT TRUCKS MANUFACTURED AFTER
1. CAPSCREW JULY, 2013
2. CHARGE PUMP
3. GASKET Remove
4. TORQUE CONVERTER HOUSING
NOTE: The charge pump can be removed from the
Inspect transmission while it is still in the lift truck but, for
the sake of clarity, the following procedures are
Inspect splines on shaft of the transmission charge shown with the transmission removed from the lift
pump for damage or worn areas that could affect truck.
operation of pump. If splines are damaged, replace
transmission charge pump. Remove four mounting capscrews, washers,
transmission charge pump, and gasket from torque
Install converter housing. Discard gasket. See Figure 3.
Install new gasket, transmission charge pump, four

washers, and mounting capscrews on torque
NOTE: THE TRANSMISSION IS SHOWN REMOVED FROM LIFT TRUCK FOR CLARITY.
1. CAPSCREW 4. GASKET
2. WASHER 5. TORQUE CONVERTER HOUSING
3. CHARGE PUMP
Figure 3. Transmission Charge Pump
2
1300 SRM 1569 Torque Converter Replace
Inspect converter housing. Tighten capscrews in star

pattern to 6 N•m (53 lbf in) on first pass. On second
Inspect splines on shaft of the transmission charge pass, tighten capscrews in star pattern to
pump for damage or worn areas that could affect 19 N•m (168 lbf in). See Figure 3.
operation of pump. If splines are damaged, replace
transmission charge pump.
Install
Install new gasket, transmission charge pump, four
washers, and mounting capscrews on torque
Torque Converter Replace

REMOVE Frame 0100SRM1891 for lift truck models
• S4.0FT, 4.5FT, 5.5FT, S5.5FTS (S80, 100,
120FT; S80, 100FTBCS; S120FTS;
WARNING S120FTPRS) (J004) and H4.0FT5/FT6;
Make sure the engine and transmission are held in H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90,
position so that they will not fall and cause an 100, 110, H120FT) (U005)
injury and damage to the equipment.
CAUTION
CAUTION Use care when disconnecting the wiring harness
Be careful that you DO NOT damage parts of the connectors from electrical connectors on the
torque converter or transmission when the transmission and control valve. The connectors on
transmission is separated from the engine. Keep the transmission and control valve are easily
the transmission and engine in alignment until damaged.
they are completely separated so parts of the
transmission are not damaged. Use a crane or NOTE: When disconnecting wiring harness
lifting device to separate the transmission from the connectors during disassembly, tag each connector
engine. to aid in connecting wiring harness during
reassembly.
1. Remove engine and transmission as a unit from Put engine and transmission on solid blocks on
2.
lift truck as described in the section: a work surface.
Frame 0100SRM1243 for lift truck models Disconnect transmission wiring harness
• S4.0FT, 4.5FT, 5.5FT, S5.5FTS (S80, 100, connectors from control valve and
120FT; S80, 100FTBCS; S120FTS; transmission.
S120FTPRS) (H004) and H4.0FT5/FT6;
H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, Remove the transmission wiring harness from
100, 110, H120FT) (R005, S005) transmission. See Figure 4.
3
Torque Converter Replace 1300 SRM 1569
NOTE: KUBOTA 3.8L DIESEL SHOWN. KUBOTA 3.6L DIESEL, KUBOTA 3.8L LPG, GM 4.3L, AND PSI 4.3L
LPG ENGINES ARE SIMILAR.
1. ENGINE 4. TRANSMISSION
2. CAPSCREW 5. ACCESS COVER
3. TRANSMISSION WIRING HARNESS 6. CONTROL VALVE
Figure 4. Engine-Transmission Combination
3. Move each bolt into view through access hole of

WARNING flywheel housing by rotating crankshaft.
Make sure that the engine/transmission assembly Remove four capscrews that attach flywheel to
is stable before attempting to rotate the engine. torque converter. See Figure 5.
Use a flashlight to see the bolts as they are rotated
into view through the access hole. DO NOT use
your fingers to check for alignment of the bolts
with the access hole.
4
A. GM 4.3L ENGINES AND PSI 4.3L LPG ENGINE B. KUBOTA DIESEL AND LPG ENGINES
1. ACCESS HOLE 2. FLYWHEEL HOUSING
Figure 5. Torque Converter Bolt Access
4. Remove access cover from torque converter 5. Carefully remove torque converter from stator
housing. Install a lifting eye bolt into rear support.
access cover bolt hole, and connect a lifting
See Figure 6 for lift trucks manufactured before
device to eye bolt. Remove ten capscrews that
July, 2013
hold torque converter housing to flywheel
housing on engine. Carefully separate See Figure 7 for lift trucks manufactured after
transmission from engine. July, 2013
NOTE: The torque converter cannot be repaired and

must be replaced as a unit, if damaged.
5
Figure 6. Torque Converter Removal, Lift Trucks Manufactured Before July, 2013
6
Legend for Figure 6.
1. TRANSMISSION OIL FILTER 9. PLUG

2. DIPSTICK 10. CAPSCREW
3. DIPSTICK TUBE 11. WASHER
4. TRANSMISSION HOUSING 12. SMALL ACCESS COVER
5. TORQUE CONVERTER HOUSING 13. TORQUE CONVERTER
6. TRANSMISSION OIL TEMPERATURE SENSOR 14. TRANSMISSION CHARGE PUMP
7. SUCTION SCREEN 15. STATOR SUPPORT
8. SUCTION SCREEN SPRING 16. PILOT HUB

Figure 7. Torque Converter Removal, Lift Trucks Manufactured After July, 2013
6. Remove plug, suction screen spring, and 7. Remove the transmission charge pump. See
suction screen from torque converter housing, Charge Pump Repair.
and drain oil from transmission.
8. Remove transmission oil filter from torque
converter housing.
July, 2013
See Figure 7 for lift trucks manufactured after
July, 2013
July, 2013
7
See Figure 7 for lift trucks manufactured after 14. Remove two mounting capscrews and harness
July, 2013 bracket from front of torque converter housing.
See Figure 8.
9. If damaged, remove the small access cover from
the torque converter housing. 15. Using a small pry bar in the designated pry
points, remove the torque converter housing
from the transmission housing. See Figure 8.
July, 2013
See Figure 7 for lift trucks manufactured after 16. Remove and discard O-rings and gasket. See
July, 2013 Figure 9.
10. Remove dipstick and dipstick tube from torque

converter housing.
July, 2013
July, 2013
11. Remove transmission oil temperature sensor

from torque converter housing.
July, 2013
July, 2013
NOTE: Perform Step 12 through Step 16 only if

repair of the of the transmission chain drive is
required. If transmission clutch packs are in need of
further repair, see Clutch Packs Repair- 1 Speed
Transmission or Clutch Packs Repair- 2 Speed
Transmission.
12. Remove two long capscrews and washers from 1. PRY POINTS
inner face of torque converter housing. See 2. TORQUE CONVERTER HOUSING
Figure 9. 3. TRANSMISSION HOUSING
4. HARNESS BRACKET
13. Remove 15 capscrews from transmission 5. CAPSCREW
housing. See Figure 8.
Figure 8. Pry Point Location
8
1. LONG CAPSCREW 5. TRANSMISSION HOUSING

2. WASHER 6. O-RING
3. TORQUE CONVERTER HOUSING 7. CAPSCREW
4. GASKET
Figure 9. Torque Converter Housing
INSTALL 4. Install two washers and long capscrews into

inner face of torque converter housing. Tighten
NOTE: Perform Step 1 through Step 4 only if repair capscrews to 38 N•m (28 lbf ft). See Figure 9.
of the transmission chain drive was performed.
1. Install new O-rings and gasket on torque 5. If removed, install small access cover on torque
converter housing and transmission housing. converter housing. Tighten capscrews to
See Figure 9. 7.9 N•m (69 lbf in).
See Figure 10 for lift trucks manufactured
2. Install harness bracket and two mounting before July, 2013
capscrews to front of torque converter housing.
See Figure 8. See Figure 11 for lift trucks manufactured after
July, 2013
3. Using 15 capscrews, install transmission
housing to torque converter housing. Tighten
capscrews to 38 N•m (28 lbf ft). See Figure 8.
9
Figure 10. Torque Converter Installation, Lift Trucks Manufactured Before July, 2013
10


Figure 11. Torque Converter Installation, Lift Trucks Manufactured After July, 2013
6. Install a new transmission oil filter on torque 7. Install transmission charge pump. See Charge
converter housing. Pump Repair.
8. Install suction screen, suction screen spring,
before July, 2013
and plug into torque converter housing.
July, 2013
before July, 2013
11
See Figure 11 for lift trucks manufactured after 13. If removed, install a lifting eye bolt into rear
July, 2013 access cover bolt hole, and connect a lifting
device to the eye bolt.
9. Install the torque converter onto stator
Align torque converter housing with flywheel
support. Make sure splines are aligned and
housing. Make sure pilot hub on torque
converter engages fully.
converter engages flywheel.
before July, 2013
See Figure 11 for lift trucks manufactured after CAUTION
July, 2013 Be careful that you DO NOT damage parts of the
torque converter or transmission when the
10. Lubricate the pilot hub on the torque converter transmission is joined to the engine. Keep the
with antiseize compound. transmission and engine in alignment until they
are completely joined so parts of the transmission
are not damaged. Use a crane or lifting device to
before July, 2013
join the transmission to the engine.
July, 2013 14. Install transmission on engine. Install 10
capscrews that connect torque converter
11. Install transmission oil temperature sensor on housing to flywheel housing. Tighten capscrews
torque converter housing. to 38 N•m (28 lbf ft). See Figure 12.
before July, 2013
CAUTION
Use care when connecting the wiring harness
July, 2013
connectors to electrical connectors on the
transmission and control valve. The connectors on
NOTE: Apply adhesive to entire surface of hole,
the transmission and control valve are easily
20.0 mm (0.79 in.) deep. Also apply adhesive to
damaged.
lower 20.0 mm (0.79 in.) of dipstick tube.
12. Install dipstick tube and dipstick into torque 15. Install transmission wiring harness on
converter housing. transmission. Connect transmission wiring
harness connectors to control valve and
transmission. See Figure 12.
before July, 2013
July, 2013
12
NOTE: Coat the bolt threads that hold the torque torque converter to flywheel through access
converter to flywheel with Loctite™ 242. hole of flywheel housing. Tighten capscrews to
56 N•m (41 lbf ft).
16. Rotate engine crankshaft to position flywheel
mounting holes in line with torque converter Remove lifting eye bolt, and install access cover
mounting holes. Install capscrews that hold on torque converter housing. See Figure 13.
13
See Periodic Maintenance 8000SRM1598 for

WARNING lift truck models
Make sure the engine and transmission are held in • S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT,
position so that they will not fall and cause an S80, 100FTBCS, S120FTS, S120FTPRS)
injury and damage to the equipment. (H004)
17. Install engine and transmission as a unit into
lift truck models
lift truck as described in section:
• H4.0FT5, H4.0FT6, H4.5FTS5, H4.5FTS,
Frame 0100SRM1243 for lift truck models H5.0FT, H5.5FT (H80-120FT) (R005)
• S4.0FT, 4.5FT, 5.5FT, S5.5FTS (S80, 100, See Periodic Maintenance 8000SRM1604 for
120FT; S80, 100FTBCS; S120FTS; lift truck models
H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, • H4.0FT5, H4.0FT6, H4.5FTS5, H4.5FTS,
100, 110, H120FT) (R005, S005) H5.0FT, H5.5FT (H80-120FT) (S005)
Frame 0100SRM1891 for lift truck models See Periodic Maintenance 8000SRM1902 for
lift truck models
• S4.0FT, 4.5FT, 5.5FT, S5.5FTS (S80, 100,
120FT; S80, 100FTBCS; S120FTS; • S4.0FT, 4.5FT, 5.5FT, S5.5FTS (S80, 100,
S120FTPRS) (J004) and H4.0FT5/FT6; 120FT; S80, 100FTBCS; S120FTS;
H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, S120FTPRS) (J004) and H4.0FT5/FT6;
100, 110, H120FT) (U005) H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90,
100, 110, H120FT) (U005)
18. Fill the transmission to the correct level using
transmission fluid and procedure indicated in
the Periodic Maintenance manual for your
lift truck model listed below:
14
1300 SRM 1569 Housings and Chain Drive Repair
Housings and Chain Drive Repair

REMOVE
CAUTION
To prevent possible damage to the transmission
WARNING
assembly when placing the assembly on a work
Make sure the engine and transmission are held in surface, place blocks under the back side of the
position so that they will not fall and cause an transmission housing for additional support.
CAUTION
CAUTION Use care when disconnecting the wiring harness
Keep the transmission and engine in alignment connectors from electrical connectors on the
until they are completely separated so parts of the transmission and control valve. The connectors on
transmission are not damaged. Use a crane or the transmission and control valve are easily
lifting device to separate the transmission from the damaged.
engine.
NOTE: When disconnecting wiring harness
1. Remove engine and transmission as a unit from connectors during disassembly, tag each connector
lift truck as described in section: to aid in connecting wiring harness during
Frame 0100SRM1243 for lift truck models reassembly.
• S4.0FT, 4.5FT, 5.5FT, S5.5FTS (S80, 100, 2. Put engine and transmission on solid blocks on
120FT; S80, 100FTBCS; S120FTS; a work surface. Disconnect transmission wiring
S120FTPRS) (H004) and H4.0FT5/FT6; harness connectors from control valve and
H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, transmission. Remove transmission wiring
100, 110, H120FT) (R005, S005) harness from transmission. See Figure 14.
Frame 0100SRM1891 for lift truck models
• S4.0FT, 4.5FT, 5.5FT, S5.5FTS (S80, 100,
S120FTPRS) (J004) and H4.0FT5/FT6;
H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90,
100, 110, H120FT) (U005)
15
Housings and Chain Drive Repair 1300 SRM 1569

16
4. Remove access cover from torque converter 5. Carefully remove torque converter from stator
housing. Install a lifting eye bolt into rear support.
access cover bolt hole, and connect a lifting
before July, 2013
hold torque converter housing to flywheel
housing. Carefully separate the transmission See Figure 17 for lift trucks manufactured after
from engine. July, 2013
17
Figure 16. Torque Converter Housing Removal, Lift Trucks Manufactured Before July, 2013
18


Figure 17. Torque Converter Removal, Lift Trucks Manufactured After July, 2013
6. Remove plug, suction screen spring, and 7. Remove the transmission charge pump. See
suction screen from torque converter housing Charge Pump Repair.
and drain oil from transmission.
8. Remove two long capscrews and washers from
inner face of torque converter housing. See
before July, 2013
Figure 18.
July, 2013
19

2. WASHER 6. O-RING
4. GASKET
Figure 18. Torque Converter Housing
9. Remove 15 capscrews from transmission

housing. See Figure 19.
10. Remove two mounting capscrews and harness

bracket from front of torque converter housing.
See Figure 19.
11. Using a small pry bar in designated pry points,

remove the torque converter housing from the
transmission housing. See Figure 19.
20
1. PRY POINTS
3. TRANSMISSION HOUSING
4. HARNESS BRACKET
5. CAPSCREW
12. Remove and discard O-rings and gasket. See

Figure 18.
NOTE: While performing Step 13, note position of

oil seal to aid in proper installation of new oil seal.
13. Remove and discard the oil seal from the rear
of the torque converter housing. See Figure 20.
Figure 19. Pry Point Location
21
NOTE: TWO SPEED TRANSMISSION SHOWN, ONE SPEED TRANSMISSION SIMILAR.
1. SNUBBER 9. DRIVING SPROCKET

2. PUMP DRIVE CHAIN 10. CAPSCREW
3. BEARING 11. LOCKWASHER
4. DRIVEN SPROCKET 12. STATOR SUPPORT
5. OIL SEAL 13. SEALING RING
6. ANGULAR CONTACT BEARING 14. TRANSMISSION HOUSING
7. BUSHING 15. BAFFLE
8. O-RING
Figure 20. Chain Drive
14. Remove the two snubbers from the 17. Remove angular contact bearing, bushing, and
transmission housing. See Figure 20. O-ring from driving sprocket. Discard O-ring.
See Figure 20.
15. Carefully remove pump drive chain, driven
sprocket, driving sprocket, and bearings from 18. Remove four capscrews, lockwashers, and
transmission housing. See Figure 20. stator support from transmission housing.
Remove and discard sealing ring and O-ring
16. Remove bearing from driven sprocket. See from the stator support. See Figure 20.
Figure 20.
19. Remove baffle from transmission housing. See
Figure 20.
22
20. Remove O-rings from transmission housing and INSTALL

discard. See Figure 20.
1. Install new O-rings on transmission housing.
See Figure 20.
CLEAN
2. Install baffle in transmission housing. See
WARNING Figure 20.
Cleaning solvents can be flammable and toxic and
can cause skin irritation. When using cleaning 3. Install new sealing ring and O-ring on stator
solvents, always follow the solvent manufacturer's support. See Figure 20.
recommended safety procedures.
4. Install stator support, lockwashers, and
Compressed air can move particles so they cause capscrews on transmission housing. See
injury to the user or to other personnel. Make sure Figure 20. Tighten the capscrews to
the path of the compressed air is away from all 38 N•m (28 lbf ft).
personnel. Wear protective goggles or a face
shield to prevent injury to the eyes. 5. On a lint-free cloth, place driving sprocket on
the right side, driven sprocket on left side, and
1. Clean snubbers with warm, soapy water and place chain around both sprockets (see
dry with compressed air. Figure 20). Install bearings on the sprockets.
The angular bearing should be installed onto
2. Clean bearings, chain, stator support, and driving sprocket with thinner shoulder of outer
gears with solvent and dry with compressed air race towards sprocket and the wider shoulder
of the outer race (side marked with part
INSPECT number) towards torque converter housing.
1. Inspect snubbers for cracks or wear. If Carefully place driving and driven sprockets,
damaged or worn, replace both snubbers. chain, and bearings assembly on transmission.
Install two snubbers on transmission housing.
2. Inspect chain, gears, and stator support for
damage. If damage is present, replace damaged 6. Install new oil seal into rear of torque converter
component. Inspect driving and driven gears housing as noted during removal.
for damage or wear to gear teeth. If gear teeth
are worn or damaged, replace gear. Inspect 7. Install the new O-rings and gasket on the
splines on input shaft for damage, and if torque converter housing. Using the front two
damaged, replace the input clutch pack. See mounting capscrews, install the torque
Clutch Packs Repair- 1 Speed Transmission or converter housing to the front cover housing.
Clutch Packs Repair- 2 Speed Transmission. Install 15 capscrews from the back of the
transmission housing. See Figure 21.
23

2. WASHER 6. O-RING
4. GASKET
Figure 21. Torque Converter Housing Installation
8. Using 15 capscrews, install transmission 11. Install the suction screen, suction screen
housing to torque converter housing. Tighten spring, and plug into the torque converter
capscrews to 38 N•m (28 lbf ft). See Figure 21. housing.
9. Install two washers and long capscrews into
before July, 2013
face of torque converter housing. Tighten
capscrews to 38 N•m (28 lbf ft). See Figure 19. See Figure 23 for lift trucks manufactured after
July, 2013
10. Install harness bracket and two mounting
capscrews to front of torque converter housing.
See Figure 19.
24
Figure 22. Torque Converter Installation, Lift Trucks Manufactured Before July, 2013
25


Figure 23. Torque Converter Installation, Lift Trucks Manufactured After July, 2013
12. Install torque converter onto input shaft and 13. Lubricate pilot hub on torque converter with
stator support of transmission. Make sure antiseize compound.
splines are aligned and converter engages fully.
See Figure 22 for lift trucks manufactured before July, 2013
before July, 2013
See Figure 23 for lift trucks manufactured after July, 2013
July, 2013
26
14. Install the transmission charge pump. See

Charge Pump Repair. CAUTION
15. If removed, install a lifting eye bolt into rear connectors to electrical connectors on the
access cover bolt hole, and connect a lifting transmission and control valve. The connectors on
device to eye bolt. Align torque converter the transmission and control valve are easily
housing with flywheel housing. Make sure pilot damaged.
hub on torque converter engages the flywheel.
17. Install transmission wiring harness on
16. Install transmission to engine. Install ten transmission. Connect transmission wiring
capscrews that connect torque converter harness connectors to control valve and
housing to flywheel housing. Tighten capscrews transmission. See Figure 24.
to 38 N•m (28 lbf ft). See Figure 24.
27
NOTE: Coat the bolt threads that hold the torque that hold torque converter to flywheel through
converter to flywheel with Loctite™ 242. access hole of flywheel housing. Tighten
capscrews to 56 N•m (41 lbf ft).
18. Rotate engine crankshaft to position the
flywheel mounting holes in line with torque Remove lifting eye bolt, and install access cover
converter mounting holes. Install capscrews on torque converter housing. See Figure 25.
A. GM 4.3L ENGINES AND PSI B. KUBOTA DIESEL AND LPG

4.3L LPG ENGINE ENGINES
19. Install engine and transmission as a unit into • S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT,
lift truck as described in the section: S80, 100FTBCS, S120FTS, S120FTPRS)
(H004)
• S4.0FT, 4.5FT, 5.5FT, S5.5FTS (S80, 100, lift truck models
S120FTPRS) (H004) and H4.0FT5/FT6; • H4.0FT5, H4.0FT6, H4.5FTS5, H4.5FTS,
H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, H5.0FT, H5.5FT (H80-120FT) (R005)
100, 110, H120FT) (R005, S005) See Periodic Maintenance 8000SRM1604 for
Frame 0100SRM1891 for lift truck models lift truck models
• S4.0FT, 4.5FT, 5.5FT, S5.5FTS (S80, 100, • H4.0FT5, H4.0FT6, H4.5FTS5, H4.5FTS,
120FT; S80, 100FTBCS; S120FTS; H5.0FT, H5.5FT (H80-120FT) (S005)
H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90,
100, 110, H120FT) (U005) lift truck models
• S4.0FT, 4.5FT, 5.5FT, S5.5FTS (S80, 100,
20. Fill the transmission to the correct level using 120FT; S80, 100FTBCS; S120FTS;
transmission fluid and procedure indicated in S120FTPRS) (J004) and H4.0FT5/FT6;
the Periodic Maintenance manual for your H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90,
lift truck model listed below: 100, 110, H120FT) (U005)
lift truck models
28
1300 SRM 1569 Clutch Packs Repair- 1 Speed Transmission
Clutch Packs Repair- 1 Speed Transmission

REMOVE AND DISASSEMBLE
CAUTION
Transmission, Remove and Disassemble
WARNING surface, place blocks under the back side of the
Make sure the engine and transmission are held in transmission housing for additional support.
position so that they will not fall and cause an
CAUTION
Use care when disconnecting the wiring harness
CAUTION connectors from electrical connectors on the
Be careful that you DO NOT damage parts of the transmission and control valve. The connectors on
torque converter or transmission when the the transmission and control valve are easily
transmission is separated from the engine. Keep damaged.
the transmission and engine in alignment until
they are completely separated so parts of the NOTE: When disconnecting wiring harness
transmission are not damaged. Use a crane or connectors during disassembly, tag each connector
lifting device to separate the transmission from the to aid in connecting wiring harness during
engine. reassembly.
2. Put engine and transmission on solid blocks on
1. Remove engine and transmission as a unit from a work surface.
lift truck as described in the section:
Disconnect two connectors of chassis wiring
Frame 0100SRM1243 for lift truck models harness from transmission wiring harness.
• S4.0FT, 4.5FT, 5.5FT, S5.5FTS (S80, 100, Disconnect transmission wiring harness
120FT; S80, 100FTBCS; S120FTS; connectors from control valve and
S120FTPRS) (H004) and H4.0FT5/FT6; transmission. Remove transmission wiring
H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90,
harness from transmission. See Figure 26.
100, 110, H120FT) (R005, S005)
• S4.0FT, 4.5FT, 5.5FT, S5.5FTS (S80, 100,
H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90,
100, 110, H120FT) (U005)
29
Clutch Packs Repair- 1 Speed Transmission 1300 SRM 1569

Make sure that the engine/transmission assembly Remove the four capscrews that attach
is stable before attempting to rotate the engine. flywheel to torque converter. See Figure 27.
30
4. Remove access cover from torque converter 5. Remove torque converter housing from
housing. Install a lifting eye bolt into rear transmission housing. See Housings and Chain
access cover bolt hole, and connect a lifting Drive Repair, Remove.
device to eye bolt. Remove 15 capscrews that
hold torque converter housing to flywheel 6. Remove bolt, stato seal, and yoke from back of
housing. Carefully separate transmission from transmission. See Figure 28.
engine.
31
1. BEARING 7. SPACER
2. SNAP RING 8. YOKE
3. SPECIAL NUT 9. STATO SEAL
4. OUTPUT GEAR 10. BOLT
5. TRANSMISSION HOUSING 11. REVERSE GEAR PACK
6. OIL SEAL 12. FORWARD CLUTCH PACK
Figure 28. Output Gear Removal
7. Remove spacer from the yoke. See Figure 28. 10. Removal and disassembly of clutch assemblies
follows. The procedures are the same for
NOTE: Note the position of the oil seal during forward and reverse clutch pack assemblies.
removal to aid in installation. See Figure 29 and Figure 30.
8. Remove oil seal from back of transmission. See
Figure 28.
9. Remove bearing, snap ring, special nut, output

gear, and bearing from transmission. See
Figure 28.
32
1. SEAL 8. SNAP RING

2. BEARING 9. CONICAL PLATE
3. GEAR ASSEMBLY DRUM 10. FRICTION DISK
4. PISTON SEAL 11. SEPARATOR PLATE
5. PISTON 12. PRESSURE PLATE
6. SPRING 13. OUTPUT GEAR
7. SPRING GUIDE
Figure 29. Forward Clutch Packs
33

7. SPRING GUIDE
Figure 30. Reverse Clutch Packs
34
Clutch Assemblies, Remove and Disassemble

STEP 1.
Pull forward clutch assembly straight from
transmission housing.
1. REVERSE CLUTCH
2. FORWARD CLUTCH
3. TRANSMISSION INPUT SPEED SENSOR
(TISS)
4. TRANSMISSION OUTPUT SPEED SENSOR
(TOSS)
STEP 2.
Remove shaft seal and bearing from input
shaft. Discard shaft seal.
1. SHAFT SEAL
2. BEARING
3. INPUT SHAFT
35
STEP 3.
Remove snap ring from output gear. Remove
output gear from input shaft.
1. SNAP RING
2. BEARING
3. OUTPUT GEAR
NOTE: Before removing seal bearing, note position of seal on bearing.
STEP 4.
Remove seal from output gear. Remove seal
bearing, snap ring, spacer, snap ring, and
bearing from output gear.
1. SEAL BEARING
2. SNAP RING
3. SPACER
4. SEAL
5. OUTPUT GEAR
6. BEARING
36
STEP 5.
Remove snap ring and pressure plate from gear
assembly drum.
1. SNAP RING
2. PRESSURE PLATE
3. GEAR ASSEMBLY DRUM
STEP 6.
Remove friction disks and separator plates
alternately until all have been removed from
gear assembly drum.
1. FRICTION DISK
2. SEPARATOR PLATE
37
STEP 7.
Remove conical plate from gear assembly drum.
1. CONICAL PLATE
38
WARNING
The springs for the piston are compressed. Make
sure the springs and spring retainer cannot cause
injury when the snap ring is removed.
NOTE: Remove piston only if there is a problem

with piston or piston seals.
STEP 8.
Using spring compression tool, (Hyster P/N
867890), and a press, place spring compression
tool on spring guide with opening of tool above
the opening of snap ring, and compress the
large and small springs just enough to allow
removal of snap ring from spring guide. Slowly
release press to decompress springs.
1. SPRING COMPRESSION TOOL

2. SPRING GUIDE
39
STEP 9.
Remove snap ring, spring guide, large spring,
and small spring from input shaft.
1. SNAP RING
2. SPRING GUIDE
3. LARGE SPRING
4. SMALL SPRING
5. INPUT SHAFT
STEP 10.
Remove piston from gear assembly drum and
piston seal from piston. Discard piston seal.
1. PISTON
2. PISTON SEAL
4. SHAFT SEAL
40
STEP 11.
Remove shaft seals and bearing from input
shaft. Discard shaft seals.
1. SHAFT SEALS
2. BEARING
3. INPUT SHAFT
CLEAN 4. The conical plate and separator plates must not

be bent, have damaged surfaces, or have large
blue areas from too much heat. If any of the
WARNING above conditions exist, replace damaged
Cleaning solvents can be flammable and toxic and component.
can cause skin irritation. When using cleaning
solvents, always follow the solvent manufacturer's 5. Check "H" dimension of the conical plate as
recommended safety procedures. shown in Figure 31. If dimension is less than
3.2 mm (0.126 in.), replace conical plate.
Clean all metal parts with cleaning solvent and
place on a lint-free cloth to dry. Ensure that 6. Check "t" dimension of conical plate as shown
cleaning and assembly environment is free of dust, in Figure 31. If dimension is less than
dirt, and any other foreign matter that would affect 2.4 mm (0.094 in.), replace conical plate.
performance of parts.
INSPECT
1. Inspect gear teeth on clutch assemblies and all
other gears for wear or damage. If gear teeth
are worn or damaged, replace damaged
component.
2. Check all parts that have splines for damage to

splines. Check for notches worn in splines.
Replace clutch pack or gears that have spline
damage. Figure 31. Conical Plate Inspection
3. Inspect friction discs for burned lining or bent 7. Inspect bearings for wear or damage. If
surfaces. Check for small holes in lining. bearings are damaged, replace them.
Replace friction discs if one-half depth of the oil
grooves is worn away or the discs are damaged. 8. Inspect piston for damage. Make sure that
Discard a friction disc that has a thickness less sealing surfaces are good. Make sure orifice is
than 2.2 mm (0.087 in.). clean.
41
9. Check for grooves or other damage on the

11. Inspect dowel pins and dowel pin holes. If any
machined surfaces of clutch pack shafts and
dowel pin is damaged at all, replace dowel pin.
transmission housing. Check mounting and
If a dowel pin hole is damaged, replace housing.
sealing surfaces in housing for damage. If there
is evidence of any damage, replace housing or 12. Check fit of bearings in transmission housings.
transmission. If clutch pack shaft is damaged, If bearings fit too loosely into housings, this
replace clutch pack. could mean that bores are oversized. Replace
housings as necessary.
10. Inspect all hardware and mounting surfaces for
the presence of rust, sealing compounds, and
ASSEMBLE AND INSTALL
usable condition. If the hardware is to be
reused, clean all rust and sealing compounds
from the threaded areas. If the hardware is not
in usable condition, replace the hardware.
CAUTION
The dowel pins are used to properly align the
housings for proper mating to each other. If the
alignment is not correct, damage to the
transmission assembly could occur.
Clutch Assemblies, Assemble and Install
STEP 1.
Install bearing and new shaft seals on input
shaft.
1. SHAFT SEALS
2. BEARING
3. INPUT SHAFT
NOTE: Perform Step 2 through Step 5 only if piston was removed.
42
STEP 2.
Lubricate all parts with clean transmission oil.
Install shaft seal on shaft and piston seal on
piston.
1. PISTON SEAL
2. PISTON
STEP 3.
Install piston into gear assembly drum.
1. PISTON
2. PISTON SEAL
4. SHAFT SEAL
43
STEP 4.
Install small spring, large spring, spring guide,
and snap ring on input shaft.
1. SNAP RING
2. SPRING GUIDE
3. LARGE SPRING
4. SMALL SPRING
5. INPUT SHAFT
44
STEP 5.
Using spring compression tool, (Hyster P/N
the opening of the snap ring, and compress
large and small springs just enough to allow
installation of snap ring in spring guide. Slowly
release press.

2. SPRING GUIDE
NOTE: The conical plate is properly installed when inner diameter is touching piston, and outer diameter of
the conical plate is touching outer diameter of friction disk.
45
STEP 6.
Install conical plate into gear assembly drum.
1. CONICAL PLATE
STEP 7.
Install separator plates and friction disks
alternately until all have been installed in gear
assembly drum.
1. FRICTION DISK
2. SEPARATOR PLATE
46
STEP 8.
Install pressure plate and snap ring in gear
assembly drum. Using a dial indicator or feeler
gauge, check clearance between the snap ring
and pressure plate. There must be
2.3 to 2.7 mm (0.090 to 0.106 in.) of clearance
for a single speed transmission and
2.6 to 3.0 mm (0.102 to 0.118 in.) of clearance
for a two speed transmission. If clearance is not
correct, check to ensure clutch pack has been
assembled correctly and that there is no
damage to conical plate, friction disks, and
separator plates. If parts must be replaced, see
Parts Manual for new parts.
1. SNAP RING
2. PRESSURE PLATE
NOTE: Make sure seal on seal bearing is in correct position as noted during removal.
STEP 9.
Install seal onto output gear. Install bearing,
snap ring, spacer, snap ring, and seal bearing
into output gear.
1. SEAL BEARING
2. SNAP RING
3. SPACER
4. SEAL
5. OUTPUT GEAR
6. BEARING
47
STEP 10.
Install output gear on input shaft. Install
bearing and snap ring in output gear.
1. SNAP RING
2. BEARING
3. OUTPUT GEAR
STEP 11.
Install bearing and shaft seal on input shaft.
1. SHAFT SEAL
2. BEARING
3. INPUT SHAFT
48
STEP 12.
Install reverse clutch assembly in transmission
housing. DO NOT damage seal rings on end of
clutch shaft.
Check gap between TOSS and TISS sensors
and reverse gear. The allowable gap for the
TOSS sensor is
0.8 to 1.8 mm (0.031 to 0.071 in.). The allowable
gap for TISS sensor is
0.8 to 2.0 mm (0.031 to 0.080 in.).
1. REVERSE CLUTCH
2. FORWARD CLUTCH
3. TISS SENSOR
4. TOSS SENSOR
49
STEP 13.
Install forward clutch assembly in transmission
housing. DO NOT damage seal rings on end of
clutch shaft.
1. REVERSE CLUTCH
2. FORWARD CLUTCH
3. TISS SENSOR
4. TOSS SENSOR
Transmission, Assemble and Install

1. Install bearing, output gear, special nut, snap
ring, and bearing on transmission. See
Figure 32.
50
2. SNAP RING 8. YOKE
3. SPECIAL NUT 9. STATO SEAL
4. OUTPUT GEAR 10. BOLT
5. TRANSMISSION HOUSING 11. REVERSE GEAR PACK
6. OIL SEAL 12. FORWARD CLUTCH PACK
Figure 32. Output Gear Installation
2. Install oil seal into back of transmission as

6. Install transmission wiring harness on
noted during removal. See Figure 32.
transmission. Connect transmission wiring
harness connectors to control valve and
3. Install spacer in the yoke. See Figure 32.
transmission. Connect two chassis wiring
4. Install yoke, stato seal and bolt in back of harness connectors to transmission wiring
transmission. Tighten bolt to harness. See Figure 33.
38 N•m (28 lbf ft). See Figure 32.
5. Install torque converter housing to

transmission. See Housings and Chain Drive
Repair, Install.
CAUTION
connectors to electrical connectors on the
damaged.
51
52
A. GM 4.3L ENGINES AND PSI B. KUBOTA DIESEL AND LPG

4.3L LPG ENGINE ENGINES
lift truck as described in the section: S80, 100FTBCS, S120FTS, S120FTPRS)
(H004)
H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90,
• S4.0FT, 4.5FT, 5.5FT, S5.5FTS (S80, 100,
lift truck models
53
Clutch Packs Repair- 2 Speed Transmission

CAUTION
Transmission, Remove and Disassemble
WARNING surface, place blocks under the back side of the
Make sure the engine and transmission are held in transmission housing for additional support.
position so that they will not fall and cause an
CAUTION
Use care when disconnecting the wiring harness
CAUTION connectors from electrical connectors on the
Be careful that you do not damage parts of the transmission and control valve. The connectors on
torque converter or transmission when the the transmission and control valve are easily
transmission is separated from the engine. Keep damaged.
the transmission and engine in alignment until
they are completely separated so parts of the NOTE: When disconnecting wiring harness
transmission are not damaged. Use a crane or connectors during disassembly, tag each connector
lifting device to separate the transmission from the to aid in connecting wiring harness during
engine. reassembly.
2. Put engine and transmission on solid blocks on
1. Remove engine and transmission as a unit from a work surface.
lift truck as described in section:
Disconnect two connectors of chassis wiring
Frame 0100SRM1243 for lift truck models harness from transmission wiring harness.
• S4.0FT, 4.5FT, 5.5FT, S5.5FTS (S80, 100, Disconnect transmission wiring harness
120FT; S80, 100FTBCS; S120FTS; connectors from control valve and
S120FTPRS) (H004) and H4.0FT5/FT6; transmission. Remove transmission wiring
H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90,
harness from transmission. See Figure 35.
100, 110, H120FT) (R005, S005)
• S4.0FT, 4.5FT, 5.5FT, S5.5FTS (S80, 100,
H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90,
100, 110, H120FT) (U005)
54

55
4. Remove the access cover from the torque 5. Remove torque converter housing from
converter housing. Install a lifting eye bolt into transmission housing. See Housings and Chain
rear access cover bolt hole, and connect a lifting Drive Repair, Remove.
hold torque converter housing to flywheel 6. Remove idler gear and two bearings. See
housing. Carefully separate transmission from Figure 37.
engine.
56
1. BEARING 8. OIL SEAL

2. IDLER GEAR 9. YOKE
3. SNAP RING 10. STATO SEAL
4. SPECIAL NUT 11. BOLT
5. OUTPUT GEAR 12. REVERSE GEAR PACK
6. TRANSMISSION HOUSING 13. FORWARD CLUTCH PACK
7. SPACER 14. HIGH FORWARD CLUTCH PACK
Figure 37. Output Gear Removal
7. Remove bolt, stato seal, and yoke from back of 11. Removal and disassembly of the clutch
transmission. See Figure 37. assemblies follows. The procedures are the
same for forward clutch - low gear, reverse, and
8. Remove spacer from the yoke. See Figure 37. forward clutch - high gear pack assemblies.
NOTE: Note position of oil seal during removal to See Figure 38 for forward clutch pack - low
aid in installation. gear
9. Remove oil seal from the back of the See Figure 39 for reverse clutch pack
transmission. See Figure 37. See Figure 40 for forward clutch pack - high
gear
10. Remove the bearing, snap ring, special nut,
output gear, and bearing from transmission.
See Figure 37.
57

6. SPRING 13. BACK PLATE
7. SPRING GUIDE 14. OUTPUT GEAR
Figure 38. Forward Clutch Pack - Low Gear
58

7. SPRING GUIDE 14. BACK PLATE
Figure 39. Reverse Clutch Pack
59
Figure 40. Forward Clutch Pack - High Gear
60

6. SPRING 13. BACK PLATE
7. SPRING GUIDE 14. OUTPUT GEAR
Clutch Assemblies, Remove and Disassemble

STEP 1.
Pull forward clutch - low gear, reverse clutch,
and forward clutch - high gear assemblies
straight out from transmission housing.
1. FORWARD CLUTCH (LOW GEAR)

2. REVERSE CLUTCH
3. FORWARD CLUTCH (HIGH GEAR)
(TISS)
(TOSS)
61
STEP 2.
Remove shaft seal and bearing from forward
(low) clutch pack input shaft. Discard shaft
seal. Remove bearing from forward (high) and
reverse gear packs.

3. REVERSE CLUTCH
4. BEARING
5. SHAFT SEAL
STEP 3.
Remove snap ring from output gear. Remove
output gear from input shaft.

3. REVERSE CLUTCH
4. OUTPUT GEAR
5. SNAP RING
NOTE: Before removing seal bearing, note position of seal on bearing.
62
STEP 4.
Remove seal from output gear. Remove seal
bearing, snap ring, and bearing from the output
gear.
1. SEAL BEARING
2. SNAP RING
3. SEAL
4. OUTPUT GEAR
5. BEARING
STEP 5.
Remove snap ring, back plate and pressure
plate from gear assembly drum.
1. SNAP RING
2. BACK PLATE
3. PRESSURE PLATE
63
STEP 6.
Remove friction disks and separator plates
alternately until all have been removed from
gear assembly drum.
1. FRICTION DISK 3. GEAR ASSEMBLY DRUM

2. SEPARATOR PLATE
64
STEP 7.
Remove conical plate from gear assembly drum.
1. CONICAL PLATE
65
WARNING
The springs for the piston are compressed. Make
sure the springs and spring retainer cannot cause
injury when the snap ring is removed.
NOTE: Remove piston only if there is a problem

with piston or piston seals.
STEP 8.
Using spring compression tool (Hyster P/N
opening of snap ring, and compress large and
small springs just enough to allow removal of
snap ring from spring guide. Slowly release
press to decompress springs.

2. SPRING GUIDE
66
STEP 9.
Remove snap ring, spring guide, large spring,
and small spring from input shaft.
1. SNAP RING
2. SPRING GUIDE
3. LARGE SPRING
4. SMALL SPRING
5. INPUT SHAFT
STEP 10.
Remove piston from gear assembly drum and
piston seal from piston. Discard piston seal.
1. PISTON
2. PISTON SEAL
4. SHAFT SEAL
67
STEP 11.
Remove shaft seals and bearing from input
shaft. Discard shaft seals.
1. SHAFT SEALS
2. BEARING
3. INPUT SHAFT
CLEAN grooves is worn away or discs are damaged.

Discard a friction disc that has a thickness less
than 2.2 mm (0.087 in.).
WARNING
Cleaning solvents can be flammable and toxic and 4. The conical plate and separator plates must not
can cause skin irritation. When using cleaning be bent, have damaged surfaces, or have large
solvents, always follow the solvent manufacturer's blue areas from too much heat. If any of the
recommended safety procedures. above conditions exist, replace damaged
component.
Clean all metal parts with cleaning solvent and
place on a lint-free cloth to dry. Ensure that 5. Check "H" dimension of conical plate as shown
cleaning and assembly environment is free of dust, in Figure 41. If dimension is less than
dirt, and any other foreign matter that would affect 3.2 mm (0.126 in.), replace conical plate.
performance of the parts.
6. Check "t" dimension of conical plate as shown
INSPECT in Figure 41. If dimension is less than
2.4 mm (0.094 in.), replace conical plate.
1. Inspect gear teeth on clutch assemblies and all
other gears for wear or damage. If gear teeth
are worn or damaged, replace damaged
component.
2. Check all parts that have splines for damage to

splines. Check for notches worn in splines.
Replace clutch pack or gears that have spline
damage.
3. Inspect friction discs for burned lining or bent

surfaces. Check for small holes in lining.
Replace friction discs if one-half the depth of oil Figure 41. Conical Plate Inspection
68
7. Inspect bearings for wear or damage. If

bearings are damaged, replace them. CAUTION
The dowel pins are used to properly align the
8. Inspect piston for damage. Make sure that housings for proper mating to each other. If the
sealing surfaces are good. Make sure orifice is alignment is not correct, damage to the
clean. transmission assembly could occur.
9. Check for grooves or other damage on 11. Inspect dowel pins and dowel pin holes. If any
machined surfaces of clutch pack shafts and dowel pin is damaged at all, replace dowel pin.
transmission housing. Check mounting and If a dowel pin hole is damaged, replace housing.
sealing surfaces in housing for damage. If there
is evidence of any damage, replace housing or 12. Check fit of bearings in transmission housings.
transmission. If clutch pack shaft is damaged, If bearings fit too loosely into the housings, this
replace clutch pack. could mean that bores are oversized. Replace
housings as necessary.
10. Inspect all hardware and mounting surfaces for
presence of rust, sealing compounds, and ASSEMBLE AND INSTALL
usable condition. If hardware is to be reused,
clean all rust and sealing compounds from
threaded areas. If hardware is not in usable
condition, replace hardware.
Clutch Assemblies, Assemble and Install
STEP 1.
Install bearing and new shaft seals on input
shaft.
1. SHAFT SEALS
2. BEARING
3. INPUT SHAFT
NOTE: Perform Step 2 through Step 5 only if piston was removed.
69
STEP 2.
Lubricate all parts with clean transmission oil.
Install shaft seal on shaft and piston seal on
piston.
1. PISTON SEAL
2. PISTON
STEP 3.
Install piston into gear assembly drum.
1. PISTON
2. PISTON SEAL
4. SHAFT SEAL
70
STEP 4.
Install small spring, large spring, spring guide,
and snap ring on input shaft.
1. SNAP RING
2. SPRING GUIDE
3. LARGE SPRING
4. SMALL SPRING
5. INPUT SHAFT
71
STEP 5.
Using spring compression tool (Hyster P/N
opening of snap ring, and compress large and
small springs just enough to allow installation
of snap ring in spring guide. Slowly release
press.

2. SPRING GUIDE
NOTE: The conical plate is properly installed when inner diameter is touching piston, and outer diameter of
conical plate is touching outer diameter of friction disk.
72
STEP 6.
Install conical plate into gear assembly drum.
1. CONICAL PLATE
73
STEP 7.
Install separator plates and friction disks
alternately until all have been installed in gear
assembly drum.
1. FRICTION DISK 3. GEAR ASSEMBLY DRUM

2. SEPARATOR PLATE
74
STEP 8.
Install pressure plate, back plate and snap ring
in gear assembly drum. Using a dial indicator
or feeler gauge, check clearance between the
snap ring and pressure plate. There must be
2.6 to 3.0 mm (0.102 to 0.118 in.) of clearance. If
clearance is not correct, check to ensure clutch
pack has been assembled correctly and that
there is no damage to conical plate, friction
disks, and separator plates. If parts must be
replaced, see Parts Manual for new parts.
1. SNAP RING
2. BACK PLATE
3. PRESSURE PLATE
NOTE: Make sure seal on seal bearing is in correct position as noted during removal.
STEP 9.
Install seal onto output gear. Install bearing,
snap ring, and seal bearing into output gear.
1. SEAL BEARING
2. SNAP RING
3. SEAL
4. OUTPUT GEAR
5. BEARING
75
STEP 10.
Install output gear on input shaft. Install
bearing and snap ring in output gear.

3. REVERSE CLUTCH
4. OUTPUT GEAR
5. SNAP RING
STEP 11.
Install bearing and shaft seal on input shaft for
Forward (low) gear pack. Install bearing to
Forward (high) and Reverse gear packs.

3. REVERSE CLUTCH
4. BEARING
5. SHAFT SEAL
76
STEP 12.
Install reverse clutch assembly in transmission
housing. DO NOT damage the seal rings on the
end of the clutch shaft.
Check the gap between TOSS and TISS sensors
and reverse gear. The allowable gap for TOSS
sensor is 0.8 to 1.8 mm (0.031 to 0.071 in.). The
allowable gap for TISS sensor is
0.8 to 2.0 mm (0.031 to 0.080 in.).

2. REVERSE CLUTCH
(TISS)
(TOSS)
STEP 13.
Install forward clutch assemblies (high and
low) in transmission housing. Do not damage
seal rings on end of clutch shaft.

2. REVERSE CLUTCH
(TISS)
(TOSS)
77
Transmission, Assemble and Install

1. Install bearing, output gear, special nut, snap
ring, and bearing on transmission. See
Figure 42.
2. IDLER GEAR 9. YOKE
3. SNAP RING 10. STATO SEAL
4. SPECIAL NUT 11. BOLT
5. OUTPUT GEAR 12. REVERSE GEAR
6. TRANSMISSION HOUSING 13. FORWARD CLUTCH PACK (LOW)
7. OIL SEAL 14. FORWARD CLUTCH PACK (HIGH)
Figure 42. Output Gear Installation
2. Install oil seal into back of transmission as 6. Install torque converter housing on
noted during removal. See Figure 42. transmission. See Housings and Chain Drive
Repair,Install.
3. Install spacer in yoke. See Figure 42.
4. Install yoke, stato seal, and bolt in back of CAUTION

transmission. Tighten bolt to Use care when connecting the wiring harness
38 N•m (28 lbf ft). See Figure 42. connectors to electrical connectors on the
5. Install two bearings and idler gear. See
Figure 42.
damaged.
78
7. Install transmission wiring harness on transmission. Connect two chassis wiring

transmission. Connect transmission wiring harness connectors to transmission wiring
harness connectors to control valve and harness. See Figure 43.
79
Control Valve Repair 1300 SRM 1569
A. GM 4.3L ENGINES AND PSI 4.3L LPG ENGINE B. ENGINE
the lift truck as described in the section: S80, 100FTBCS, S120FTS, S120FTPRS)
(H004)
H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90,
• S4.0FT, 4.5FT, 5.5FT, S5.5FTS (S80, 100,
lift truck models
Control Valve Repair

NOTE: For lift truck models S4.0FT, 4.5FT, 5.5FT,
S5.5FTS (S80, 100, 120FT; S80, 100FTBCS;
80
1300 SRM 1569 Control Valve Repair
S120FTS; S120FTPRS) (J004) and H4.0FT5/FT6;

H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110,
H120FT) (U005) equipped with a hydraulic fan
drive, remove the hydraulic fan drive manifold and
mounting bracket first, before removing the
transmission control valve. See Hydraulic Fan
Drive 1900SRM1894 for procedures.
CAUTION
Use care when disconnecting the wiring harnesses
from the connectors. The connectors are easily
damaged.
1. Clean area around control valve. Put

identification tags on wire harness connectors
and connectors on transmission and control
valve. Disconnect wiring harness connectors
from transmission and control valve
connectors. Remove cable connector from
standoff located on torque converter housing.
See Figure 45.
1. TRANSMISSION ASSEMBLY
2. GASKET
3. CONTROL VALVE ASSEMBLY
4. LOCKWASHER
5. CAPSCREW
6. TRANSMISSION INPUT SPEED SENSOR (TISS)
(TOSS)
Figure 46. Control Valve Removal
3. Remove control valve assembly and gasket

from transmission. Discard gasket. Put a cover
on top of the transmission to keep dirt out of
the transmission. See Figure 46.
2. HARNESS STANDOFF 4. Remove capscrew, lock washer and
3. TRANSMISSION WIRING HARNESS transmission input speed sensor (TISS). See
Figure 47.
Figure 45. Transmission Assembly
2. Remove capscrews and lockwashers from

control valve and transmission. See Figure 46.
81
1. TRANSMISSION ASSEMBLY
(TOSS)
3. TRANSMISSION INPUT SPEED SENSOR (TISS)
4. LOCK WASHER
5. CAPSCREW
5. Remove capscrew, lock washer and

transmission output speed sensor (TOSS) from
transmission. See Figure 47.
NOTE: Disassemble control valve only to extent

required for repairs.
NOTE: Disassemble control valve in a clean,
contamination-free area.
6. Remove two pressure transducers and two
fittings from the control valve body. See
Figure 48.
Figure 47. Transmission Speed Sensor
82
1300 SRM 1569 Control Valve Repair
1. CONTROL VALVE BODY 7. FORWARD PROPORTIONAL VALVE

2. PRESSURE TRANSDUCER 8. SOCKET HEAD CAPSCREW
3. FITTING 9. TORQUE CONVERTER REGULATOR SPOOL
4. PROPORTIONAL SUPPLY REGULATOR 10. REVERSE PROPORTIONAL VALVE
SPOOL 11. TRANSMISSION ENABLE VALVE
5. SPRING 12. SUPPLY SPOOL
6. PLUG
Figure 48. Control Valve Arrangement
7. Remove plug for proportional supply regulator

WARNING spool. Discard O-ring. See Figure 48.
There are compressed springs under the plugs in
the control valve. Carefully remove the plugs so 8. Remove spring and proportional supply
that the compressed springs do not cause injury. regulator spool from control valve body. See
Figure 48.
83
9. Remove plug for torque converter regulator 3. Check that springs are not bent or damaged.
spool. Discard O-ring. See Figure 48. Make sure spools move freely in their bores.
10. Remove spring and torque converter regulator 4. Inspect connectors on proportional and solenoid
spool from control valve body. See Figure 48. valves and, if they are damaged, replace
damaged proportional or solenoid valves.
11. Remove plug for supply spool. Discard O-ring.
See Figure 48. ASSEMBLE AND INSTALL
12. Remove spring and supply spool from control NOTE: Lubricate parts of control valve with clean
valve body. See Figure 48. transmission oil during assembly.
1. Install transmission enable valve and socket
13. Remove socket head screws and forward head screws into the control valve body.
proportional valve from control valve body. Tighten socket head screws to
Repeat for reverse proportional valve. See 3 to 4 N•m (27 to 35 lbf in). See Figure 48.
Figure 48.
2. Install reverse proportional valve, forward
14. Remove socket head screws and transmission proportional valve, and socket head capscrews
enable valve from control valve body. See onto control valve body. Tighten socket head
Figure 48. screws to 3 to 4 N•m (27 to 35 lbf in). See
Figure 48.
CLEAN
3. Install supply spool and spring into control
valve body. Install new O-ring on plug. Install
WARNING plug into control valve body. See Figure 48.
Cleaning solvents can be flammable and toxic and
can cause skin irritation. When using cleaning 4. Install torque converter regulator spool and
solvents, always follow the solvent manufacturer's spring into control valve body. Install new O-
recommended safety procedures. ring on plug. Install plug into control valve
body. See Figure 48.
Compressed air can move particles so they cause
injury to the user or to other personnel. Make sure
5. Install proportional supply regulator spool and
the path of the compressed air is away from all
spring into control valve body. Install new O-
personnel. Wear protective goggles or a face
ring on plug. Install plug into control valve
shield to prevent injury to the eyes.
body. See Figure 48.
6. Install two fittings and two pressure

CAUTION transducers into control valve body. See
Do not allow cleaning solvent to come in contact Figure 48.
with rubber or plastic components as it can
damage those components. 7. Install transmission input speed sensor (tiss)
and capscrew in transmission. Tighten
Clean all metal components in solvent and dry with capscrews to 6.9 N•m (61 lbf in). See Figure 48.
compressed air.
8. Install transmission output speed sensor (toss)
INSPECT and capscrew in transmission. Tighten
capscrews to 6.9 N•m (61 lbf in). See Figure 48.
1. Make sure there are no scratches or damage on
spools or in bores of the control valve body. If Install a new control valve gasket on
9.
the control valve body bores are damaged, transmission. Install control valve on
replace control valve. transmission. See Figure 46. Install capscrews
that hold control valve on transmission. DO
2. Inspect control valve body for presence of burrs.
NOT tighten at this time. See Figure 48.
Burrs may be removed using a fine file, emery
cloth, or crocus cloth.
84
1300 SRM 1569 MONOTROL® Pedal Repair
10. Tighten capscrews to 13.3 N•m (118 lbf in) in

the sequence shown in Figure 49. Re-tighten CAUTION
capscrews to 19 N•m (168 lbf in) in the Use care when connecting the wiring harnesses to
sequence shown in Figure 49. the connectors. The connectors are easily
damaged.
11. Install cable connector in standoff and connect

the wiring harness connectors to transmission
and control valve as tagged during removal.
See Figure 45.
Figure 49. Control Valve Mounting Screw

Tightening Sequence
MONOTROL® Pedal Repair

1. Remove five screws, dash panel, and kick plate
from lift truck. For procedures, see:
• S4.0FT, 4.5FT, 5.5FT, S5.5FTS (S80, 100,
H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90,
100, 110, H120FT) (R005, S005)
• S4.0FT, 4.5FT, 5.5FT, S5.5FTS (S80, 100,
H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90,
100, 110, H120FT) (U005)
Remove three capscrews and swing hydraulic
lever assembly toward operator's seat.
Disconnect two cable assemblies from the pedal
assembly. See Figure 50.
85
MONOTROL® Pedal Repair 1300 SRM 1569
1. CAPSCREWS
1. CAPSCREW 2. PEDAL ASSEMBLY
2. HYDRAULIC LEVER ASSEMBLY 3. COWL
Figure 50. Hydraulic Lever Relocation Figure 51. MONOTROL Pedal Removal
2. Remove three capscrews that hold throttle base 3. Remove two pan head screws, lockwashers, and
to cowl, and remove the pedal assembly from accelerator position sensor from throttle base.
lift truck. See Figure 51. See Figure 52.
CAUTION
Use care when removing the connector from its
holder as the connector can be easily damaged.
NOTE: Remove only those components necessary to

complete the repair of the MONOTROL pedal.
4. Remove connector from connector holder on
throttle base. Remove outer and inner springs
from throttle base and MONOTROL pedal
assembly.
5. Remove e-clip and throttle base from throttle

pedal shaft. Remove roll pin and throttle pedal
shaft from MONOTROL pedal assembly.
Discard roll pin.
86
1. PAN HEAD SCREW 6. THROTTLE PEDAL SHAFT

2. LOCKWASHER 7. E-CLIP
3. ACCELERATOR POSITION SENSOR (APS) 8. ROLL PIN
4. PEDAL FRAME 9. INNER AND OUTER SPRINGS
5. CONNECTOR 10. MONOTROL ASSEMBLY
Figure 52. MONOTROL Pedal Bracket Disassembly
NOTE: Tag wires prior to removing from 7. Remove two hex head screws, lockwashers,
microswitches to aid in connecting. nuts, and microswitch from pedal pad. Repeat
for remaining microswitch and remove wiring
6. Remove u-clip, foam lock seal, and wiring
harness from pedal frame.
harness from pedal frame. Remove four pan
head screws, lockwashers, washers, pedal pad,
8. If damaged, remove stop screw and nut from
and springs from pedal frame. If any metal
pedal frame.
inserts in pedal pad are damaged, replace as
necessary. See Figure 53.
87
MONOTROL® Pedal Repair 1300 SRM 1569
1. WIRING HARNESS 9. METAL INSERT

2. FOAM LOCK SEAL 10. NUT
3. U-CLIP 11. LOCKWASHER
4. PAN HEAD SCREW 12. MICROSWITCH
5. LOCKWASHER 13. HEX HEAD SCREW
6. WASHER 14. SPRING
7. STOP SCREW 15. PEDAL PAD
8. NUT 16. PEDAL FRAME
Figure 53. MONOTROL Pedal Disassembly
88
ASSEMBLE AND INSTALL 4. Install wiring harness in pedal frame. Install

the foam lock seal and u-clip. Install pedal pad
1. If removed, install stop screw and nut on pedal and springs in pedal frame. Coat threads of
frame. See Figure 53. four pan head screws with Loctite 222. Install
pan head screws, lockwashers, and washers in
2. Install microswitch and two hex head screws in
the pedal pad. Tighten pan head screws to
pedal pad. Coat exposed threads of hex head
2.25 to 2.50 N•m (19 to 32 lbf in).
screws with Loctite™ 222. Install two
lockwashers and nuts on hex head screws. DO 5. Using an ohmmeter, check for continuity
NOT tighten nuts at this time. Repeat for other between pins 3 and 4 of the MONOTROL
microswitch. wiring harness connector with MONOTROL
pedal in reverse position, and between pins 1
3. Put wires through hole in pedal frame. The
and 2 with pedal in the forward position. See
white banded wire is for reverse microswitch,
Figure 55.
and the blue banded wire is for forward
microswitch. Adjust each microswitch in its
mount so that measurement between the edge
of mount and base of the microswitch equals
0.0 to 0.5 mm (0.0 to 0.02 in.). Tighten the
mounting nuts of each microswitch as
adjustment is completed. See Figure 54.
1. WIRING HARNESS CONNECTOR

2. WIRING HARNESS
Figure 55. Microswitch Continuity Check
6. Install throttle pedal shaft and new roll pin in

MONOTROL pedal assembly. Install throttle
base and e-clip on throttle pedal shaft. See
Figure 52.
CAUTION
Use care when installing the connector in its
holder as the connector can be easily damaged.
7. Install inner and outer springs on throttle base

and MONOTROL pedal assembly. Install
connector in connector holder on throttle base.
1. MICROSWITCH MOUNT 8. Install actuator and magnet in throttle base.

2. MICROSWITCH BASE Install accelerator position sensor, lockwashers,
and two pan head screws in throttle base.
Figure 54. Microswitch Adjustment
Tighten screws to 2.25 N•m (19 lbf in).
89
Direction Control Lever 1300 SRM 1569
9. Apply adhesive compound to three mounting Frame 0100SRM1891 for lift truck models
bolts. Using three capscrews that hold throttle S4.0FT, 4.5FT, 5.5FT, S5.5FTS (S80, 100,
•
base to cowl, install pedal assembly on lift 120FT; S80, 100FTBCS; S120FTS;
truck. Tighten bolts to S120FTPRS) (J004) and H4.0FT5/FT6;
19 to 25 N•m (168 to 221 lbf in). See Figure 51. H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90,
100, 110, H120FT) (U005)
10. Connect two cable assemblies to pedal
assembly. Swing hydraulic lever assembly 11. Depress MONOTROL pedal until it stops.
toward cowl and install three capscrews. See Unscrew stop screw until it contacts metal floor
Figure 50. Install dashboard on the lift truck. plate. Tighten nut to 10 N•m (89 lbf in).
For procedures, see:
• S4.0FT, 4.5FT, 5.5FT, S5.5FTS (S80, 100,
H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90,
100, 110, H120FT) (R005, S005)
Direction Control Lever

REMOVE 3. Repeat above steps on opposite side of direction
control lever. Remove direction control lever
NOTE: There is no repair of direction control lever. from display panel.
1. Insert a small, flat-blade screwdriver with a
3.175 mm (0.125 in.) or less, wide blade into INSTALL
opening on display panel on an outward angle
Slide direction control lever into opening on left side
enough to compress spring tab on direction
of the display panel until locking tabs are engaged
control lever. See A, Figure 56.
in display panel.
2. Pry spring tab toward body of direction control
lever and, at same time, pull on handle of lever
enough to free tab of interior lock of display
panel. See B, Figure 56.
90
1300 SRM 1569 Direction Control Lever
NOTE: DISPLAY SWITCH CLUSTER SHOWN OUTSIDE OF LIFT TRUCK FOR CLARITY.
A. STEP 1 B. STEP 2
1. DIRECTION CONTROL LEVER 3. DISPLAY SWITCH CLUSTER

2. FLAT-BLADE SCREWDRIVER
Figure 56. Direction Control Lever Removal
91
NOTES
92
TECHNICAL PUBLICATIONS
1300 SRM 1569 11/18 (5/16)(3/15)(8/13)(3/13)(9/12)

Transmissão H90 - (11-2018) - US-EN

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ONE AND TWO SPEED

PART NO. 4047207 1300 SRM 1569

©2018 HYSTER COMPANY i

This section is for the following models:

H4.0FT5, H4.0FT6, H4.5FTS5, H4.5FT6, H5.0FT, H5.5FT (H80-120FT) [R005,

1. TRANSMISSION SERIAL NUMBER

Figure 1. Transmission Serial Number Location

Charge Pump Repair

Figure 2. Transmission Charge Pump

Legend for Figure 2. converter housing. Tighten capscrews to

Install new gasket, transmission charge pump, four

Figure 3. Transmission Charge Pump

Inspect converter housing. Tighten capscrews in star

Torque Converter Replace

Figure 4. Engine-Transmission Combination

3. Move each bolt into view through access hole of

1. ACCESS HOLE 2. FLYWHEEL HOUSING

Figure 5. Torque Converter Bolt Access

NOTE: The torque converter cannot be repaired and

Legend for Figure 6.

1. TRANSMISSION OIL FILTER 9. PLUG

1. TRANSMISSION OIL FILTER 9. PLUG

10. Remove dipstick and dipstick tube from torque

11. Remove transmission oil temperature sensor

NOTE: Perform Step 12 through Step 16 only if

1. LONG CAPSCREW 5. TRANSMISSION HOUSING

Figure 9. Torque Converter Housing

INSTALL 4. Install two washers and long capscrews into

Legend for Figure 10.

1. TRANSMISSION OIL FILTER 9. PLUG

1. TRANSMISSION OIL FILTER 9. PLUG

Figure 12. Engine-Transmission Combination

1. ACCESS HOLE 2. FLYWHEEL HOUSING

Figure 13. Torque Converter Bolt Access

See Periodic Maintenance 8000SRM1598 for

Housings and Chain Drive Repair

Figure 14. Engine-Transmission Combination

3. Move each bolt into view through access hole of

1. ACCESS HOLE 2. FLYWHEEL HOUSING

Figure 15. Torque Converter Bolt Access

Legend for Figure 16.

1. TRANSMISSION OIL FILTER 9. PLUG

1. TRANSMISSION OIL FILTER 9. PLUG

1. LONG CAPSCREW 5. TRANSMISSION HOUSING

Figure 18. Torque Converter Housing

9. Remove 15 capscrews from transmission

10. Remove two mounting capscrews and harness

11. Using a small pry bar in designated pry points,

Legend for Figure 19.

12. Remove and discard O-rings and gasket. See

NOTE: While performing Step 13, note position of

Figure 19. Pry Point Location

NOTE: TWO SPEED TRANSMISSION SHOWN, ONE SPEED TRANSMISSION SIMILAR.

1. SNUBBER 9. DRIVING SPROCKET

Figure 20. Chain Drive

20. Remove O-rings from transmission housing and INSTALL

1. LONG CAPSCREW 5. TRANSMISSION HOUSING

Figure 21. Torque Converter Housing Installation

Legend for Figure 22.

1. TRANSMISSION OIL FILTER 9. PLUG

1. TRANSMISSION OIL FILTER 9. PLUG

14. Install the transmission charge pump. See

Figure 24. Engine-Transmission Combination