Series 610 all terrain forklift

I have my forklift up and running with the hydraulics working! Thanks to the help on this forum. I had asked a couple questions previously and got some good direction thanks to the folks here.    

Looks like one last problem. The reverse seems to work with the shuttle clutch, in all the gears. the tractor moves with letting the clutch out, and pulling the hand lever back. There does not seem to be a neutral with the hand lever, like the machine is stuck in reverse.

If I push the lever forward, and let the clutch out, the tractor seems to sense severe resistance, like you are pushing against a wall, and it dies from the resistance to moving forward. Something is wrong with the shuttle clutch, I think. It sat for a long time with the inspection cover open...

I am not sure how to explain it any better.     

As I understand it, the clutch itself is no different than a standard power director in a D15. The shuttle (forward-reverse) function is achieved by additional idler gear in the torque tube ahead of the clutch compartment, which makes the shaft turn in reverse rotation when it’s in the respective position. It sounds like one side of the hand clutch is stuck. That would make it try to drive in both directions when in forward position, killing the engine. Also likely explains the “no neutral” condition. The clutch was probably engaged in the reverse position while it sat for a long time with the clutch inspection cover removed, causing the plates to stick (seems plausible if the oil was drained and the cavity exposed to the elements for an extended amount of time). I would remove the cover and see if you can gently unstick the plates with a pocket screwdriver or similar tool with the lever in neutral, or opposite of the “stuck” position. Should be pretty obvious once you take a close look at the clutch. Hopefully it won’t require a teardown and replacement of the clutch plates. I have an I-600 forklift that needs the shuttle clutch plates replaced. Looks like an extra fun job due to the full length outer frame of forklift. Keep us posted on your findings.

I can't imagine bearings not being rust balls in that compartment. Good luck!

I got that junk moving!

I think you guys were exactly right. I got it running and did a bunch of reverse easing in and out, then switching forward till it almost died and then back and neutral and easing it forward, and it finally let go, it went forward a little, then I just kept working it. It got better and better. I might be out of the woods.

I was going to put a filter on the hose running to the transmission oil cooler, and just keep trying it. hopefully it will be ok.

thanks for all the help, you guys really nailed it on that one.

It may well function but I doubt it will "be okay".

OK, I played with it for a while today, and I am pretty sure the shuttle clutch is stuck in reverse. I tried to push the lever forward a few times and it just wants to die from resistance. reverse works perfectly in all gears. Also, after a long time idling, when it gets hot, it will start to die from resistance of the shuttle clutch starting to grab and slow the engine down, even with the transmission in neutral. I am not sure what is wrong, but it looks like I'll have to split the cases. I was hoping it was a rusted in place issue, but it looks like not.

hopefully someone will chime in with some good advice. hint hint.

Hello all. I got a chance to work on my forklift today, and I went and did it. It would not split apart, all bolts off, everything was loose. I was using a jack to jack it up and then jamming shims in the top of the case, then letting it down and jamming shims in the bottom gap of the case, and it just was not working. I think whatever was locked up in the shuttle clutch would not allow the shafts to slide out, So I used my big truck and winch and went crazy, because at this point, I didn't care if I broke it.

Well, I broke the input shaft of the transmission. I think it is just going to be a total loss, for now, I will put it out of the way, and look for some used parts. I think I can find a good D15trans and shuttle clutch eventually.   thanks for the help.

I would appreciate that. Also, if anyone knows where a new transmission is, I would appreciate it. I think a D15ii transmission would work, but i'm not 100% on that....

I am pretty sure the 610 has a torque converter and has very little in common with the D15 transmission.

it definitely has the shuttle clutch with the long handle on the left side (remember this faces backwards, big wheels are forward on a forklift.) the shuttle clutch is broken and when I push forward the engine dies, like it is stuck in both forward and reverse. I am told, the shuttle clutch itself is the exact same as the power divertor, two speed clutch.   

im thinking a D14 farm tractor trans would fit  ??

I have an I-600 forklift for sale in KS, if you are interested. I would say it’s likely the same as your transmission (based on a D15 II tractor, industrial ) Needs new clutch discs for the shuttle clutch, but I have a good set of those too. PM if interested. Lots of good parts on this machine, see classified section for a picture of it.

Edited by RedHeeler79 - 10 Sep 2026 at 9:49am