Hyster p177 (h2.0 ft europe) forklift service repair manual

SERVICE REPAIR
H2.0FT H2.5FT H3.0FT H3.5FT Europe [P177]

Lift Truck Lifting Capacity
Model Weight
S2.0 (S40FT) (H187) H2.0 (H40FT) (P177) 1814 kg (4000 lb)
S2.5FT (S50FT) (H187) H2.5FT (H50FT) (P177) 2268 kg (5000 lb)
S55FTS (H187) 2495 kg (5500 lb)
NOTE: Load center at 500 mm (24 in.).
Counterweight Weights
Model Model
S2.0FT (S40FT) (H187) 1040 kg (2293 lb)
S2.5FT (S50FT) (H187) 1395 kg (3075 lb)
S55FTS (H187) 1643 kg (3622 lb)
S3.0FT (S60FT) (H187) 1819 kg (4010 lb)
S3.5FT (S70FT) (H187) 2153 kg (4747 lb)
H2.0FT (H40FT) (P177) 996 kg (2196 lb)
H2.5FT (H50FT) (P177) 1340 kg (2954 lb)
H3.0FT (H60FT) (P177) 1666 kg (3672 lb)
H3.5FT (H70FT) (P177) 1967 kg (4336 lb)
Tire Sizes
Truck Drive Tires Steer Tires
S2.0-2.5FT (S40-50FT) (H187) 21 × 7 × 15 16 × 5 × 10.5
S3.0FT (S55FTS-60FT) (H187) 21 × 8 × 15 16 × 6 × 10.5
S3.5FT (S70FT) (H187) 21 × 9 × 15 16 × 6 × 10.5
H2.0-2.5FT (H40-50FT) (P177) 7.00 x 12 6.00 x 9
H2.0-3.5FT (H40-70FT) (P177) 28 x 9 6.50 x 10
8000 SRM 1763 Lift Truck Lifting Capacity
1

Capacities
Item Quantity Specifications
Fuel Capacity
Gas* 52.8 liter (13.9 gal) 86 Octane -
Gasoline Mini-
mum
LPG 29.9 liter (7.9 gal)
15.2 kg (33.5 lb)
LPG-HD 5, HD
10
Yanmar Diesel
H2.0-3.5FT (H40-70FT) (P177) Trucks
Only
52.0 liter (13.7 gal) Diesel No. 2
Kubota 2.4L Diesel
H2.0-3.5FT (H40-70FT) (P177) Trucks
Only
52.0 liter (13.7 gal) Ultra-Low Sul-
fur
≤ 15 ppm
Diesel No. 2
Engine Oil (With Oil Filter)
PSI 2.4L - Gas* and LPG 4.9 liter (5.2 qt) −7°C (20°F) and be-
low
SAE 5W-20
16°C (60 °F) and be-
low
SAE 5W-30
−18°C (0°F) and above
SAE 10W-30
API SL
ILSAC GF3
SAE J2362
Kubota 2.5L - LPG 6.6 liter (7.0 qt) All Temperatures
SAE 10W-30
API SL
ILSAC GF3
SAE J2362
Capacities 8000 SRM 1763
2

Yanmar 2.6L, 3.0L**, and 3.3L -
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
API CG-4 or
Better
Kubota 2.4L - Diesel 9.5 liter (10.0 qt) -10°C (14°F)
and above
SAE 15W-40
-10°C (14°F)
and below
SAE 10W-30
API CJ-4 Only
8000 SRM 1763 Capacities
3

Cooling System
PSI 2.4L 11.0 liter (11.6 qt)
CAUTION
Additives may dam-
age the cooling sys-
tem. Before using ad-
ditives, 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.
PSI 2.4L
With Air Oil Cooler
10.6 liter (11.2 qt)
CAUTION
Additives may dam-
Use Ethylene Glycol
deionized water.
4

Kubota 2.5L LPG 10.6 liter (11.2 qt)
CAUTION
Additives may dam-
Use Ethylene Glycol
deionized water.
Yanmar Diesel 11.5 liter (12.1 qt)
CAUTION
Additives may dam-
Use Ethylene Glycol
deionized water.
5

Kubota 2.4L Diesel 10.5 liter (11.1 qt)
CAUTION
Additives may dam-
Use Ethylene Glycol
deionized water.
Hydraulic Tank Oil Capacity
S2.0-3.5FT (S40-70FT, S55FTS)
(H187)
36.1 liter (38.1 qt) Initial Fill
30.1 liter (32.0 qt) Drain and Fill
CAUTION
Additives may dam-
age the hydraulic sys-
ISO VG-46 Hy-
draulic Oil
−15°C (5°F) and
above
H2.0-3.5FT (H40-70FT) (P177) 45.8 liter (48.4 qt) Initial Fill
39.8 liter (42.0 qt) Drain and Fill
CAUTION
Additives may dam-
age the hydraulic sys-
ISO VG-46 Hy-
draulic Oil
−15°C (5°F) and
above
6

Transmission - Aluminum Housing
Single Speed PS Transmission 13 liter (14.0 qt) John Deere
JDM J20C
DuraMatch Transmission 13 liter (14.0 qt) John Deere
JDM J20C
Transmission - Iron Housing
Basic PS Transmission 20 liter (21.0 qt) John Deere
JDM J20C
DuraMatch Transmission 20 liter (21.0 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)
(H187)
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) (P177)
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) (P177)
0.5 liter (0.5 qt) SAE 80W-90
Planetary Housing, Right Side
H2.0-3.5FT (H40-70FT) (P177)
2.0 liter (2.1 qt) SAE 80W-90
Wet Brake Portion Of Drive Axle Center Sec-
tion
H2.0-3.5FT (H40-70FT) (P177)
1.0 liter (1.1 qt) John Deere
JDM J20C
*Gas fuel used only on lift truck models S40FT, S50FT, S55FTS, S60FT, S70FT (H187) and H40FT,
H50FT, H60FT, H70FT (P177).
**Yanmar 3.0L diesel engine used only on lift truck models H2.0FT, H2.5FT, H3.0FT, H3.5FT (P177).
7

Electrical System
Item PSI 2.4L Kubota 2.5L Yanmar Kubota 2.4L
Battery 12-volt, negative
ground
12-volt, negative
ground
12-volt, negative
ground
12-volt, negative
ground
Spark Plugs TORCH DK7RTC N/A N/A N/A
Spark Plugs Stand-
ard
N/A NKG BKR6EiX N/A N/A
Spark Plugs Long-
life
N/A NKG 1FR6F8DN N/A N/A
Spark Plug Gap 0.9 mm
(0.035 in.)
0.7 to 0.8 mm
(0.028 to 0.032 in.)
N/A N/A
Ignition Timing:
Dual Fuel Not Adjustable - Coil
Over Plug Ignition
System
N/A N/A N/A
LPG Not Adjustable - Coil
Over Plug Ignition
System
0.52 rad (30 °) be-
fore T.D.C. /
2700 min-1 (rpm)
0.23 rad (13 °) be-
fore T.D.C. / 700
min-1 (rpm)
N/A N/A
Diesel N/A N/A 2.6L engine preset
@ 4° ATDC
3.3L engine preset
@ 6° ATDC
3.0 L engine preset
@ 4.5° ATDC
Not Adjustable
Electrical System 8000 SRM 1763
8

PSI 2.4L
Alternator Output (14 Volts) Dual Fuel
Cold Stabilized
Idle 35 amps @ 800 rpm 28 amps @ 800 rpm
High Idle 62 amps @ 2700 rpm 50 amps @ 2700 rpm
Kubota 2.5L
Alternator Output (14 Volts) LPG
Idle 20 amps @ 800 rpm
High Idle 80 amps @ 2500 rpm - 25°C (77°F) Ambient Temperature
65 amps @ 2500 rpm - Maximum Operating Temperature
Yanmar
Alternator Output (13.5 Volts) D DS
2.6L
Low Idle 14 amps @ 825 rpm 20 amps @ 825 rpm
3.0L
3.3L
Kubota 2.4L
Alternator Output (12 Volts) D
Idle 20 amps @ 800 rpm
High Idle 80 amps @ 2400 rpm - 25°C (77°F) Ambient Temperature
65 amps @ 2400 rpm - Maximum Operating Temperature
8000 SRM 1763 Electrical System
9

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).
Transmission Oil Pressures 8000 SRM 1763
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 Con-
verter
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 1763 Transmission Oil Pressures
11

General
This section has the repair procedures for the transmission.
SERIAL NUMBER
The transmission serial number is located on the right side of the transmission control valve directly below
the floor plate. See Figure 1.
Figure 1. Transmission Serial Number Location
Legend for Figure 1
1. TRANSMISSION SERIAL NUMBER
Charge Pump Repair
REMOVE
NOTE: The charge pump can be removed from the
transmission while it is still in the lift truck but, for
the sake of clarity, the following procedures are
shown with the transmission removed from the lift
truck.
Remove four mounting capscrews, washers, trans-
mission charge pump, and gasket from torque con-
verter housing. Discard gasket. See Figure 2.
INSPECT
Inspect the splines on shaft of transmission charge
pump for damage or worn areas that could affect
operation of the pump. If the splines are damaged,
replace the transmission charge pump.
1300 SRM 1764 General
1

INSTALL
Install new gasket, transmission charge pump, four washers, and mounting capscrews on torque converter
housing. Tighten capscrews in star pattern to 6 N•m (53 lbf in) on first pass. On second pass, tighten cap-
screws in star pattern to 19 N•m (168 lbf in). See Figure 2.
NOTE: THE TRANSMISSION IS SHOWN REMOVED FROM LIFT TRUCK FOR CLARITY.
1. CAPSCREW
2. WASHER
3. CHARGE PUMP
4. GASKET
5. TORQUE CONVERTER HOUSING
Figure 2. Transmission Charge Pump
Charge Pump Repair 1300 SRM 1764
2

Torque Converter Replace
REMOVE
WARNING
Make sure the engine and transmission are held
in position so that they will not fall and cause an
injury and damage to the equipment.
CAUTION
Be careful that you DO NOT damage parts of the
torque converter or transmission when the trans-
mission is separated from the engine. Keep the
transmission and engine in alignment until they
are completely separated so parts of the transmis-
sion are not damaged. Use a crane or lifting de-
vice to separate the transmission from the engine.
1. Remove engine and transmission as a unit from
lift truck. as described in Frame
0100SRM1754.
CAUTION
Use care when disconnecting the wiring harness
connectors from electrical connectors on the
transmission and control valve. The connectors
on the transmission and control valve are easily
damaged.
NOTE: When disconnecting wiring harness connec-
tors during disassembly, tag each connector to aid
in connecting the wiring harness during reassem-
bly.
2. Put engine and transmission on solid blocks on
a work surface.
Disconnect transmission wiring harness connec-
tors from control valve and transmission.
Remove transmission wiring harness from trans-
mission. See Figure 3.
1300 SRM 1764 Torque Converter Replace
3

1. PSI 2.4L ENGINE
2. CAPSCREW
3. TRANSMISSION WIRING HARNESS
4. CONTROL VALVE
5. TRANSMISSION
6. ACCESS COVER
Figure 3. Engine-Transmission Combination
WARNING
Make sure that the engine/transmission assembly
is stable before attempting to rotate the engine.
Use a flashlight to see the bolts as they are rota-
ted into view through the access hole. DO NOT
use your fingers to check for alignment of the
bolts with the access hole.
3. Move each bolt into view through access hole of
flywheel housing by rotating crankshaft. Re-
move four capscrews that attach flywheel to
torque converter. See Figure 4.
Torque Converter Replace 1300 SRM 1764
4

A. KUBOTA 2.5L ENGINE B. YANMAR 3.3L ENGINE C. PSI 2.4L ENGINE
1. ACCESS HOLE 2. FLYWHEEL HOUSING
Figure 4. Torque Converter Bolt Access
4. Remove access cover from torque converter housing. Install a lifting eye bolt into rear access cover bolt
hole, and connect a lifting device to eye bolt. Remove ten capscrews that hold torque converter housing to
flywheel housing on engine. Carefully separate transmission from engine.
NOTE: The torque converter cannot be repaired and must be replaced as a unit, if damaged.
5. Carefully remove torque converter from stator support. See Figure 5.
5

1. TRANSMISSION OIL FILTER
2. DIPSTICK
3. DIPSTICK TUBE
4. TRANSMISSION HOUSING
6. TRANSMISSION OIL TEMPERATURE SENSOR
7. SUCTION SCREEN
8. SUCTION SCREEN SPRING
9. PLUG
10. CAPSCREW
11. WASHER
12. SMALL ACCESS COVER
13. TORQUE CONVERTER
14. TRANSMISSION CHARGE PUMP
15. STATOR SUPPORT
16. PILOT HUB
Figure 5. Torque Converter Removal
6. Remove plug, suction screen spring, and suc-
tion screen from torque converter housing, and
drain oil from transmission. See Figure 5.
7. Remove transmission charge pump. See Charge
Pump Repair.
8. Remove transmission oil filter from torque con-
verter housing. See Figure 5.
9. If damaged, remove two cap screws and small
access cover from the torque converter housing.
10. Remove dipstick and dipstick tube from torque
converter housing. See Figure 5.
11. Remove transmission oil temperature sensor
from torque converter housing. See Figure 5.
6

NOTE: Perform Step 12 through Step 16 only if re-
pair of the of the transmission chain drive is re-
quired. If the transmission clutch packs are in need
of further repair, see Clutch Packs Repair.
12. Remove two long capscrews and washers from
inner face of torque converter housing. See Fig-
ure 7.
13. Remove 15 capscrews from transmission hous-
ing. See Figure 6.
14. Remove two mounting capscrews and harness
bracket from front of torque converter housing.
See Figure 6.
15. Using a small pry bar in the designated pry
points, remove the torque converter housing
from the transmission housing. See Figure 6.
16. Remove and discard O-rings and gasket. See
Figure 7.
1. PRY POINTS
4. HARNESS BRACKET
5. CAPSCREW
Figure 6. Pry Point Location
7

1. LONG CAPSCREW
2. WASHER
4. GASKET
6. O-RING
7. CAPSCREW
Figure 7. Torque Converter Housing
INSTALL
NOTE: Perform Step 1 through Step 4 only if re-
pair of the transmission chain drive was performed.
1. Install new O-rings and gasket to torque con-
verter housing and transmission housing. See
Figure 7.
2. Install harness bracket and two mounting cap-
screws to front of torque converter housing. See
Figure 6.
3. Using fifteen capscrews, install transmission
housing to torque converter housing. Tighten
capscrews to 38 N•m (28 lbf ft).
4. Install two washers and long capscrews into
face of torque converter housing. Tighten cap-
screws to 38 N•m (28 lbf ft). See Figure 7.
5. If removed, install small access cover and two
capscrews on torque converter housing. Tighten
capscrews to 7.9 N•m (69 lbf in). See Figure 8.
8

2. DIPSTICK
3. DIPSTICK TUBE
7. SUCTION SCREEN
9. PLUG
10. CAPSCREW
11. WASHER
15. STATOR SUPPORT
16. PILOT HUB
Figure 8. Torque Converter Installation
6. Install a new transmission oil filter on torque
converter housing.
7. Install the transmission charge pump. See
Charge Pump Repair.
8. Install suction screen, suction screen spring,
and plug into torque converter housing. See
Figure 8.
9. Install torque converter onto stator support.
Make sure splines are aligned and converter
engages fully. See Figure 8.
10. Lubricate the pilot hub on the torque converter
with antiseize compound. See Figure 8.
11. Install transmission oil temperature sensor on
torque converter housing. See Figure 8.
NOTE: Apply adhesive to entire surface of hole,
20.0 mm (0.79 in.) deep. Also apply adhesive to
lower 20.0 mm (0.79 in.) of dipstick tube.
12. Install dipstick tube and dipstick into torque
13. If removed, install a lifting eye bolt into rear ac-
cess cover bolt hole, and connect a lifting device
to eye bolt.
Align torque converter housing with flywheel
housing. Make sure pilot hub on torque con-
verter engages flywheel.
9

CAUTION
Be careful that you DO NOT damage parts of the
torque converter or transmission when the trans-
mission is joined to the engine. Keep the trans-
mission and engine in alignment until they are
completely joined so parts of the transmission are
not damaged. Use a crane or lifting device to join
the transmission to the engine.
14. Install transmission on engine. Install ten cap-
screws that connect torque converter housing to
flywheel housing. Tighten capscrews to
38 N•m (28 lbf ft). See Figure 9.
CAUTION
Use care when connecting the wiring harness
connectors to electrical connectors on the trans-
mission and control valve. The connectors on the
transmission and control valve are easily dam-
aged.
15. Install transmission wiring harness on trans-
mission. Connect transmission wiring harness
connectors to control valve and transmission.
See Figure 9.
10

1. PSI 2.4L ENGINE
2. CAPSCREW
4. CONTROL VALVE
5. TRANSMISSION
6. ACCESS COVER
11

A. KUBOTA 2.5L ENGINE B. YANMAR 3.3L ENGINE C. PSI 2.4L ENGINE
NOTE: Coat the bolt threads that hold the torque
converter to flywheel with Loctite™ 242.
16. Rotate engine crankshaft to position the fly-
wheel mounting holes in line with torque con-
verter mounting holes. Install capscrews that
hold torque converter to flywheel through ac-
cess hole of flywheel housing. See Figure 10.
Tighten capscrews to 56 N•m (41 lbf ft).
Remove lifting eye bolt, and install access cover
on torque converter housing.
WARNING
17. Install engine and transmission as a unit into
lift truck as described in Frame
0100SRM1754.
18. Fill transmission to correct level using trans-
mission fluid and procedure indicated in Peri-
odic Maintenance 8000SRM1762.
12

Housings and Chain Drive Repair
REMOVE
WARNING
CAUTION
Keep the transmission and engine in alignment
until they are completely separated so parts of the
transmission are not damaged. Use a crane or lift-
ing device to separate the transmission from the
engine.
1. Remove engine and transmission as a unit from
lift truck as described in Frame
0100SRM1754.
CAUTION
To prevent possible damage to the transmission
assembly when placing the assembly on a work
surface, place blocks under the back side of the
transmission housing for additional support.
CAUTION
Use care when disconnecting the wiring harness
connectors from electrical connectors on the
transmission and control valve. The connectors
on the transmission and control valve are easily
damaged.
NOTE: When disconnecting wiring harness connec-
tors during disassembly, tag each connector to aid
in connecting the wiring harness during reassem-
bly.
2. Put engine and transmission on solid blocks on
a work surface. Disconnect transmission wiring
connectors from control valve and transmission.
Remove transmission wiring harness from
transmission. See Figure 11.
1300 SRM 1764 Housings and Chain Drive Repair
13

1. PSI 2.4L ENGINE
2. CAPSCREW
4. CONTROL VALVE
5. TRANSMISSION
6. ACCESS COVER
WARNING
Make sure that the engine/transmission assembly
is stable before attempting to rotate the engine.
Use a flashlight to see the bolts as they are rota-
ted into view through the access hole. DO NOT
use your fingers to check for alignment of the
bolts with the access hole.
3. Move each bolt into view through access hole of
flywheel housing by rotating crankshaft. Re-
move four capscrews that attach flywheel to
torque converter. See Figure 12.
Housings and Chain Drive Repair 1300 SRM 1764
14

A. KUBOTA 2.5L ENGINE
B. YANMAR 3.3L ENGINE
C. PSI 2.4L ENGINE
4. Remove access cover from torque converter housing. Install a lifting eye bolt into rear access cover bolt
hole, and connect a lifting device to eye bolt. Remove ten capscrews that hold torque converter housing to
flywheel housing. Carefully separate transmission from the engine.
5. Carefully remove torque converter from stator support. See Figure 13.
15

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2. DIPSTICK
3. DIPSTICK TUBE
7. SUCTION SCREEN
9. PLUG
10. CAPSCREW
11. WASHER
15. STATOR SUPPORT
16. PILOT HUB
Figure 13. Torque Converter Housing Removal
6. Remove plug, suction screen spring, and suc-
tion screen from torque converter housing and
drain oil from the transmission.Figure 13
7. Remove transmission charge pump. See Charge
Pump Repair.
8. Remove two long capscrews and washers from
inner face of torque converter housing. See Fig-
ure 14.
16

1. LONG CAPSCREW
2. WASHER
4. GASKET
6. O-RING
7. CAPSCREW
Figure 14. Torque Converter Housing
9. Remove 15 capscrews from transmission hous-
ing. See Figure 15.
10. Remove two mounting capscrews and harness
bracket from front of torque converter housing.
See Figure 15.
11. Using a small pry bar in the designated pry
points, remove the torque converter housing
from the transmission housing. See Figure 15.
17

1. PRY POINTS
4. HARNESS BRACKET
5. CAPSCREW
Figure 15. Pry Point Location
12. Remove and discard O-rings and gasket. See
Figure 14.
NOTE: While performing Step 13, note position of
oil seal to aid in installation of new oil seal.
13. Remove and discard oil seal from rear of torque
14. Remove two snubbers from transmission hous-
ing. See Figure 16.
15. Carefully remove pump drive chain, driven
sprocket, driving sprocket, and bearings from
transmission housing. See Figure 16.
16. Remove bearing from driven sprocket. See Fig-
ure 16.
17. Remove angular contact bearing, bushing, and
O-ring from driving sprocket. Discard O-ring.
See Figure 16.
18. Remove four capscrews, lockwashers, and sta-
tor support from transmission housing. Remove
and discard sealing ring and O-ring from stator
support. See Figure 16.
19. Remove baffle from transmission housing. See
Figure 16.
20. Remove O-rings from transmission housing and
discard. See Figure 16.
18

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Hyster p177 (h2.0 ft europe) forklift service repair manual