Hyster b274 (h50 ct) forklift service repair manual

Lift Truck Lifting Capacity
Model Weight
S50CT (B267) 2268 kg (5000 lb)
H2.0-2.5CT (H50CT) (B274) 2268 kg (5000 lb)
NOTE: Load center at 500 mm (24 in.).
Counterweight Weights
Model Weight
S50CT (B267) 1401 kg (3088 lb)
H2.0CT (B274) 950 kg (2094 lb)
H2.5CT (H50CT) (B274) 1230 kg (2712 lb)
Tire Sizes
Truck Drive Tires Steer Tires
S50CT (B267) 21 × 7 × 15 16 × 5 × 10.5
H50CT (B274) 6.50 x 10 PR Wide Tread Width
Solid Pneumatic
5.00 x 8 PR Wide Tread Width
Solid Pneumatic
H50CT (B274) 6.50 x 10 Single Tread Width Solid
Pneumatic
18 x 7-8 Single Tread Width Solid
Pneumatic
8000 SRM 1775 Lift Truck Lifting Capacity
1

Capacities
Item Quantity Specifications
Fuel Capacity
LPG 38.4 liter
(10.1 gal) 15.2 kg (33.5 lb)
Full
LPG-HD 5, HD 10
Diesel 38.4 liter
(10.1 gal)
Diesel No. 2
Gas 38.4 liter
(10.1 gal)
Minimum 86 Octane
Engine Oil
PSI 2.4L 4.9 liter (5.2 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 SL
ILSAC GF3
Yanmar 2.6L 10.2 liter (10.8 gal) 20°C (68°F) and over
SAE 40
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
Capacities 8000 SRM 1775
2

Cooling System
PSI 2.4L 11.0 liter (11.6 qt)
CAUTION
Additives may damage the
cooling system. Before using
additives, contact your local
Hyster dealer.
Use Ethylene Glycol Boron-
free Antifreeze. Purchase a
pre-diluted 50/50 solution; or
mix 50% concentrate with 50%
distilled water or deionized
water.
Yanmar 2.6L Diesel 11.5 liter (12.1 qt)
CAUTION
cooling system. Before using
additives, contact your local
Hyster dealer.
Use Ethylene Glycol Boron-
free Antifreeze. Purchase a
pre-diluted 50/50 solution; or
mix 50% concentrate with 50%
distilled water or deionized
water.
Hydraulic Tank Oil Capacity
S50CT (B267) 29.9 liter (31.6 qt)
Drain and Fill CAUTION
hydraulic system. Before us-
ing additives, contact your lo-
cal Hyster dealer.
ISO VG-46 Hydraulic
Oil −15°C (5°F) and
above
H2.0-2.5CT (H50CT) (B274) 39.2 liter (41.4 qt)
Drain and Fill CAUTION
hydraulic system. Before us-
ing additives, contact your lo-
cal Hyster dealer.
ISO VG-46 Hydraulic
Oil −15°C (5°F) and
above
8000 SRM 1775 Capacities
3

Transmission Oil
Single Speed Powershift Transmission 13 liter (14.0 qt) John Deere
JDM J20C
Brake Oil (Master Cylinder) 0.25 liter (0.26 qt) SAE J-1703 (DOT 3)
Differential and Drive Axle Oil 4.3 liter (4.5 qt) SAE 80W-90 or 85W-140
Electrical System
Item PSI 2.4L Dual Fuel Yanmar 2.6L Diesel
Battery 12-volt, negative ground 12-volt, negative ground
Ignition Timing
Dual Fuel
(With ECU in
Set Mode)
Non-Adjustable; Coil Over Plug Ignition N/A
Diesel N/A Preset @ 4° ATDC
Alternator
Output
14 Volts 13.5Volts
Cold Stabilized Cold Hot
Idle 35 amps @ 800
rpm
28 amps @ 800 rpm N/A N/A
Governed
High Idle
62 amps @ 2600
rpm
50 amps @ 2600 rpm 45 amps @ 2400
rpm
36.5 amps @ 2400
Spark Plug
Type
Torch DK7RTC N/A
Spark Plug
Size
M14 x 1.25 N/A
Spark Plug
Gap
0.9 mm (0.035 in.) N/A
Capacities 8000 SRM 1775
4

Transmission Oil Pressures
1-Speed Transmission - Aluminum Housing All Pressures at 2000 rpm and Oil at 18 to 65°C (65 to
150°F)
Port 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)
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).
8000 SRM 1775 Transmission Oil Pressures
5

Hydraulic System Relief Pressures
Item Specification
Oil Temperature for Setting Relief Pressure 50 to 65°C (122 to 149°F)
Primary Relief Valve Pressure (High Idle) 21.4 ±0.48 MPa (3103 ±70 psi)
Secondary Relief Valve Pressure (High Idle) 18.0 MPa (2610 psi)
Steering System
Item Quantity
Oil Temperature for Setting Relief Pressure 50 to 65°C (122 to 149°F)
Steering Relief Pressure at 800 rpms 11.0 ±0.3 MPa (1595 ±43.5 psi)
Steering Cylinder Stroke (Each Side) 135.2 mm (5.3 in.)
Inside Steering Tire Angle 82.3°
Number of Turns Lock to Lock 3.50
Turning Radius (±50 mm NO LOAD) Outside Inside
S50CT (B267) 2062 75
H2.0-2.5CT (H50CT) (B274) 2236 103
Stall Speeds
Engine Transmission New Engine Broken-In Engine
(30 hrs)
Yanmar 2.6L Diesel Single Speed Powershift 1752 rpm* 1845 rpm*
PSI 2.4L Dual Fuel** Single Speed Powershift 1985 rpm* 2040 rpm*
PSI 2.4L LPG Fuel Single Speed Powershift 1995 rpm* 2060 rpm*
*±100 rpm
**Results Achieved With Engine in Standard Mode and Mode 2
Hydraulic System Relief Pressures 8000 SRM 1775
6

Mast Speeds
NOTE: Lift speed is measured in meters/sec (inch/
sec) at governed engine RPM with full open valve
and 65°C (149°F) oil temperature.
Lowering speed is measured in meters/sec (inch/
sec) with full open valve and 65°C (149°F) oil tem-
perature.
Plus or minus 10% acceptable lifting or lowering.
Engine Model Mast
Lowering M/Sec
(Inch/Sec)
Lifting M/Sec
(Inch/Sec)
No Load Rated Load No Load Rated Load
Yanmar 2.6L
Diesel
H2.0-2.5CT
(B274)
2-Stage LFL 0.48 (18.9) 0.51 (20.1) 0.65 (25.6) 0.63 (24.8)
PSI 2.4L Dual
Fuel
S50CT (B267)
and
H2.0-2.5CT
(B274)
2-Stage LFL 0.48 (18.9) 0.51 (20.1) 0.65 (25.6) 0.63 (24.8)
S50CT (B267) 3-Stage FFL 0.42 (16.5) 0.49 (19.3) 0.61 (24.1) 0.59 (23.2)
H2.0-2.5CT
(H50CT)
(B274)
3-Stage FFL 0.42 (16.5) 0.49 (19.3) 0.61 (24.1) 0.59 (23.2)
Tilt Angles
Lift truck should be on level ground and in unloa-
ded condition.
Mast Type Model Forward Tolerance Back Tolerance
3-Stage FFL S50CT (B267) 10° +1°, −0.5° 5° +0°, −0.5°
3-Stage FFL S50CT (B267) 5° +1°, −0.5° 5° +0°, −0.5°
3-Stage FFL H2.0-2.5CT
(H50CT) (B274)
5° +1°, −0.5° 5° +0°, −0.5°
2-Stage LFL H2.0-2.5CT
(B274)
5° +1°, −0.5° 5° +0°, −0.5°
8000 SRM 1775 Mast Speeds
7

General
This manual covers the repair procedures for the
drive axle and differential assembly.
IDENTIFICATION PLATE
There is an identification plate located on the
differential assembly cover. See Figure 1.
A. FRONT OF TRUCK B. REAR OF TRUCK
1. SERIAL NUMBER
2. DATE
3. IDENTIFICATION PLATE
4. DIFFERENTIAL ASSEMBLY COVER
Figure 1. Drive Axle Identification Plate
1400 SRM 1768 General
1

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, one-
piece units.
1. Put blocks on each side (front and back) of the
steering tires to prevent movement of the lift
truck.
2. Raise lift truck and put blocks under frame so
that drive wheels do not touch floor. Put blocks
under counterweight for stability.
3. Remove mast assembly as described in section
Mast Repair (S/N A698 and A699)
4000SRM1773.
CAUTION
Disposal of lubricants and fluids must meet local
environmental regulations.
4. Remove oil drain plug and drain oil from drive
axle into a suitable container. See Figure 2.
Discard oil drain plug O-ring.
NOTE: BOTTOM VIEW OF DRIVE AXLE SHOWN.
1. OIL DRAIN PLUG
2. DRIVE AXLE CENTER SECTION
3. LEFT HUB
Figure 2. Oil Drain Plug
Drive Axle Repair 1400 SRM 1768
2

WARNING
On lift trucks with pneumatic tires, completely re-
move 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 in-
ner and outer wheel halves when there is air pres-
sure in tire.
5. Remove wheels.
6. Disconnect brake line connecting master cylin-
der to brake manifold located on top of drive
axle assembly. See Figure 4.
7. Remove parking brake cable. Refer to section
Brake System 1800SRM1743 for procedures.
8. Place blocks under drive axle assembly and
connect slings and lifting device to drive axle.
9. Place blocks under transmission to support the
transmission while removing drive axle.
10. Remove two bolts and remove universal joint
from transmission. See Figure 3.
11. Remove transmission isolator mounting bolt
from transmission mounting bracket, located on
top of drive axle assembly. See Figure 7.
12. Remove four drive axle mounting capscrews
from hanger assembly. See Figure 4.
13. Remove blocks, lower drive axle assembly, and
disengage the drive axle assembly from trans-
mission.
14. Place blocks under the drive axle center section
assembly.
15. Remove the drive axle shafts, hub/brake drum
assemblies, and back plates. Refer to the sec-
tion Brake System 1800SRM1743.
16. Remove hanger assembly capscrews and
hanger assembly. Repeat this step on the oppo-
site side. See Figure 4.
1. BOLTS
2. UNIVERSAL JOINT
4. TRANSMISSION MOUNTING BRACKET
Figure 3. Universal Joint Removal
1400 SRM 1768 Drive Axle Repair
3

1. CAPSCREW
2. DRIVE AXLE SHAFT
3. LOCKNUT
4. BEARING LOCKWASHER
5. WASHER
6. TAPER ROLLER BEARING
7. HUB/BRAKE ASSEMBLY
8. HUB BOLT
9. ROLLER BEARING
10. INNER SEAL
11. INNER BEARING
12. OUTER SEAL
13. WEAR SLEEVE
14. BRAKE ASSEMBLY
15. LEFT BRAKE LINE
16. DRIVE AXLE MOUNTING CAPSCREW
17. DRIVE AXLE MOUNTING NUT
18. DIFFERENTIAL COVER
19. RIGHT BRAKE LINE
21. UNIVERSAL JOINT
22. DUST COVER
23. INPUT SHAFT (YOKE)
24. BRAKE MANIFOLD
25. HANGER ASSEMBLY
Figure 4. Drive Axle
4

CLEAN AND INSPECT
WARNING
Cleaning solvents can be flammable and toxic and
can cause skin irritation. When using cleaning
solvents, always follow the solvent manufactur-
er's recommended safety precautions.
1. Clean all the parts of the drive axle assembly
with solvent.
2. Inspect the bearings and seals for damage.
3. Inspect the drive axle shafts for wear and
cracks at the flange, shaft, and damaged
splines. If axle shafts show signs of wear or
damage, replace the axle shafts.
ASSEMBLE AND INSTALL
1. Apply grease to new O-rings and install O-rings
on the hanger assemblies. See Figure 4 and
Figure 5.
1. O-RING
2. HANGER ASSEM-
BLY
3. DRIVE AXLE SPIN-
DLE
Figure 5. Hanger Assembly
2. Place hanger assembly in position on differen-
tial cover. Apply Loctite®
242 to capscrews and
install capscrews. Tighten capscrews in se-
quence shown in Figure 6 to 90 to 99 N•m (66
to 73 lbf ft). Repeat step for opposite side.
Figure 6. Hanger Assembly Tightening Sequence
NOTE: Apply Loctite®
515 or High Performance
RTV Silicone Gasket Maker on the drive axle shaft
flange when installing.
3. Install the back plates, hub/brake drum assem-
blies, and drive axle shafts. Refer to the section
Brake System 1800SRM1743.
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 multi-
plier to achieve the torque specification in Step 6.
6. Install four drive axle mounting capscrews and
nuts. Tighten capscrews to 245 to
270 N•m (181 to 199 lbf ft).
5

7. Install universal joint to transmission using
two bolts. Tighten bolts to 30 to 37 N•m (22 to
27 lbf ft). See Figure 3.
8. Install the isolators as shown in Figure 7.
9. Apply adhesive sealant, Loctite®
271, to trans-
mission isolator mounting bolt. Install trans-
mission isolator mounting bolt and snubbing
washer into transmission mounting bracket, lo-
cated on top of drive axle assembly. Tighten the
bolt to 225 to 250 N•m (166 to 184 lbf ft). See
Figure 7.
10. Remove blocks from under transmission.
11. Install parking brake cable. Make sure brake
cable is routed properly and has no interfer-
ence. Verify that parking brake operates prop-
erly. Refer to section Brake System
1800SRM1743.
12. Connect the brake line connecting the master
cylinder to the brake manifold located on top of
the drive axle assembly. See Figure 4.
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: 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 155 to
175 N•m (114 to 129 lbf ft).
1. TRANSMISSION MOUNTING BRACKET
2. TRANSMISSION ISOLATOR MOUNTING BOLT
3. WASHER
4. SNUBBING WASHER
5. ISOLATOR
6. TRANSMISSION
Figure 7. Transmission to Center Section Housing Mounting Bolt
6

14. Apply multipurpose grease with 2 to 4% molyb-
denum disulfide to new drain plug O-ring and
install O-ring on drain plug. Install the drain
plug and tighten to 50 to 55 N•m (37 to
41 lbf ft). See Figure 2.
15. Remove the fill plug and fill the drive axle to
the proper level as shown in Figure 8. See sec-
tion Periodic Maintenance 8000SRM1774 for
oil quantity and oil type to use. Install the fill
plug.
16. Remove air from brake system as described in
section Brake System 1800SRM1743.
17. Install mast assembly as described in section
Mast Repair (S/N A698 and A699)
4000SRM1773.
18. Raise lift truck and remove blocks from under
frame and counterweight. Lower lift truck.
19. Remove blocks on each side (front and back) of
steering tires.
20. Operate lift truck and check for proper opera-
tion and leaks.
A. LEFT SIDE VIEW B. FRONT VIEW
1. OIL FILL PLUG
2. OIL FILL LEVEL
Figure 8. Oil Fill Level
7

Differential Repair
REMOVE
For the following repair procedures, the drive axle
must be removed and disassembled. Refer to sec-
tion Drive Axle Repair for removal and dissemble
procedures.
Differential Assembly From Drive Axle Center Section Assembly
STEP 1.
Using a retainer ring special tool, Hyster Part No.
1663599, loosen the differential retainer rings. If
necessary, loosen retainer ring capscrews to allow
the retainer rings to turn freely. Remove differen-
tial retainer rings and retainer ring capscrews
from center section.
1. RETAINER RING CAPSCREW
2. DIFFERENTIAL RETAINER RING
1. RETAINER RING SPECIAL TOOL
Differential Repair 1400 SRM 1768
8

STEP 2.
Remove differential assembly cover capscrews and
remove differential assembly cover.
1. DIFFERENTIAL ASSEMBLY COVER CAP-
SCREWS
3. DIFFERENTIAL ASSEMBLY
STEP 3.
Remove differential assembly from drive axle cen-
ter section.
2. HYPOID GEAR
1400 SRM 1768 Differential Repair
9

Drive Pinion, Pinion Gear, and Bearings From Drive Axle Center Section
STEP 1.
Remove capscrews, washers, and pinion cover.
1. CAPSCREW
2. WASHER
3. PINION COVER
4. PINION NUT
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, flat chisel, unstake the pinion nut.
Remove pinion nut and washer.
1. PINION NUT
2. WASHER
3. PINION SHAFT
10

STEP 3.
Remove input shaft (yoke), oil seal, and dust cover
from drop box housing.
1. INPUT SHAFT (YOKE)
2. DUST COVER
3. OIL SEAL
STEP 4.
Remove capscrews and washers from the drop box
housing.
1. CAPSCREW
2. WASHER
3. DROP BOX HOUSING
STEP 5.
Install two capscrews removed in STEP 4 in loca-
tion shown. Tighten each capscrew alternately,
until drop box housing can be removed. If the cap-
screws do not have enough threaded length, use a
pry bar to finish removing the housing.
11

STEP 6.
Remove outer tapered bearing from drop box
housing.
1. INSERT TWO CAPSCREWS
1. OUTER TAPERED ROLLER BEARING
2. DROP BOX HOUSING
3. PINION SHAFT
12

NOTE: When removing pinion shaft, be sure to retain the shims.
STEP 7.
Carefully remove pinion shaft assembly from
drive axle center section. Using a press and bear-
ing puller, remove inner shims and inner tapered
roller bearing from pinion shaft assembly.
1. INNER TAPERED ROLLER BEARING
2. INNER SHIMS
3. PINION SHAFT
5. DRIVEN GEAR
STEP 8.
Remove driven gear and pinion crush sleeve
1. DRIVEN GEAR
2. PINION CRUSH SLEEVE
13

STEP 9.
Using a press or suitable soft drift, remove the
outer tapered roller bearing cup from drop box
housing.
1. OUTER TAPERED ROLLER BEARING CUP
2. DROP BOX HOUSING
STEP 10.
Using a suitable soft drift, remove the pinion in-
ner tapered roller bearing cup.
1. PINION INNER TAPERED ROLLER BEARING
CUP
14

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DISASSEMBLE
Differential Assembly
STEP 1.
Remove the bearing cups. Using a suitable bear-
ing puller, remove the tapered roller bearings
from the differential assembly.
1. BEARING CUP
2. TAPERED ROLLER BEARING
STEP 2.
Remove the capscrews and hypoid gear from dif-
ferential assembly case.
1. HYPOID GEAR
2. DIFFERENTIAL ASSEMBLY CASE
3. CAPSCREW
15

STEP 3.
Remove pin from differential assembly case and
pinion shaft. Remove pinion shaft. Inspect pinion
shaft for wear. Replace as needed.
1. PIN
3. PINION SHAFT
16

STEP 4.
Rotate side gears until pinion gears can be re-
moved from the differential assembly case. Re-
move pinion gears. Inspect pinion gears spherical
washers for wear. Replace as needed.
2. PINION GEARS
17

Hyster b274 (h50 ct) forklift service repair manual

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