Capacities
(H40-70FT) (N177)
(S40-70FT, S55FTS)
(H40-70FT) (N177)
(H40-70FT) (N177) Trucks
Oil (With Oil Filter)
Item Quantity Specifications Fuel Capacity Gas S2.0-3.5FT
(G187) 40.5 liter (10.7 gal) 86 Octane Gas H2.0-3.5FT
52.0 liter (13.7 gal) 86 Octane LPG S2.0-3.5FT
(G187) 29.9 liter (7.9 gal) 15.2 kg (33.5 lb) LPG-HD 5, HD 10 LPG H2.0-3.5FT
29.9 liter (7.9 gal) 15.2 kg (33.5 lb) LPG-HD 5, HD 10 Diesel
Only 52.0 liter (13.7 gal) Diesel No. 2 Engine
Mazda 4.2 liter (4.4 qt) 7°C (20°F) and below SAE 5W-20 16°C (60 °F) and below SAE 5W-30 18°C (0°F) and above SAE 10W-30 API SM ILSAC GF4 SAE
Capacities 8000 SRM 1688 2
H2.0-3.5FT
J2362
ILSAC GF4
SAE J2362
10 to 30°C (50 to 86°F)
SAE 30
0 to 20°C (32 to 68°F)
SAE 20
16 to 40°C (3 to 104°F)
SAE 15W-40
20 to 30°C ( 4 to 86°F)
SAE 10W-30
10 to 10°C (14 to 50°F)
SAE 20W
20 to 10°C ( 4 to 50°F)
SAE 10W
Additives may damage the cooling system. Before using additives, contact your local dealer.
Use Ethylene Glycol Boronfree Antifreeze. Purchase a pre-diluted 50/50 solution; or mix 50% concentrate with 50% distilled water or deionized water.
Item Quantity Specifications Kubota 2.5L 6.6 liter (7.0 qt) SAE 10W-30
API SM
Yanmar Diesel 10.2 liter (10.8 qt) 20°C (68°F) and over SAE
40
Mazda 2.2L Serpentine and Square Wave 11.0 liter (11.6 qt)
Cooling System
CAUTION
8000 SRM 1688 Capacities 3
Mazda 2.2L Square Wave with Air Oil Cooler
10.6 liter (11.2 qt)
CAUTION
Additives may damage the cooling system. Before using additives, contact your local dealer.
Use Ethylene Glycol Boronfree Antifreeze. Purchase a pre-diluted 50/50 solution; or mix 50% concentrate with 50% distilled water or deionized water.
Kubota 2.5L
10.5 liter (11.2 qt)
CAUTION
Additives may damage the cooling system. Before using additives, contact your local dealer.
Use Ethylene Glycol Boronfree Antifreeze. Purchase a pre-diluted 50/50 solution; or mix 50% concentrate with 50% distilled water or deionized water.
Yanmar Diesel
11.5 liter (12.1 qt)
CAUTION
Additives may damage the cooling system. Before using additives, contact your local dealer.
Use Ethylene Glycol Boronfree Antifreeze. Purchase a pre-diluted 50/50 solution; or mix 50% concentrate with 50% distilled water or deionized water.
Hydraulic Tank Oil Capacity
CAUTION
Additives may damage the hydraulic system. Before using additives, contact your local dealer.
ISO VG-46 Hydraulic Oil 15°C (5°F) and above
Item Quantity Specifications
(G187)
liter (38.1 qt) Initial Fill
liter (32.0 qt) Drain and Fill
S2.0-3.5FT (S40-70FT, S55FTS)
36.1
30.1
Capacities 8000 SRM 1688 4
Differential
S2.0-3.5FT (S40-70FT, S55FTS) (G187)
Differential and Drive Axle Oil (Dry Brake)
H2.0-3.5FT (H40-70FT) (N177)
Drive Axle (Wet Brake) Planetary Housing, Left Side
(H40-70FT) (N177)
Planetary Housing, Right Side
(H40-70FT) (N177)
Wet Brake Portion Of Drive Axle Center Section
(H40-70FT) (N177)
CAUTION
Item Quantity Specifications H2.0-3.5FT (H40-70FT) (N177) 45.8 liter (48.4 qt) Initial Fill 39.8 liter (42.0 qt) Drain and Fill
hydraulic system.
additives,
local dealer. ISO VG-46 Hydraulic Oil 15°C (5°F) and
Transmission Basic Powershift Transmission (Iron Housing) 20 liter (21.0 qt) John Deere JDM J20C Single Speed PS Transmission (Aluminum Housing) 13 liter (14.0 qt) John Deere JDM J20C DuraMatch Transmission (Iron Housing) 20 liter (21.0 qt) John Deere JDM J20C DuraMatch Transmission (Aluminum Housing) 13 liter (14.0 qt) John Deere JDM J20C
Fluid (Dry Brake) Master Cylinder 0.25 liter (0.53 pt) SAE J-1703, DOT 3 Brake Oil (Wet Brake) Master Cylinder 0.35 liter (0.74 pt) Dexron III
Additives may damage the
Before using
contact your
above
Brake
and
Brake)
5.0 liter (5.3 qt) SAE 80W-90 or 85W-140
Drive Axle Oil (Dry
6.5 liter (6.9 qt) SAE 80W-90 or 85W-140
H2.0-3.5FT
0.5 liter (0.5 qt) SAE 80W-90
2.0 liter (2.1 qt) SAE 80W-90
H2.0-3.5FT
1.0 liter (1.1 qt) John Deere JDM J20C 8000 SRM 1688 Capacities 5
H2.0-3.5FT
Transmission Oil Pressures
A. EARLY MODELS
B. LATER MODELS
*Relief Pressure **Clutch pack pressure difference between the forward and reverse packs cannot exceed manufacturing limit of 48 kPa (7 psi) or service limit of 70 kPa (10 psi). ***
1-Speed Transmission - Iron Housing All Pressures at 2000 rpm and Oil at 50 to 65°C (120 to 150°F) Port 1 Transmission Pump Port 2 Port 3 Port 4 Port 5 ***Low Pressure ***High Pressure Reverse Clutch Forward Clutch Torque Converter Lubrication 1138 ±96* kPa (165 ±14 psi) 1482 ±96* kPa (215 ±15 psi) 983 ±58** kPa (142.5 ±8.5 psi) 983 ±58** kPa (142.5 ±8.5 psi) 738 ±52 kPa (107 ±7.5 psi) 138 ±34.5 kPa (20 ±5 psi)
8000 SRM 1688 Transmission Oil Pressures 7
1-Speed Transmission - Aluminum Housing All Pressures at 2000 rpm and Oil at 18 to 65°C (65 to 150°F)
A. TOP VIEW
B. RIGHT SIDE VIEW
*Relief Pressure **Clutch pack pressure difference between the forward and reverse packs cannot exceed manufacturing limit of 48 kPa (7 psi) or service limit of 70 kPa (10 psi). ***Low pressure at 800 rpm and oil at 27 to 32°C (80 to 90°F).
1 Transmission Pump Port 2 Port 3 Port 5 ***Low Pressure High Pressure Reverse Clutch Forward Clutch Lubrication 1089 ±69* kPa (158 ±10 psi) 1241 ±138* kPa (180 ±20 psi) 983 ±58** kPa (142.5 ±8.5 psi) 983 ±58** kPa (142.5 ±8.5 psi) 62 ±41 kPa (9 ±6 psi)
Port
Transmission Oil Pressures 8000 SRM 1688 8
*Relief Pressure **Clutch pack pressure difference between the forward and reverse packs cannot exceed manufacturing limit of 48 kPa (7 psi) or service limit of 70 kPa (10 psi).
2-Speed Transmission All Pressures at 2500 rpm and Oil at 50 to 65°C (120 to 150°F) Port 1 Port 2 Port 3 Port 5 Port 6 Transmission Pump Reverse Clutch Forward Clutch Torque Converter Lubrication 1138 ±96* kPa (165 ±14 psi) 983 ±58** kPa (142.5 ±8.5 psi) 983 ±58** kPa (142.5 ±8.5 psi) 738 ±52 kPa (107 ±7.5 psi) 55 ±28 kPa (8 ±4 psi)
A. REAR VIEW
B. FRONT VIEW
8000 SRM 1688 Transmission Oil Pressures 9
General
This section has the repair procedures for the drive axle and differential assembly.
Drive Axle Repair
REMOVE AND DISASSEMBLE
WARNING
When putting the lift truck on blocks, make sure the surface is solid, even, and level. Any blocks used to support the lift truck must be solid, onepiece units.
1. Put blocks on each side (front and back) of the steering tires to prevent movement of the lift truck.
2. Raise the lift truck and put blocks under the frame so that the drive wheels do not touch the floor. Put blocks under the counterweight for stability.
3. Remove the mast assembly as described in the section Mast Repair (S/N F507, F562, F508, and F563) 4000SRM1669.
4. Drain the oil from the drive axle.
5. Remove the drain plug and drain the oil from the drive axle into a suitable container. See Figure 1.
1.CENTER SECTION 2.DRAIN PLUG
1400 SRM 1680 General 1
Figure 1. Drain Plug
WARNING
On lift trucks with pneumatic tires, completely remove air from tires before removing them from lift truck. Air pressure in tires can cause tire and rim parts to explode, which can cause serious injury or death. Never loosen nuts that hold together inner and outer wheel halves when there is air pressure in tire.
6. Remove the wheels.
7. Disconnect the brake line connecting the master cylinder to the brake manifold located on top of the assembly. See Figure 2 and Figure 3.
8. Remove the parking brake cable. Refer to the section Brake System 1800SRM1682.
9. Place blocks under the axle assembly and connect slings and lifting device.
10. Place blocks under the transmission to support the transmission while removing the drive axle.
11. Remove the capscrews retaining the drive shaft and remove the drive shaft.
12. Remove the transmission isolator mounting bolt located on top of the assembly.
13. Remove the four mounting capscrews from the drive axle assembly. See Figure 2 and Figure 3.
Drive Axle Repair 1400 SRM 1680 2
15.LOCK PLATE
16.LOCK NUT
17.AXLE SHAFT
18.CAPSCREW
19.PIN
20.WHEEL NUT
21.HUB BOLT
22.INNER SEAL
23.ROLLER BEARING
24.OUTER SEAL
25.CAPSCREW
26.BRAKE LINE, RIGHT SIDE
27.WASHER
28.CAPSCREW
1.UNIVERSAL JOINT
2.INPUT SHAFT (YOKE) 3.DUST COVER 4.BRAKE MANIFOLD 5.BRAKE LINE, LEFT SIDE 6.HANGER ASSEMBLY 7.BRAKE ASSEMBLY 8.HUB/BRAKE DRUM ASSEMBLY 9.CENTER SECTION HOUSING 10.O-RING 11.WASHER 12.CAPSCREW 13.ROLLER BEARING 14.WHEEL BEARING WASHER
1400 SRM 1680 Drive Axle Repair 3
Figure 2. Drive Axle for Lift Truck Models S2.0-3.5FT (S40-70FT, S55FTS) (G187)
Drive Axle Repair 1400 SRM 1680 4
Figure 3. Drive Axle for Lift Truck Models H2.0-3.5FT (H40-70FT) (N177)
1.UNIVERSAL
Legend for Figure 3
NOTE: The drive line yoke is a slip joint and should slide out from the differential easily.
14. Remove blocks and lower the drive axle assembly and disengage the drive axle assembly from the transmission.
15. Place blocks under the differential assembly.
16. Remove the axle shafts, hub/brake drum assemblies, and back plates. Refer to the section Brake System 1800SRM1682.
17. Remove the capscrews that hold the hanger assembly to the center section housing. Remove the hanger assembly. Repeat this step on the opposite side.
CLEAN AND INSPECT WARNING
Cleaning solvents can be flammable and toxic and can cause skin irritation. When using cleaning solvents, always follow the solvent manufacturer's recommended safety precautions.
1. Clean all the parts of the drive axle with solvent.
2. Inspect the bearings and seals for damage.
3. Inspect the axle shafts for wear and cracks at the flange, shaft, and splines. If axle shafts show signs of wear or damage, replace the axle shafts. The splines for the axle shafts must not be damaged.
ASSEMBLE AND INSTALL
1. Apply grease to new O-rings and install O-rings on the hanger assemblies. See Figure 4.
JOINT
SHAFT (YOKE)
COVER
MANIFOLD
SECTION HOUSING
BEARING
BEARING WASHER
PLATE
NUT
SHAFT
DRUM ASSEMBLY
SEAL
BEARING
SEAL
ASSEMBLY 21.BRAKE LINE
ASSEMBLY
2.INPUT
3.DUST
4.BRAKE
5.CENTER
6.O-RING 7.WASHER 8.CAPSCREW 9.ROLLER
10.WHEEL
11.LOCK
12.LOCK
13.AXLE
14.CAPSCREW 15.HUB/BRAKE
16.INNER
17.ROLLER
18.OUTER
19.CAPSCREW 20.BRAKE
22.HANGER
23.WASHER 24.CAPSCREW
1.O-RING
2.HANGER ASSEMBLY
1400 SRM 1680 Drive Axle Repair 5
Figure 4. Hanger Assembly
2. Place the hanger assembly in position on the center section housing. Apply Loctite® 242 to the capscrews and install capscrews to retain hanger assembly. Tighten capscrews in sequence shown in Figure 5 and Figure 6 to . Repeat this step on the opposite side.
NOTE: Apply Loctite® 515 or High Performance RTV Silicone Gasket Maker on the axle shaft flange when installing.
3. Install the back plates, hub/brake drum assemblies, and axle shafts. Refer to the section Brake System 1800SRM1682.
4. Connect slings and lifting device to drive axle.
NOTE: When installing the drive axle, ensure the drive axle is held with the upper surface of the drive axle against the frame. This will prevent any gap between the frame and the drive axle mount, and will ensure even weight bearing distribution.
5. Position the drive axle in the lift truck.
NOTE: It is recommended to use a torque multiplier to achieve the torque specification in Step 6.
6. Install the four mounting capscrews and washers. Tighten the capscrews to 820 to 902 N•m (605 to 665 lbf ft).
7. Place the drive shaft in position and install the retaining capscrews. Tighten the drive shaft capscrews to 30 to 37 N•m (22 to 27 lbf ft).
NOTE: When installing the transmission isolator, make sure to place one washer above and below the isolators.
8. Install the transmission isolator mounting bolt located on top of the assembly. Tighten the bolt to 225 to 250 N•m (166 to 184 lbf ft). See Figure 7 and Figure 8.
Figure 5. Hanger Assembly Tightening Sequence for Lift Truck Models S2.0-3.5FT (S40-70FT, S55FTS) (G187)
Figure 6. Hanger Assembly Tightening Sequence for Lift Truck Models H2.0-3.5FT (H40-70FT) (N177)
Drive Axle Repair 1400 SRM 1680 6
1.TRANSMISSION
2.CENTER SECTION HOUSING
3.ISOLATOR, TRANSMISSION
4.WASHER
5.LOCKWASHER
6.MOUNTING BOLT
1.TRANSMISSION
2.CENTER SECTION HOUSING
3.ISOLATOR, TRANSMISSION
4.WASHER
5.LOCKWASHER
6.MOUNTING BOLT
Figure 7. Transmission to Center Section Housing Mounting Bolt for Lift Truck Models S2.0-3.5FT (S40-70FT, S55FTS) (G187)
1400 SRM 1680 Drive Axle Repair 7
Figure 8. Transmission to Center Section Housing Mounting Bolt for Lift Truck Models H2.0-3.5FT (H40-70FT) (N177)
9. Remove blocks from under the transmission.
10. Install the parking brake cable. Make sure the brake cable is routed properly and has no interference. Verify that the parking brake operates properly. Refer to the section Brake System 1800SRM1682.
11. Connect the brake line connecting the master cylinder to the brake manifold located on top of the assembly.
NOTE: Perform this step for Lift Truck Models S2.0-3.5FT (S40-70FT, S55FTS) (G187).
12. Install the wheels and nuts and tighten the nuts to 340 to 380 N•m (251 to 280 lbf ft).
WARNING
Add air to the tires only in a safety cage. Inspect safety cage for damage before use. When adding air, use a clip-on chuck with enough hose to let the operator stand clear of the cage.
NOTE: Perform this step for Lift Truck Models H2.0-3.5FT (H40-70FT) (N177).
NOTE: When tightening the wheel nuts, DO NOT use any lubricant on the studs or nuts.
13. Inflate the tires using a safety cage. Install the wheels and nuts and tighten the nuts to 340 to 380 N•m (251 to 280 lbf ft).
14. Install the drain plug and tighten to 50 to 55 N•m (37 to 41 lbf ft).
NOTE: Perform this step for Lift Truck Models H2.0-3.5FT (H40-70FT) (N177).
15. Remove the fill plug and fill the drive axle to the proper level as shown in Figure 9, with 6.3 to 6.8 liter (6.6 to 7.1 qt) of SAE 80W-90 gear oil through the fill hole. Install the fill plug.
16. Remove the air from the brake system as described in the section Brake System 1800SRM1682.
17. Install the mast assembly as described in the section Mast Repair (S/N F507, F562, F508, and F563) 4000SRM1669.
18. Raise the lift truck and remove blocks from under the frame and from under the counterweight. Lower the lift truck.
19. Remove the blocks on each side (front and back) of the steering tires.
20. Operate the lift truck and check for proper operation and leaks.
1.OIL FILL PLUG 2.OIL FILL LEVEL
9. Oil Fill Level
Figure
Drive Axle Repair 1400 SRM 1680 8
REMOVE
Differential Repair
For the following repair procedures, the drive axle must be removed and disassembled. Refer to the section Drive Axle Repair.
Differential Assembly From Center Section
STEP 1. Remove the capscrews retaining the center section cover and remove cover.
1.CENTER SECTION COVER
2.CAPSCREW
3.CENTER SECTION
NOTE: Before working on the differential assembly, inspect the hypoid gear set for damage. If inspection shows no damage, the same gear set can be used again. Using a dial indicator, measure the backlash of the gear set and make a record of the dimension. See the procedure Gear Set, Tooth Contact Pattern Check. During differential reassembly, adjust the backlash to the original recorded dimension when the gear set is installed into the center section.
NOTE: If the lift truck was manufactured prior to October 2006 and the retaining rings have not been replaced, go to STEP 2. If the lift truck was manufactured after October 2006 or the retaining rings have been replaced in a lift truck manufactured prior to October 2006, go to STEP 3.
1400 SRM 1680 Differential Repair 9
STEP 2.
Remove differential assembly retainer ring cotter pins. Using a retainer ring special tool, Hyster Part No. 1581188, loosen the retainer rings. If necessary, loosen the bearing cap capscrews to allow the retainer rings to turn freely.
1.COTTER PIN 2.RETAINER RING
Differential Repair 1400 SRM 1680 10
1.RETAINER RING SPECIAL TOOL
STEP 3.
Remove differential assembly retainer ring cotter pins. Using a retainer ring special tool, Hyster Part No. 1663599, loosen the retainer rings. If necessary, loosen the bearing cap capscrews to allow the retainer rings to turn freely.
1.COTTER PIN 2.RETAINER RING
1400 SRM 1680 Differential Repair 11
1.RETAINER RING SPECIAL TOOL
STEP 4.
Mark one differential carrier leg and bearing cap to correctly match the parts when assembling differential assembly. Mark the parts using a center punch and hammer. Remove the capscrews and washers retaining the bearing caps. Remove the bearing caps.
STEP
1.CENTER SECTION
2.WASHER
3.CAPSCREW 4.BEARING CAP
5. Remove the retainer rings.
Differential Repair 1400 SRM 1680 12
1.CENTER SECTION 2.RETAINER RING
STEP 6.
Remove the differential assembly.
1.CENTER SECTION
2.DIFFERENTIAL ASSEMBLY
3.TAPERED ROLLER BEARING AND CUP
1.CENTER SECTION
2.DIFFERENTIAL ASSEMBLY
3.TAPERED ROLLER BEARING AND CUP
1400 SRM 1680 Differential Repair 13
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Drive Pinion, Pinion Gear, and Bearings From Center Section
1.CENTER SECTION
2.SNAP RING
3.PINION
1.CENTER SECTION
2.WASHER
3.CAPSCREW
Differential Repair 1400 SRM 1680 14
4.PINION SUPPORT BRACKET
STEP
1.PINION SUPPORT BRACKET
2.BEARING
1. Remove the capscrews and washers retaining the pinion cover and remove cover.
1.CAPSCREW
2.WASHER
1400 SRM 1680 Differential Repair 15
3.PINION NUT 4.CENTER SECTION
CAUTION
When removing the pinion nut, make sure the staked areas do not touch the pinion threads. The staked areas can cause damage to the pinion threads, making the pinion unserviceable.
STEP 2. Using a small and flat chisel, unstake the pinion nut.
1.CENTER SECTION 2.WASHER
3.PINION NUT
1.CENTER SECTION 2.SHIMS 3.BEARING CONE
Differential Repair 1400 SRM 1680 16
4.WASHER 5.PINION NUT
