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

Description

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

• 1. RM0324-(10-2003)-US-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)-US-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)-US-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. RM0339-(10-2003)-US-EN
• 4.1. Hydraulic Pump Drive Assembly
• 4.2. Safety Precautions Maintenance and Repair
• 4.3. General
• 4.4. Description
• 4.5. Hydraulic Pump Drive Assembly Repair
• 4.6. Remove and Disassemble
• 4.7. Inspect
• 4.8. Assemble and Install
• 4.9. Troubleshooting
• 5. RM0393-(06-2009)-US-EN
• 5.1. Periodic Maintenance
• 5.2. Safety Precautions Maintenance and Repair
• 5.3. General
• 5.4. Serial Number Data
• 5.5. How to Move Disabled Lift Truck
• 5.6. How to Tow Lift Truck
• 5.7. How to Put Lift Truck on Blocks
• 5.8. How to Raise Drive Tires
• 5.9. How to Raise Steering Tires
• 5.10. Maintenance Schedule
• 5.11. Safety Procedures When Working Near Mast
• 5.12. Maintenance Procedures Every 8 Hours or Daily
• 5.13. How to Make Checks With Engine Stopped
• 5.14. Hydraulic System
• 5.15. Engine Oil
• 5.16. Drive Belts
• 5.17. Intake Manifold Rubber Cap
• 5.18. Cooling System
• 5.19. Air Filter
• 5.20. Fuel System
• 5.21. Primary Fuel Filter, Diesel Engine
• 5.22. Battery
• 5.23. Tires and Wheels
• 5.24. Forks, Mast, and Lift Chains, Inspect
• 5.25. Operator Restraint System
• 5.26. Safety Labels
• 5.27. How to Make Checks With Engine Running
• 5.28. Gauges, Lights, Horn, and Fuses
• 5.29. Oil Level, Powershift Transmission
• 5.30. Oil Level, Oil Clutch System, S6.00-7.00XL (S135-155XL)
• 5.31. Control Levers and Pedals
• 5.32. Lift System Operation
• 5.33. Inching/Brake Pedal
• 5.34. Service Brakes
• 5.35. Parking Brake
• 5.36. Steering System
• 5.37. Maintenance Procedures Every 250 Hours or 6 Weeks
• 5.38. Engine Oil and Filter, GM V-6
• 5.39. Mast, Lubrication
• 5.40. Lift Chains, Lubrication
• 5.41. Crankcase Breather, GM V-6 Engine
• 5.42. Drive Shafts, S6.00-7.00XL (S135-155XL)
• 5.43. Air Filter GM V-6 EPA Compliant Engine
• 5.44. Maintenance Procedures Every 350 Hours or 2 Months
• 5.45. Drive Belts
• 5.46. Perkins Diesel Engine
• 5.47. GM V-6 Engine, Early Models
• 5.48. GM V-6 Engine, Late Models
• 5.49. Forks, Wear and Damage Check
• 5.50. Lift Chains, Wear Check
• 5.51. Hydraulic Tank Breather, Clean and Check
• 5.52. Brake Fluid
• 5.53. Fuel System, Checks and Adjustments
• 5.54. Diesel Fuel System
• 5.55. LPG Carburetor
• 5.56. Gasoline Carburetor (Early Models)
• 5.57. Fuel Injection (Late Model GM V-6)
• 5.58. Steering Axle, Lubrication
• 5.59. Cooling System, Clean Debris from Radiator Core
• 5.60. Air Filter
• 5.61. Maintenance Procedures Every 500 Hours or 3 Months
• 5.62. Engine Oil and Filter, Perkins Diesel Engine
• 5.63. Crankcase Breather, Perkins Diesel Engine
• 5.64. PCV Valve, GM V-6
• 5.65. Maintenance Procedures Every 1000 Hours or 6 Months
• 5.66. Manifold Heat Valve, GM V-6
• 5.67. Crankcase Breather, GM V-6
• 5.68. Ignition System, GM V-6
• 5.69. Valve Clearance, Check and Adjust
• 5.70. Fuel Filter, Diesel Engine, Replace
• 5.71. Fuel System Air Removal, Perkins (1004.42 Diesel Engine)
• 5.72. Fuel Injection Pump With Vent Tube
• 5.73. Fuel Injection Pump With Vent Screw
• 5.74. Differential and Drive Axle, Oil Level Check
• 5.75. Differential S3.50-5.50XL (S70-120XL)
• 5.76. Differential and Drive Axle for Powershift Transmission S6.00-7.
• 5.77. Differential, Speed Reducer, and Drive Axle for Manual Transmiss
• 5.78. Control Levers and Pedals, Lubrication
• 5.79. Cooling System GM V-6 EPA Compliant Engine
• 5.80. LPG Fuel Filter GM V-6 EPA Compliant Engine, Replace
• 5.81. Inspect Engine Electrical System, Connectors, and FCVS Connectio
• 5.82. Spark Plug Replacement
• 5.83. Install
• 5.84. Maintenance Procedures Every 2000 Hours or Yearly
• 5.85. Hydraulic System
• 5.86. Hydraulic Oil and Filter S3.50-5.50XL (S70-120XL), Replace
• 5.87. Hydraulic Oil and Filter S6.00-7.00XL (S135-155XL), Replace
• 5.88. Powershift Transmission (All Units), Oil Change and Oil Filter,
• 5.89. Manual Transmission and Differential S6.00-7.00XL (S135-155XL),
• 5.90. Oil Clutch System S6.00-7.00XL (S135-155XL), Oil and Filter Chan
• 5.91. Differential and Drive Axle for Powershift Transmission (All Uni
• 5.92. Cooling System
• 5.93. PCV Valve, GM V-6
• 5.94. Service Brakes
• 5.95. LPG Filter, Replace (Pre-2004)
• 5.96. Oxygen Sensor GM V-6 EPA Compliant Engine
• 5.97. Gasoline Fuel Filter, Replace
• 5.98. Air Filter Element, GM V-6 EPA Compliant Engine
• 5.99. Test LPG/GAS Regulator Pressure
• 5.100. Inspect Low Pressure Regulator (LPR) for Oil Buildup and Leaks
• 5.101. Check Throttle Shaft for Sticking
• 5.102. Inspect Exhaust Manifold and Piping for Leaks
• 5.103. Hood Latch Check
• 5.104. Lift Chain Adjustments
• 5.105. Fuel Injectors Repair
• 5.106. Lift and Tilt System Leak Check
• 5.107. Lift Cylinders, Leak Check
• 5.108. Tilt Cylinders, Leak Check
• 5.109. Welding Repairs
• 5.110. Overhead Guard Changes
• 5.111. Wheel and Tire Replacement
• 5.112. Solid Rubber Tire, Change
• 5.113. Wheels, Install
• 5.114. Adhesives and Sealants
• 5.115. Hydraulic Oil, Lubricant, and Coolant Specifications
• 5.116. Table 1. Maintenance Schedule
• 5.117. Table 2. Hook-Type Carriage Chain Adjustment
• 5.118. Table 3. Pin-Type Carriage Chain Adjustment
• 6. RM0449-(02-2007)-US-EN
• 6.1. Safety Precautions Maintenance and Repair
• 6.2. General
• 6.3. Description
• 6.4. Counterweight Repair
• 6.5. Install
• 6.6. Hood Repair
• 6.7. Install
• 6.8. Overhead Guard Repair
• 6.9. Install
• 6.10. Operator Restraint System Repair
• 6.11. Automatic Locking Retractor (ALR)
• 6.12. Emergency Locking Retractor (ELR)
• 6.13. Fuel and Hydraulic Tanks Repair
• 6.14. Inspect
• 6.15. Small Leaks, Repair
• 6.16. Large Leaks, Repair
• 6.17. Steam Method of Cleaning
• 6.18. Chemical Solution Method of Cleaning
• 6.19. Additional Preparations for Repair
• 6.20. Radiator Repair
• 6.21. Install
• 6.22. Exhaust System Repair
• 6.23. Muffler
• 6.24. Install
• 6.25. Engine Repair
• 6.26. Install
• 6.27. Throttle Pedal Adjustment
• 6.28. Perkins 1104C-44(RE) Diesel Engine
• 6.29. Safety Labels
• 7. RM0450-(09-2003)-US-EN
• 7.1. Drive Axle
• 7.2. Safety Precautions Maintenance and Repair
• 7.3. General
• 7.4. Description
• 7.5. Drive Axle Repair
• 7.6. Units With Manual Transmission
• 7.7. Units With Powershift Transmission
• 7.8. Disassemble
• 7.9. Inspect
• 7.10. Assemble
• 7.11. Install
• 7.12. Units With Manual Transmission
• 7.13. Units With Powershift Transmission
• 7.14. Torque Specifications
• 7.15. Troubleshooting
• 8. RM0451-(09-2003)-US-EN
• 8.1. Steering Axle
• 8.2. Safety Precautions Maintenance and Repair
• 8.3. General
• 8.4. Description
• 8.5. Steering Axle Assembly Repair
• 8.6. Install
• 8.7. Wheels and Hubs Repair
• 8.8. Remove and Disassemble
• 8.9. Assemble and Install
• 8.10. Spindles, Bearings, and Tie Rods Repair
• 8.11. Assemble and Install
• 8.12. Steering Cylinder Repair
• 8.13. Remove and Disassemble
• 8.14. Clean and Inspect
• 8.15. Assemble and Install
• 8.16. Troubleshooting
• 9. RM0452-(02-2004)-US-EN
• 9.1. Brake System
• 9.2. Safety Precautions Maintenance and Repair
• 9.3. General
• 9.4. Description and Operation
• 9.5. Brake Booster and Master Cylinder
• 9.6. Service Brake Assembly
• 9.7. Parking Brake
• 9.8. Brake Shoe Assemblies Repair
• 9.9. Remove and Disassemble
• 9.10. Inspect
• 9.11. Assemble and Install
• 9.12. Master Cylinder Repair
• 9.13. Disassemble
• 9.14. Clean and Inspect
• 9.15. Assemble
• 9.16. Install
• 9.17. Brake Booster Repair
• 9.18. Disassemble
• 9.19. Clean and Inspect
• 9.20. Assemble
• 9.21. Install
• 9.22. Brake System Air Removal
• 9.23. Brake Pedal Adjustment
• 9.24. Brake Shoes Adjustment
• 9.25. Parking Brake Adjustment
• 9.26. Brake Booster Relief Valve Check
• 9.27. Troubleshooting
• 10. RM0453-(09-2003)-US-EN
• 10.1. Hydraulic System
• 10.2. Safety Precautions Maintenance and Repair
• 10.3. General
• 10.4. Description and Operation
• 10.5. Main Hydraulic Pump
• 10.6. Steering Pump
• 10.7. Main Control Valve
• 10.8. Control Valve Lever
• 10.9. Steering Control Unit
• 10.10. Brake Booster
• 10.11. Main Hydraulic Pump Repair
• 10.12. Disassemble
• 10.13. Clean and Inspect
• 10.14. Assemble
• 10.15. Install
• 10.16. Specifications
• 10.17. Hydraulic System
• 10.18. Hydraulic Tank
• 10.19. Hydraulic Oil
• 10.20. Relief Pressures
• 10.21. Hydraulic Pump
• 10.22. Steering Pump
• 10.23. Troubleshooting
• 10.24. Lift, Lower, and Tilt Circuit
• 10.25. Steering and Brake System
• 11. RM0454-(10-2003)-US-EN
• 11.1. Capacities and Specifications
• 11.2. Safety Precautions Maintenance and Repair
• 11.3. Lift Truck Weights