Hyster J006 Operating instructions

Hyster J006 (H135FT, H155FT) Forklift Service Repair
Manual

DRIVE AXLE AND
DIFFERENTIAL
ASSEMBLY REPAIR
(WET BRAKE)
H6.0FT, H7.0FT (H135FT, H155FT)
[H006, J006, K006, L006];
H8.0FT, H8.0FT9, H9.0FT
(H170FT, H175FT36, H190FT)
[A299, B299, C299]
PART NO. 1661537 1400 SRM 1344

SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• The Service Manuals are updated on a regular basis, but may not reflect recent design changes to the
product. Updated technical service information may be available from your local authorized Hyster®
dealer. Service Manuals provide general guidelines for maintenance and service and are intended for
use by trained and experienced technicians. Failure to properly maintain equipment or to follow in-
structions contained in the Service Manual could result in damage to the products, personal injury,
property damage or death.
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and
that the load being lifted is balanced. Make sure the crane, cables, and chains have the capacity to
support the weight of the load.
• Do not lift heavy parts by hand, use a lifting mechanism.
• Wear safety glasses.
• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift
trucks. Disconnect the battery ground cable on internal combustion lift trucks.
• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT
TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance section.
• Keep the unit clean and the working area clean and orderly.
• Use the correct tools for the job.
• Keep the tools clean and in good condition.
•Always use HYSTER APPROVED parts when making repairs. Replacement parts must meet or ex-
ceed the specifications of the original equipment manufacturer.
• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to
remove parts.
• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the unit
needs repairs.
•Be sure to follow the WARNING and CAUTION notes in the instructions.
• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are flamma-
ble. Be sure to follow the necessary safety precautions when handling these fuels and when working
on these fuel systems.
• Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the
area. Make sure the area is well ventilated.
NOTE: The following symbols and words indicate safety information in this
manual:
WARNING
Indicates a hazardous situation which, if not avoided, could result in death
or serious injury.
CAUTION
Indicates a hazardous situation which, if not avoided, could result in minor
or moderate injury and property damage.
On the lift truck, the WARNING symbol and word are on orange back-
ground. The CAUTION symbol and word are on yellow background.

©2015 HYSTER COMPANY
TABLE OF CONTENTS
General .....................................................................................................................................................................1
Identification Plate ............................................................................................................................................. 1
Drive Axle Removal .................................................................................................................................................2
Planetary Reduction Gear Repair ........................................................................................................................ 12
Remove and Disassemble ................................................................................................................................. 12
Clean and Inspect ............................................................................................................................................. 22
Assemble and Install ........................................................................................................................................ 22
Brake Repair ..........................................................................................................................................................30
Remove and Disassemble ................................................................................................................................. 30
Clean and Inspect ............................................................................................................................................. 42
Assemble and Install ........................................................................................................................................ 42
Differential Repair ................................................................................................................................................ 52
Remove .............................................................................................................................................................. 52
Disassemble .......................................................................................................................................................57
Clean and Inspect ............................................................................................................................................. 63
Assemble ............................................................................................................................................................63
Install .................................................................................................................................................................70
Bevel Pinion ...........................................................................................................................................................75
Remove and Disassemble ................................................................................................................................. 75
Clean and Inspect ............................................................................................................................................. 79
Assemble and Install ........................................................................................................................................ 80
Drive Axle Installation ..........................................................................................................................................89
Special Tools ........................................................................................................................................................ 101
Torque Specifications .......................................................................................................................................... 102
This section is for the following models:
H6.0FT, H7.0FT (H135FT, H155FT) [H006, J006, K006, L006];
H8.0FT, H8.0FT9, H9.0FT (H170FT, H175FT36, H190FT) [A299, B299, C299]
Table of Contents
i

"THE
QUALITY
KEEPERS"
HYSTER
APPROVED
PARTS

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General
This manual covers the repair of the drive axle,
differential, and the wet disc brakes.
IDENTIFICATION PLATE
See Figure 1.
1. DANA PART NUMBER
2. DANA SERIAL NUMBER
3. HYSTER PART NUMBER
4. AXLE OVERALL RATIO
Figure 1. Identification Plate
1400 SRM 1344 General
1

Drive Axle Removal
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 Repairs, 2- and 3-Stage Masts (S/N
A513, A514, A613, A614, A702, A703, A704,
A705, A706, A707, A751, A752, B513, B514,
B586, B587, B588, B589, B590, B591, B749,
B750, B751, B752, B753, B754) 4000SRM1250
for lift truck models
• H6.0FT, H7.0FT (H135FT, H155FT)
(H006, J006, K006)
Mast Repair (S/N A513, A514, A613, A614,
A643, A644, A683, A684) 4000SRM1406 for lift
truck models
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (A299, B299)
.
Mast Repair (S/N A613, A614, A643, A644,
A683, A684) 4000SRM1956for lift truck models
• H6.0FT, H7.0FT (H135FT, H155FT)
(L006)
Mast Repair (S/N A613, A614, A643, A644,
A683, A684) 4000SRM1956 for lift truck models
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (C299)
.
WARNING
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.
4. Remove the air from the tires and remove the
wheels.
NOTE: Perform Step 5 through Step 23 for lift
truck models H6.0FT, H7.0FT (H135FT, H155FT)
(H006, J006, K006, L006), .
5. Remove the drive axle main housing center fill/
level plug and O-ring. See Figure 2.
6. Remove the oil fill plugs and O-rings on both
sides of the drive axle. See Figure 2.
7. Remove the oil drain plugs on both sides of the
drive axle. Drain the oil into a suitable con-
tainer. See Figure 2.
8. Remove the drive axle main housing center
drain plug. Drain the oil into a suitable con-
tainer. See Figure 2.
Drive Axle Removal 1400 SRM 1344
2

1. DRIVE AXLE MAIN HOUSING CENTER DRAIN
PLUG
2. OIL FILL PLUG, RIGHT SIDE
3. O-RING
4. OIL FILL PLUG, LEFT SIDE
5. OIL DRAIN PLUG, LEFT SIDE
6. DRIVE AXLE MAIN HOUSING CENTER FILL/
LEVEL PLUG
7. OIL DRAIN PLUG, RIGHT SIDE
Figure 2. Drive Axle Drain and Fill/Level Plugs for Lift Truck Models H6.0FT, H7.0FT (H135FT, H155FT)
(H006, J006, K006, L006),
1400 SRM 1344 Drive Axle Removal
3

9. Remove the parking brake cables. Refer to the
section
Brake System 1800SRM1247 for lift truck mod-
els
• H6.0FT, H7.0FT (H135FT, H155FT)
(H006, J006, K006)
.
Brake System 1800SRM1247 for lift truck mod-
els
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (A299, B299)
.
Wet Brake System 1800SRM1977 for lift truck
models
• H6.0FT, H7.0FT (H135FT, H155FT)
(L006)
.
Wet Brake System 1800SRM1977 for lift truck
models
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (C299)
.
10. Disconnect the brake supply line from the
brake line cross fitting on the drive axle. See
Figure 3.
11. Disconnect the accumulator/brake booster sup-
ply line from the manifold on the drive axle.
See Figure 3.
12. Disconnect the brake booster return line from
the manifold on the drive axle. See Figure 3.
NOTE: Note placement of hose clamps prior to re-
moval of hoses to aid in installation.
13. Disconnect the drive axle to transmission cool-
ing return hose from the manifold on the drive
axle. See Figure 3.
14. Disconnect the transmission to drive axle cool-
ing supply hose from the manifold on the drive
axle. See Figure 3.
Drive Axle Removal 1400 SRM 1344
4

Figure 3. Drive Axle and Brake Cooling Lines and Brake Lines for Lift Truck Models H6.0FT, H7.0FT
(H135FT, H155FT) (H006, J006, K006, L006)
1400 SRM 1344 Drive Axle Removal
5

Legend for Figure 3
1. ACCUMULATOR
2. TRANSMISSION TO DRIVE AXLE COOLING
SUPPLY HOSE
3. DRIVE AXLE TO TRANSMISSION COOLING
RETURN HOSE
4. DRIVE AXLE COOLING RETURN HOSE, LEFT
SIDE
5. BRAKE COOLING LINE, LEFT SIDE
6. BRAKE LINE, LEFT SIDE
7. ACCUMULATOR/BRAKE BOOSTER SUPPLY
LINE
8. BRAKE BOOSTER RETURN LINE
9. BRAKE SUPPLY LINE
10. BRAKE COOLING LINE, RIGHT SIDE
11. BRAKE LINE, RIGHT SIDE
12. DRIVE AXLE COOLING RETURN HOSE, RIGHT
SIDE
15. Place blocks under the axle assembly and con-
nect slings and lifting device.
16. Remove the capscrews retaining the drive
shaft. Remove the drive shaft.
17. Remove the four mounting capscrews and
washers from the drive axle. See Figure 4.
18. Remove blocks and lower the drive axle assem-
bly. Pull axle forward and away from frame.
19. Place blocks under the differential assembly.
20. Disconnect the cooling hoses from the manifold
and drive axle. Remove the cooling hoses. See
Figure 5.
21. Disconnect the brake cooling lines from the
manifold and the drive axle. Remove the brake
cooling lines. See Figure 5.
22. Remove the socket head screws retaining the
brake manifold to the drive axle. Remove the
manifold. See Figure 5.
23. Disconnect the brake lines from the drive axle.
Remove the brake lines with cross fitting, as an
assembly, from the drive axle. See Figure 5.
1. CAPSCREW
2. WASHER
3. DRIVE AXLE
Figure 4. Drive Axle Mounting Capscrews
Drive Axle Removal 1400 SRM 1344
6

1. MANIFOLD
2. DRIVE AXLE COOLING RETURN HOSE, LEFT
SIDE
3. BRAKE COOLING LINE, LEFT SIDE
4. BRAKE LINE, LEFT SIDE
5. SOCKET HEAD SCREWS
6. CROSS FITTING
7. BRAKE COOLING LINE, RIGHT SIDE
8. BRAKE LINE, RIGHT SIDE
9. DRIVE AXLE COOLING RETURN HOSE, RIGHT
SIDE
Figure 5. Manifold and Cooling Hoses Removal for Lift Truck Models H6.0FT, H7.0FT (H135FT, H155FT)
(H006, J006, K006, L006)
1400 SRM 1344 Drive Axle Removal
7

NOTE: Perform Step 24 through Step 43 for lift
truck model H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (A299, B299, C299), .
24. Remove drive axle main housing center fill plug
from main housing. See Figure 6.
25. Remove right side and left side drain plugs
from drive axle. Drain oil into suitable con-
tainer. See Figure 6.
26. Remove drive axle main housing center drain
plug from main housing, Drain oil into suitable
container. See Figure 6.
27. Remove the parking brake cables. Refer to the
section
Brake System 1800SRM1247 for lift truck mod-
els
• H6.0FT, H7.0FT (H135FT, H155FT)
(H006, J006, K006)
Brake System 1800SRM1247 for lift truck mod-
els
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (A299, B299)
.
Wet Brake System 1800SRM1977 for lift truck
models
• H6.0FT, H7.0FT (H135FT, H155FT)
(L006)
Wet Brake System 1800SRM1977 for lift truck
models
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (C299)
.
NOTE: Note placement of hose clamps prior to re-
moval of hoses to aid in installation.
28. Disconnect load sense in and load sense out
hose assemblies from accumulator charge
valve. See Figure 7.
29. Disconnect brake line from modulating brake
valve. See Figure 7.
30. Disconnect hydraulic pressure supply hose from
accumulator charge valve. See Figure 7.
31. Disconnect hydraulic return hose from accumu-
lator charge valve and modulating brake valve.
See Figure 7.
Drive Axle Removal 1400 SRM 1344
8

1. DRIVE AXLE MAIN HOUSING CENTER DRAIN
PLUG
2. DRIVE AXLE MAIN HOUSING CENTER FILL
PLUG
3. RIGHT SIDE DRAIN PLUG
4. LEFT SIDE DRAIN PLUG
Figure 6. Drive Axle Drain and Fill Plugs for Lift Truck Model H8.0FT, H8.0FT9, H9.0FT (H170FT, H175FT36,
H190FT) (A299, B299, C299),
1400 SRM 1344 Drive Axle Removal
9

Figure 7. Drive Axle, Manifold, Cooling Hoses, and Brake Lines for Lift Truck Model H8.0FT, H8.0FT9,
H9.0FT (H170FT, H175FT36, H190FT) (A299, B299, C299)
Drive Axle Removal 1400 SRM 1344
10

Legend for Figure 7
A. FRONT VIEW B. REAR VIEW
1. MODULATING BRAKE VALVE
2. BRAKE LINE
3. LOAD SENSE IN HOSE ASSEMBLY
4. LOAD SENSE OUT HOSE ASSEMBLY
5. ACCUMULATOR CHARGE VALVE
6. HYDRAULIC PRESSURE SUPPLY HOSE
7. HYDRAULIC RETURN HOSE
8. COOLING RETURN HOSE
9. MANIFOLD
10. DRIVE AXLE
11. COOLING RETURN TO TRANSMISSION HOSE
12. COOLING SUPPLY FROM TRANSMISSION
HOSE
13. AXLE VENT LINE
14. COOLING SUPPLY LINES
15. SOCKET HEAD SCREW
16. BRAKE LINE
1400 SRM 1344 Drive Axle Removal
11

32. Place blocks under the axle assembly. Connect
slings and lifting device to axle assembly.
33. Remove the capscrews and the drive shaft from
the drive axle.
34. Remove the four mounting capscrews and
washers from the drive axle. See Figure 8.
35. Remove blocks and lower the drive axle assem-
bly. Pull axle forward and away from frame.
36. Place blocks under the differential assembly.
37. Remove cooling return hoses from manifold and
drive axle. See Figure 7.
38. Disconnect cooling return to transmission hose
from manifold. See Figure 7.
39. Disconnect cooling supply from transmission
hose from manifold. See Figure 7.
40. Disconnect axle vent line from drive axle. See
Figure 7.
41. Remove cooling supply lines from manifold and
drive axle. See Figure 7.
42. Remove two socket head screws and manifold
from drive axle. See Figure 7.
43. Disconnect brake lines from drive axle. Remove
brake lines with cross fitting, as an assembly,
from drive axle. See Figure 7.
1. CAPSCREW
2. WASHER
3. DRIVE AXLE
Figure 8. Drive Axle Mounting Capscrews
Planetary Reduction Gear Repair
REMOVE AND DISASSEMBLE
Refer to Figure 9 and Figure 10 for the following repair procedures.
Drive Axle Removal 1400 SRM 1344
12

1. O-RING
2. OIL LEVEL PLUG
3. DRIVE AXLE HOUSING ARM
4. CAPSCREW
5. O-RING
6. RING GEAR
7. WHEEL HUB SUPPORT
8. AXLE SHAFT
9. SOCKET HEAD SCREW
10. SHOULDER RING
11. CAPSCREW
12. WHEEL STUD
13. BEARING
14. WHEEL HUB
15. BEARING
16. SEAL
17. CAPSCREW
18. OUTER AXLE SHAFT
19. O-RING
20. PLANETARY GEAR CARRIER
21. CENTERING RING
22. RETAINING SCREW
23. SUN GEAR
24. DRAIN PLUG
25. RETAINING RING
26. PLANETARY GEAR
Figure 9. Planetary Reduction Gear Assembly for Lift Truck Models H6.0FT, H7.0FT (H135FT, H155FT)
(H006, J006, K006, L006)
1400 SRM 1344 Planetary Reduction Gear Repair
13

1. AXLE CASE - LH
2. O-RING
3. HEXAGON BOLT
4. RING GEAR
5. CAPSCREW
6. SEAL
7. INNER BEARING
8. WHEEL HUB
9. WHEEL STUD
10. WHEEL HUB SUPPORT
11. BEARING
12. SHOULDER RING
13. OUTER AXLE SHAFT
14. RETAINING RING
15. PLANETARY GEAR
16. SUN GEAR
17. CENTERING RING
18. PLANETARY GEAR CARRIER
19. PLUG
20. MAGNET PLUG
21. HALF SHAFT - SHORT OR LONG
22. AXLE CASE - RH
23. SOCKET HEAD SCREW
24. RETAINING SCREW
25. CAPSCREW
26. OUTER BEARING
Figure 10. Planetary Reduction Gear Assembly for Lift Truck Model H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (A299, B299, C299)
Planetary Reduction Gear Repair 1400 SRM 1344
14