Hyster H6.00-7.00XL, S6.00-7.00XL Two-Speed Powershift Transmission Maintenance And Repair

Description

• Model List:
  • H6.00-7.00XL, S6.00-7.00XL Two-Speed Powershift Transmission

• 1. RM0324-(10-2003)-UK-EN
• 1.1. Two-Speed Powershift Transmission
• 1.2. Safety Precautions Maintenance and Repair
• 1.3. General
• 1.4. Mechanical Description
• 1.5. Torque Converter
• 1.6. Transmission Pump
• 1.7. Shaft Assemblies
• 1.8. Input Shaft
• 1.9. Forward Clutch Shaft
• 1.10. Clutch Assemblies
• 1.11. Countershaft
• 1.12. Output Shaft
• 1.13. Hydraulic Operation
• 1.14. Torque Converter
• 1.15. Seal Rings
• 1.16. Control Valve
• 1.17. System Pressure Regulator
• 1.18. Clutch Pressure Regulator
• 1.19. Torque Converter Regulator
• 1.20. Inching Spool
• 1.21. Direction Spool, Direction Control Lever
• 1.22. Direction Spool, MONOTROL Pedal
• 1.23. Range Spool
• 1.24. Drain Spool
• 1.25. Accumulator
• 1.26. Modulator Spool
• 1.27. Operation
• 1.28. Lubrication Circuit
• 1.29. MONOTROL Pedal
• 1.30. Oil Flow Diagrams
• 1.31. Neutral
• 1.32. Forward-Low
• 1.33. Forward-Low-Inching
• 1.34. Reverse-Low
• 2. RM0325-(10-2003)-UK-EN
• 2.1. Two-Speed Powershift Transmission
• 2.2. Safety Precautions Maintenance and Repair
• 2.3. General
• 2.4. Transmission Repair
• 2.5. Transmission and Torque Converter, Remove
• 2.6. Transmission, Disassemble
• 2.7. Reverse-Low Clutch, Disassemble
• 2.8. Reverse-High Clutch, Disassemble
• 2.9. Forward-Low Clutch, Disassemble
• 2.10. Forward-High Clutch, Disassemble
• 2.11. Clean and Inspect
• 2.12. Forward Low and High Clutches Assembly
• 2.13. Forward Clutches, Assemble
• 2.14. Reverse-Low Clutch, Assemble
• 2.15. Reverse Clutches, Assemble
• 2.16. Transmission, Assemble
• 2.17. Torque Converter, Install
• 2.18. Control Valve Repair
• 2.19. Disassemble
• 2.20. Assemble
• 2.21. Install
• 2.22. MONOTROL Pedal
• 2.23. Remove and Disassemble
• 2.24. Assemble and Install
• 2.25. Stall Test
• 2.26. Linkage Adjustments
• 2.27. Linkage for Inching Pedal H6.00-7.00XL (H135-155XL, H135-155XL 2
• 2.28. Linkage for Inching Pedal S6.00-7.00XL (S135-155XL, S135-155XL 2
• 2.29. Linkage for Range Lever – Early Model H6.00-7.00XL (H135-155XL)
• 2.30. Linkage for Direction Control Lever – Early Model H6.00-7.00XL (
• 2.31. Linkage for Range Lever – Later Model H6.00-7.00XL (H135-155XL,
• 2.32. Linkage for Direction Control Lever – Later Model H6.00-7.00XL (
• 2.33. Linkage for Range Lever S6.00-7.00XL (S135-155XL, S135-155XL 2 )
• 2.34. Linkage for Direction Control Lever S6.00-7.00XL (S135-155XL, S1
• 2.35. Oil Pressure Check
• 2.36. System Pressure Check Port
• 2.37. Torque Converter Check Port
• 2.38. Clutch Pressure Check Port
• 2.39. Inching Pressure
• 2.40. Solenoid Check Ports (MONOTROL Control Only)
• 2.41. Lubrication Pressure Check Ports
• 2.42. Specifications
• 2.43. Troubleshooting
• 2.44. Correct System Pressure 1300 124 kPa ( 189 18 psi)
• 2.45. Correct Clutch Pressure 924 69 kPa ( 134 10 psi)
• 2.46. Correct Solenoid Pressure (MONOTROL Only) 965 138 kPa ( 140 2
• 2.47. Torque Converter Pressure 834 69 kPa ( 121 10 psi)
• 2.48. Lubrication Pressure 83 21 kPa ( 12 3 psi)
• 2.49. Table 1. Stall Speed Specifications
• 3. RM0329-(09-2010)-UK-EN
• 3.1. Safety Precautions Maintenance and Repair
• 3.2. General
• 3.3. Description and Operation
• 3.4. General
• 3.5. Safety Procedures When Working Near Mast
• 3.6. Two-Stage Mast
• 3.7. Three-Stage Mast
• 3.8. Carriage Repair
• 3.9. Sideshift Carriage, Disassemble
• 3.10. Sideshift Carriage, Assemble
• 3.11. Install
• 3.12. Two-Stage Mast Repair
• 3.13. Disassemble
• 3.14. Clean and Inspect
• 3.15. Assemble
• 3.16. Install
• 3.17. Three-Stage Mast Repair
• 3.18. Disassemble
• 3.19. Clean and Inspect
• 3.20. Assemble
• 3.21. Install
• 3.22. Mast Operation Check
• 3.23. Lift and Tilt System Leaks Check
• 3.24. Lift System
• 3.25. Tilt System
• 3.26. Tilt Cylinder Stroke and Backward Tilt Angle Adjustment
• 3.27. Lift Chain Adjustments
• 3.28. Mast Adjustments
• 3.29. Carriage Adjustment
• 3.30. Troubleshooting
• 3.31. Table 1. Mast Parts Weight
• 3.32. Table 2. Hook-Type Carriage Chain Adjustment
• 3.33. Table 3. Pin-Type Carriage Chain Adjustment
• 4. RM0335-(02-2004)-UK-EN
• 4.1. Three-Speed Manual Transmission
• 4.2. Safety Precautions Maintenance and Repair
• 4.3. General
• 4.4. Description
• 4.5. Operation
• 4.6. Transmission Repair
• 4.7. Selector Rails and Forks, Disassemble
• 4.8. Gear Assemblies, Disassemble
• 4.9. Output Gear and Differential, Disassemble
• 4.10. Inspect
• 4.11. Shaft Assemblies, Assemble
• 4.12. Output Gear and Differential, Assemble
• 4.13. Pinion and Ring Gear, Adjust
• 4.14. Input Yoke, Install
• 4.15. Transmission, Install Cover
• 4.16. Selector Rails and Forks, Install
• 4.17. Install
• 4.18. Shift Linkage Adjustment
• 4.19. H3.50-5.00XL (H70-110XL) Shift Linkage, Adjust
• 4.20. S6.00-7.00XL (S135-155XL) Shift Linkage, Adjust
• 4.21. Clutch Pedal and Linkage Adjustment
• 4.22. Troubleshooting
• 4.23. Differential Troubleshooting
• 4.24. Specifications
• 4.25. Torque Specifications
• 4.26. Lubrication
• 4.27. Table 1. Pinion Assembly Shims Adjustment
• 4.28. Table 2. Ring and Pinion Tooth Contact Adjustment
• 5. RM0339-(10-2003)-UK-EN
• 5.1. Hydraulic Pump Drive Assembly
• 5.2. Safety Precautions Maintenance and Repair
• 5.3. General
• 5.4. Description
• 5.5. Hydraulic Pump Drive Assembly Repair
• 5.6. Remove and Disassemble
• 5.7. Inspect
• 5.8. Assemble and Install
• 5.9. Troubleshooting
• 6. RM0348-(09-2001)-UK-EN
• 6.1. LPG Fuel System
• 6.2. Safety Precautions Maintenance and Repair
• 6.3. General
• 6.4. Description and Operation
• 6.5. Fuel Tank
• 6.6. Fuel Filter and Fuel Valve Unit
• 6.7. Vaporizer
• 6.8. Carburetor
• 6.9. Governor
• 6.10. LPG Tank Repair
• 6.11. LPG Tanks with Fixed Mounting Bracket
• 6.12. LPG Tanks with EZ Lift Mounting Bracket
• 6.13. Install
• 6.14. LPG Tanks with Fixed Mounting Bracket
• 6.15. LPG Tanks with EZ Lift Mounting Bracket
• 6.16. Hydrostatic Relief Valve Repair
• 6.17. Remove and Install
• 6.18. Filter Unit Repair
• 6.19. Fuel Filter Element, Replace
• 6.20. Diaphragm and Fuel Valve, Replace
• 6.21. Hoses Replacement
• 6.22. Vaporizer Repair
• 6.23. Disassemble
• 6.24. Inspect
• 6.25. Assemble
• 6.26. Install
• 6.27. Carburetor Repair
• 6.28. Disassemble
• 6.29. Assemble
• 6.30. Install
• 6.31. Governor Repair
• 6.32. Filter Unit Check
• 6.33. Vaporizer Check
• 6.34. Pressure Reducer Valve
• 6.35. Vapor Valve
• 6.36. Carburetor Adjustment
• 6.37. Idle Mixture
• 6.38. Idle Speed
• 6.39. Power Mixture
• 6.40. Throttle Linkage Adjustment
• 6.41. Troubleshooting
• 7. RM0393-(06-2009)-UK-EN
• 7.1. Periodic Maintenance
• 7.2. Safety Precautions Maintenance and Repair
• 7.3. General
• 7.4. Serial Number Data
• 7.5. How to Move Disabled Lift Truck
• 7.6. How to Tow Lift Truck
• 7.7. How to Put Lift Truck on Blocks
• 7.8. How to Raise Drive Tires
• 7.9. How to Raise Steering Tires
• 7.10. Maintenance Schedule
• 7.11. Safety Procedures When Working Near Mast
• 7.12. Maintenance Procedures Every 8 Hours or Daily
• 7.13. How to Make Checks With Engine Stopped
• 7.14. Hydraulic System
• 7.15. Engine Oil
• 7.16. Drive Belts
• 7.17. Intake Manifold Rubber Cap
• 7.18. Cooling System
• 7.19. Air Filter
• 7.20. Fuel System
• 7.21. Primary Fuel Filter, Diesel Engine
• 7.22. Battery
• 7.23. Tires and Wheels
• 7.24. Forks, Mast, and Lift Chains, Inspect
• 7.25. Operator Restraint System
• 7.26. Safety Labels
• 7.27. How to Make Checks With Engine Running
• 7.28. Gauges, Lights, Horn, and Fuses
• 7.29. Oil Level, Powershift Transmission
• 7.30. Oil Level, Oil Clutch System, S6.00-7.00XL (S135-155XL)
• 7.31. Control Levers and Pedals
• 7.32. Lift System Operation
• 7.33. Inching/Brake Pedal
• 7.34. Service Brakes
• 7.35. Parking Brake
• 7.36. Steering System
• 7.37. Maintenance Procedures Every 250 Hours or 6 Weeks
• 7.38. Engine Oil and Filter, GM V-6
• 7.39. Mast, Lubrication
• 7.40. Lift Chains, Lubrication
• 7.41. Crankcase Breather, GM V-6 Engine
• 7.42. Drive Shafts, S6.00-7.00XL (S135-155XL)
• 7.43. Air Filter GM V-6 EPA Compliant Engine
• 7.44. Maintenance Procedures Every 350 Hours or 2 Months
• 7.45. Drive Belts
• 7.46. Perkins Diesel Engine
• 7.47. GM V-6 Engine, Early Models
• 7.48. GM V-6 Engine, Late Models
• 7.49. Forks, Wear and Damage Check
• 7.50. Lift Chains, Wear Check
• 7.51. Hydraulic Tank Breather, Clean and Check
• 7.52. Brake Fluid
• 7.53. Fuel System, Checks and Adjustments
• 7.54. Diesel Fuel System
• 7.55. LPG Carburetor
• 7.56. Gasoline Carburetor (Early Models)
• 7.57. Fuel Injection (Late Model GM V-6)
• 7.58. Steering Axle, Lubrication
• 7.59. Cooling System, Clean Debris from Radiator Core
• 7.60. Air Filter
• 7.61. Maintenance Procedures Every 500 Hours or 3 Months
• 7.62. Engine Oil and Filter, Perkins Diesel Engine
• 7.63. Crankcase Breather, Perkins Diesel Engine
• 7.64. PCV Valve, GM V-6
• 7.65. Maintenance Procedures Every 1000 Hours or 6 Months
• 7.66. Manifold Heat Valve, GM V-6
• 7.67. Crankcase Breather, GM V-6
• 7.68. Ignition System, GM V-6
• 7.69. Valve Clearance, Check and Adjust
• 7.70. Fuel Filter, Diesel Engine, Replace
• 7.71. Fuel System Air Removal, Perkins (1004.42 Diesel Engine)
• 7.72. Fuel Injection Pump With Vent Tube
• 7.73. Fuel Injection Pump With Vent Screw
• 7.74. Differential and Drive Axle, Oil Level Check
• 7.75. Differential S3.50-5.50XL (S70-120XL)
• 7.76. Differential and Drive Axle for Powershift Transmission S6.00-7.
• 7.77. Differential, Speed Reducer, and Drive Axle for Manual Transmiss
• 7.78. Control Levers and Pedals, Lubrication
• 7.79. Cooling System GM V-6 EPA Compliant Engine
• 7.80. LPG Fuel Filter GM V-6 EPA Compliant Engine, Replace
• 7.81. Inspect Engine Electrical System, Connectors, and FCVS Connectio
• 7.82. Spark Plug Replacement
• 7.83. Install
• 7.84. Maintenance Procedures Every 2000 Hours or Yearly
• 7.85. Hydraulic System
• 7.86. Hydraulic Oil and Filter S3.50-5.50XL (S70-120XL), Replace
• 7.87. Hydraulic Oil and Filter S6.00-7.00XL (S135-155XL), Replace
• 7.88. Powershift Transmission (All Units), Oil Change and Oil Filter,
• 7.89. Manual Transmission and Differential S6.00-7.00XL (S135-155XL),
• 7.90. Oil Clutch System S6.00-7.00XL (S135-155XL), Oil and Filter Chan
• 7.91. Differential and Drive Axle for Powershift Transmission (All Uni
• 7.92. Cooling System
• 7.93. PCV Valve, GM V-6
• 7.94. Service Brakes
• 7.95. LPG Filter, Replace (Pre-2004)
• 7.96. Oxygen Sensor GM V-6 EPA Compliant Engine
• 7.97. Gasoline Fuel Filter, Replace
• 7.98. Air Filter Element, GM V-6 EPA Compliant Engine
• 7.99. Test LPG/GAS Regulator Pressure
• 7.100. Inspect Low Pressure Regulator (LPR) for Oil Buildup and Leaks
• 7.101. Check Throttle Shaft for Sticking
• 7.102. Inspect Exhaust Manifold and Piping for Leaks
• 7.103. Hood Latch Check
• 7.104. Lift Chain Adjustments
• 7.105. Fuel Injectors Repair
• 7.106. Lift and Tilt System Leak Check
• 7.107. Lift Cylinders, Leak Check
• 7.108. Tilt Cylinders, Leak Check
• 7.109. Welding Repairs
• 7.110. Overhead Guard Changes
• 7.111. Wheel and Tire Replacement
• 7.112. Solid Rubber Tire, Change
• 7.113. Wheels, Install
• 7.114. Adhesives and Sealants
• 7.115. Hydraulic Oil, Lubricant, and Coolant Specifications
• 7.116. Table 1. Maintenance Schedule
• 7.117. Table 2. Hook-Type Carriage Chain Adjustment
• 7.118. Table 3. Pin-Type Carriage Chain Adjustment
• 8. RM0412-(08-1997)-UK-EN
• 8.1. PERKINS DIESEL ENGINES, SERIES 1000
• 8.2. CYLINDER HEAD ASSEMBLY
• 8.3. PISTON AND CONNECTING ROD ASSEMBLIES
• 8.4. CRANKSHAFT ASSEMBLY
• 8.5. TIMING CASE AND TIMING GEARS
• 8.6. ENGINE BLOCK ASSEMBLY
• 8.7. TURBOCHARGER, ENGINES AB AND YB
• 8.8. LUBRICATION SYSTEM
• 8.9. FUEL SYSTEM
• 8.10. COOLING SYSTEM
• 8.11. FLYWHEEL AND FLYWHEEL HOUSING
• 8.12. ELECTRICAL EQUIPMENT
• 8.13. AIR COMPRESSOR, ENGINES YA AND YB
• 8.14. ENGINE SPECIFICATIONS
• 8.15. TORQUE SPECIFICATIONS
• 8.16. SPECIAL TOOLS
• 9. RM0449-(02-2007)-UK-EN
• 9.1. Safety Precautions Maintenance and Repair
• 9.2. General
• 9.3. Description
• 9.4. Counterweight Repair
• 9.5. Install
• 9.6. Hood Repair
• 9.7. Install
• 9.8. Overhead Guard Repair
• 9.9. Install
• 9.10. Operator Restraint System Repair
• 9.11. Automatic Locking Retractor (ALR)
• 9.12. Emergency Locking Retractor (ELR)
• 9.13. Fuel and Hydraulic Tanks Repair
• 9.14. Inspect
• 9.15. Small Leaks, Repair
• 9.16. Large Leaks, Repair
• 9.17. Steam Method of Cleaning
• 9.18. Chemical Solution Method of Cleaning
• 9.19. Additional Preparations for Repair
• 9.20. Radiator Repair
• 9.21. Install
• 9.22. Exhaust System Repair
• 9.23. Muffler
• 9.24. Install
• 9.25. Engine Repair
• 9.26. Install