2. Lift Truck Lifting Capacity
Model Weight
S2.0 (S40FT) (G187) H2.0 (H40FT) (N177) 1814 kg (4000 lb)
S2.5FT (S50FT) (G187) H2.5FT (H50FT) (N177) 2268 kg (5000 lb)
S55FTS (G187) 2495 kg (5500 lb)
S3.0FT (S60FT) (G187) H3.0FT (H60FT) (N177) 2722 kg (6000 lb)
S3.5FT (S70FT) (G187) H3.5FT (H70FT) (N177) 3175 kg (7000 lb)
NOTE: Load center at 500 mm (24 in.).
Counterweight Weights
Model Model
S2.0FT (S40FT) (G187) 1040 kg (2293 lb)
S2.5FT (S50FT) (G187) 1395 kg (3075 lb)
S55FTS (G187) 1643 kg (3622 lb)
S3.0FT (S60FT) (G187) 1819 kg (4010 lb)
S3.5FT (S70FT) (G187) 2153 kg (4747 lb)
H2.0FT (H40FT) (N177) 996 kg (2196 lb)
H2.5FT (H50FT) (N177) 1340 kg (2954 lb)
H3.0FT (H60FT) (N177) 1666 kg (3672 lb)
H3.5FT (H70FT) (N177) 1967 kg (4336 lb)
Tire Sizes
Truck Drive Tires Steer Tires
S2.0-2.5FT (S40-50FT) (G187) 21 × 7 × 15 16 × 5 × 10.5
S3.0FT (S55FTS-60FT) (G187) 21 × 8 × 15 16 × 6 × 10.5
S3.5FT (S70FT) (G187) 21 × 9 × 15 16 × 6 × 10.5
H2.0-2.5FT (H40-50FT) (N177) 7.00 x 12 6.00 x 9
H2.0-3.5FT (H40-70FT) (N177) 28 x 9 6.50 x 10
8000 SRM 1688 Lift Truck Lifting Capacity
1
3. Capacities
Item Quantity Specifications
Fuel Capacity
Gas
S2.0-3.5FT (S40-70FT, S55FTS)
(G187)
40.5 liter (10.7 gal) 86 Octane
Gas
H2.0-3.5FT (H40-70FT) (N177)
52.0 liter (13.7 gal) 86 Octane
LPG
S2.0-3.5FT (S40-70FT, S55FTS)
(G187)
29.9 liter (7.9 gal)
15.2 kg (33.5 lb)
LPG-HD 5, HD 10
LPG
H2.0-3.5FT (H40-70FT) (N177)
29.9 liter (7.9 gal)
15.2 kg (33.5 lb)
LPG-HD 5, HD 10
Diesel
H2.0-3.5FT (H40-70FT) (N177) Trucks
Only
52.0 liter (13.7 gal) Diesel No. 2
Engine Oil (With Oil Filter)
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 J2362
Capacities 8000 SRM 1688
2
4. Item Quantity Specifications
Kubota 2.5L 6.6 liter (7.0 qt) SAE 10W-30
API SM
ILSAC GF4
SAE J2362
Yanmar Diesel 10.2 liter (10.8 qt) 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
Cooling System
Mazda 2.2L
Serpentine and Square Wave
11.0 liter (11.6 qt)
CAUTION
Additives may damage the
cooling system. Before using
additives, contact your local
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.
8000 SRM 1688 Capacities
3
5. Item Quantity Specifications
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 Boron-
free 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 Boron-
free 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 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
S2.0-3.5FT (S40-70FT, S55FTS)
(G187)
36.1 liter (38.1 qt)
Initial Fill
30.1 liter (32.0 qt)
Drain and Fill
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
Capacities 8000 SRM 1688
4
6. 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
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
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
Brake 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
Differential and Drive Axle Oil (Dry
Brake)
S2.0-3.5FT (S40-70FT, S55FTS)
(G187)
5.0 liter (5.3 qt) SAE 80W-90 or 85W-140
Differential and Drive Axle Oil (Dry
Brake)
H2.0-3.5FT (H40-70FT) (N177)
6.5 liter (6.9 qt) SAE 80W-90 or 85W-140
Drive Axle (Wet Brake)
Planetary Housing, Left Side
H2.0-3.5FT (H40-70FT) (N177)
0.5 liter (0.5 qt) SAE 80W-90
Planetary Housing, Right Side
H2.0-3.5FT (H40-70FT) (N177)
2.0 liter (2.1 qt) SAE 80W-90
Wet Brake Portion Of Drive Axle Center
Section
H2.0-3.5FT (H40-70FT) (N177)
1.0 liter (1.1 qt) John Deere
JDM J20C
8000 SRM 1688 Capacities
5
7. Electrical System
Item Mazda 2.2L Kubota 2.5L Yanmar
Battery 12-volt, negative ground 12-volt, negative ground 12-volt, negative ground
Spark Plugs ND W9EXR-U NGK IFR6F8DN N/A
Spark Plugs Longlife
Optional
N/A NGK BKR6EIX N/A
Spark Plug Gap 0.8±0.1 mm
(0.031±.0.004 in.)
0.7 to 089 mm
(0.028 to 0.032 in.)
N/A
Ignition Timing:
Gas 6° BTDC (Orange timing
mark)
Not Adjustable N/A
LPG 6° BTDC (Orange timing
mark)
Not Adjustable N/A
Diesel N/A N/A 2.6L engine preset @ 4°
ATDC 3.0L engine preset
@ 4.5° ATDC 3.3L engine
preset @ 6° ATDC
Mazda 2.2L
Alternator Output (14 Volts) G and LPG
Idle 18 amps @ 800 rpm
High Idle 42 amps @ 2700 rpm
Kubota 2.5L
Alternator Output (14 Volts) G and LPG
Idle 20 amps @ 800 rpm
High Idle 70 amps @ 2500 rpm
Yanmar
Alternator Output (13.5 Volts) D
Idle 14 amps @ 825 rpm
High Idle (2.6L) 57 amps @ 2700 rpm
High Idle (3.3L) 56 amps @ 2600 rpm
Electrical System 8000 SRM 1688
6
8. Transmission Oil Pressures
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)
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). ***
8000 SRM 1688 Transmission Oil Pressures
7
9. 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).
Transmission Oil Pressures 8000 SRM 1688
8
10. 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
*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).
8000 SRM 1688 Transmission Oil Pressures
9
11. 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, 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 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
Figure 1. Drain Plug
1400 SRM 1680 General
1
12. 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.
6. Remove the wheels.
7. Disconnect the brake line connecting the mas-
ter 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 con-
nect 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. Legend for Figure 3
1. UNIVERSAL JOINT
2. INPUT SHAFT (YOKE)
3. DUST COVER
4. BRAKE MANIFOLD
5. CENTER SECTION HOUSING
6. O-RING
7. WASHER
8. CAPSCREW
9. ROLLER BEARING
10. WHEEL BEARING WASHER
11. LOCK PLATE
12. LOCK NUT
13. AXLE SHAFT
14. CAPSCREW
15. HUB/BRAKE DRUM ASSEMBLY
16. INNER SEAL
17. ROLLER BEARING
18. OUTER SEAL
19. CAPSCREW
20. BRAKE ASSEMBLY
21. BRAKE LINE
22. HANGER ASSEMBLY
23. WASHER
24. CAPSCREW
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 assem-
bly and disengage the drive axle assembly from
the transmission.
15. Place blocks under the differential assembly.
16. Remove the axle shafts, hub/brake drum as-
semblies, and back plates. Refer to the section
Brake System 1800SRM1682.
17. Remove the capscrews that hold the hanger as-
sembly 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 manufactur-
er's recommended safety precautions.
1. Clean all the parts of the drive axle with sol-
vent.
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.
1. O-RING
2. HANGER ASSEMBLY
Figure 4. Hanger Assembly
1400 SRM 1680 Drive Axle Repair
5
16. 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 se-
quence shown in Figure 5 and Figure 6 to . Re-
peat this step on the opposite side.
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)
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 assem-
blies, 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 multi-
plier to achieve the torque specification in Step 6.
6. Install the four mounting capscrews and wash-
ers. 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 Fig-
ure 7 and Figure 8.
Drive Axle Repair 1400 SRM 1680
6
17. 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)
1. TRANSMISSION
2. CENTER SECTION HOUSING
3. ISOLATOR, TRANSMISSION
4. WASHER
5. LOCKWASHER
6. MOUNTING BOLT
Figure 8. Transmission to Center Section Housing
Mounting Bolt for Lift Truck Models H2.0-3.5FT
(H40-70FT) (N177)
1400 SRM 1680 Drive Axle Repair
7
18. 9. Remove blocks from under the transmission.
10. Install the parking brake cable. Make sure the
brake cable is routed properly and has no inter-
ference. 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.
1. OIL FILL PLUG 2. OIL FILL LEVEL
Figure 9. Oil Fill Level
16. Remove the air from the brake system as de-
scribed 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 un-
der the frame and from under the counter-
weight. 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 op-
eration and leaks.
Drive Axle Repair 1400 SRM 1680
8
19. Differential Repair
REMOVE
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 re-
placed, 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
20. 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 al-
low the retainer rings to turn freely.
1. COTTER PIN 2. RETAINER RING
1. RETAINER RING SPECIAL TOOL
Differential Repair 1400 SRM 1680
10
21. 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 al-
low the retainer rings to turn freely.
1. COTTER PIN 2. RETAINER RING
1. RETAINER RING SPECIAL TOOL
1400 SRM 1680 Differential Repair
11
22. STEP 4.
Mark one differential carrier leg and bearing cap
to correctly match the parts when assembling dif-
ferential assembly. Mark the parts using a center
punch and hammer. Remove the capscrews and
washers retaining the bearing caps. Remove the
bearing caps.
1. CENTER SECTION
2. WASHER
3. CAPSCREW
4. BEARING CAP
STEP 5.
Remove the retainer rings.
1. CENTER SECTION 2. RETAINER RING
Differential Repair 1400 SRM 1680
12
23. 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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25. Drive Pinion, Pinion Gear, and Bearings From Center Section
1. CENTER SECTION
2. SNAP RING
3. PINION
1. CENTER SECTION
2. WASHER
3. CAPSCREW
4. PINION SUPPORT BRACKET
Differential Repair 1400 SRM 1680
14
26. 1. PINION SUPPORT BRACKET
2. BEARING
STEP 1.
Remove the capscrews and washers retaining the
pinion cover and remove cover.
1. CAPSCREW
2. WASHER
3. PINION NUT
4. CENTER SECTION
1400 SRM 1680 Differential Repair
15
27. 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
4. WASHER
5. PINION NUT
Differential Repair 1400 SRM 1680
16