Hyster R005 Operating instructions

Hyster R005 (H80FT, H90FT, H100FT, H110FT, H120FT)
Forklift Service Repair Manual

DRIVE AXLE AND
DIFFERENTIAL
ASSEMBLY REPAIR
(WET BRAKE - NMHG)
S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT;
S80, 100FTBCS; S120FTS; S120FTPRS)
[H004, J004];
H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT
(H80, 90, 100, 110, 120FT) [R005, S005, U005]
PART NO. 4053147 1400 SRM 1582

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 .................................................................................................................................................1
Reduction Gear Assembly .......................................................................................................................................5
Remove ................................................................................................................................................................ 5
Disassemble .........................................................................................................................................................9
Clean and Inspect ............................................................................................................................................. 13
Assemble ............................................................................................................................................................13
Install .................................................................................................................................................................20
Wet Disc Brake Repair ..........................................................................................................................................21
General .............................................................................................................................................................. 21
Remove .............................................................................................................................................................. 21
Clean and Inspect ............................................................................................................................................. 26
Install .................................................................................................................................................................27
Initial Steps For Install ................................................................................................................................27
Shimming Brake Disc Pack ..........................................................................................................................31
Final Steps For Install ................................................................................................................................. 34
Piston Housing ...................................................................................................................................................... 36
Remove .............................................................................................................................................................. 36
Disassemble .......................................................................................................................................................37
Clean and Inspect ............................................................................................................................................. 38
Assemble ............................................................................................................................................................38
Install .................................................................................................................................................................38
Parking Brake Control Lever ............................................................................................................................... 39
Remove .............................................................................................................................................................. 39
Clean and Inspect ............................................................................................................................................. 40
Install .................................................................................................................................................................40
Differential Repair ................................................................................................................................................ 42
Initial Removal Steps for Differential Housing and drive axle trumpet arm (right side) ............................ 42
Input Pinion Carrier ......................................................................................................................................... 42
Remove .............................................................................................................................................................. 42
Disassemble .......................................................................................................................................................43
Clean and Inspect ............................................................................................................................................. 44
Assemble ............................................................................................................................................................44
Preload Pinion Bearings ...................................................................................................................................45
Differential Housing and Drive Axle Trumpet Arm (Right Side) .................................................................. 46
Remove .............................................................................................................................................................. 47
Disassemble .......................................................................................................................................................47
Clean and Inspect ............................................................................................................................................. 48
Assemble ............................................................................................................................................................48
Install .................................................................................................................................................................49
Ring Gear Backlash .......................................................................................................................................... 50
Final Installation Steps for Differential Housing and drive axle trumpet arm (right side) .........................51
Pinion and Motor Carrier ................................................................................................................................. 51
Install .................................................................................................................................................................51
Drive Axle Installation ..........................................................................................................................................55
Special Tools ......................................................................................................................................................59
Torque specifications .............................................................................................................................................59
Table of Contents
i

This section is for the following models:
S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; S80, 100FTBCS; S120FTS;
S120FTPRS) [H004, J004];
H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT)
[R005, S005, U005]
Table of Contents
ii

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General
This manual covers the repair of the drive axle,
differential, and wet disc brakes.
IDENTIFICATION PLATE
See Figure 1.
1. IDENTIFICATION PLATE
Figure 1. Identification Plate
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
steering tires to prevent movement of 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 Repairs (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.
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.
4. Remove wheels.
5. Remove fill plugs on both sides of drive axle.
See Figure 2 for lift truck models
• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100,
120FT; S80, 100FTBCS; S120FTS;
S120FTPRS) (H004, J004)
See Figure 3 for lift truck models
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(R005, S005, U005)
6. Remove the drive axle trumpet arm (right side)
fill/level plug.
See Figure 2 for lift truck models
• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100,
120FT; S80, 100FTBCS; S120FTS;
S120FTPRS) (H004, J004)
1400 SRM 1582 General
1

See Figure 3 for lift truck models
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(R005, S005, U005)
7. Remove the drain plugs to drain the oil into a
suitable container.
See Figure 2 for lift truck models
• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100,
120FT; S80, 100FTBCS; S120FTS;
S120FTPRS) (H004, J004)
See Figure 3 for lift truck models
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(R005, S005, U005)
8. Remove the parking brake cable. Refer to the
section Wet Brakes - NMHG 1800SRM1597.
A. TOP VIEW SHOWN B. BOTTOM VIEW SHOWN
1. SERVICE BRAKE PORT
2. FILL PLUG
3. OIL BREATHER
4. FILL/LEVEL PLUG
5. BRAKE BLEEDER VALVE
6. DRAIN PLUG
Figure 2. Drive Axle Drain and Fill/Level Plugs for Lift Truck Models S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100,
120FT; S80, 100FTBCS; S120FTS; S120FTPRS) (H004, J004)
Drive Axle Removal 1400 SRM 1582
2

A. TOP VIEW SHOWN B. BOTTOM VIEW SHOWN
1. SERVICE BRAKE PORT
2. FILL PLUG
3. OIL BREATHER
4. FILL/LEVEL PLUG
5. BRAKE BLEEDER VALVE
6. DRAIN PLUG
Figure 3. Drive Axle Drain and Fill/Level Plugs for Lift Truck Models H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
H5.0-5.5FT (H80, 90, 100, 110, 120FT) (R005, S005, U005)
1400 SRM 1582 Drive Axle Removal
3

9. Disconnect the brake line from the piston
chamber and drain oil into a suitable container.
See Figure 4.
1. BRAKE LINE
Figure 4. Brake Line and Piston Chamber
10. Place blocks under the axle assembly and con-
nect slings and lifting device.
11. Place blocks under the transmission to support
the transmission while removing the drive axle.
12. Remove the capscrews holding the drive shaft
and remove the drive shaft.
13. Remove the transmission isolator mounting
bolt located on top of the assembly. See Fig-
ure 5.
14. Remove the four mounting capscrews and
washers from the drive axle. See Figure 6.
15. Remove blocks and lower the drive axle assem-
bly. Pull axle forward and away from frame.
16. Place blocks under the differential assembly.
NOTE: DRIVE AXLE FOR H4.0FT5/FT6; H4.5FTS5,
H4.5FT6, H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(R005, S005, U005) SHOWN. TRANSMISSION
MOUNTING FOR S4.0, 4.5, 5.5FT, S5.5FTS (S80,
100, 120FT; S80, 100FTBCS; S120FTS;
S120FTPRS) (H004, J004) IS SIMILAR.
1. ISOLATORS
2. WASHER
3. WASHER
4. CAPSCREW
5. TRANSMISSION
6. DRIVE AXLE
Figure 5. Transmission to Differential Mounting
Bolt
Drive Axle Removal 1400 SRM 1582
4

Figure 6. Drive Axle Mounting Capscrews
Legend for Figure 6
NOTE: DRIVE AXLE FOR H4.0FT5/FT6; H4.5FTS5,
H4.5FT6, H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(R005, S005, U005) SHOWN. TRANSMISSION
MOUNTING FOR S4.0, 4.5, 5.5FT, S5.5FTS (S80,
100, 120FT; S80, 100FTBCS; S120FTS;
S120FTPRS) (H004, J004) IS SIMILAR.
1. CAPSCREW
2. WASHER
3. DRIVE AXLE
Reduction Gear Assembly
REMOVE
1. Remove fourteen capscrews in wheel hub cou-
pler.
See Figure 7 for lift truck models
• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100,
120FT; S80, 100FTBCS; S120FTS;
S120FTPRS) (H004, J004)
See Figure 8 for lift truck models
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(R005, S005, U005)
2. Install two of fourteen capscrews in wheel hub
removal holes. DO NOT tighten capscrews.
See Figure 9 for lift truck models
• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100,
120FT; S80, 100FTBCS; S120FTS;
S120FTPRS) (H004, J004)
See Figure 10 for lift truck models
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(R005, S005, U005)
3. Once capscrews are snug, begin an alternating
tightening sequence between two capscrews.
Make sure to turn each capscrew same amount
before returning to previous capscrew. Before
capscrews bottom out, wheel hub coupler will
be freed from wheel hub.
4. Once wheel hub coupler is free, bearing cap
may be driven free from wheel hub coupler (if it
shows signs of damage) with a soft hammer/
mallet. Discard bearing cap if removed.
5. Remove two O-rings from wheel hub coupler
and discard.
See Figure 9 for lift truck models
• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100,
120FT; S80, 100FTBCS; S120FTS;
S120FTPRS) (H004, J004)
See Figure 10 for lift truck models
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(R005, S005, U005)
6. Remove ten capscrews holding retaining plate
to wheel bearing support. See Figure 11.
7. Rotate wheel hub to access socket head cap-
screws in wheel bearing support.
8. Remove twelve socket head capscrews in wheel
bearing support. See Figure 12.
9. Remove reduction gear assembly from drive
axle trumpet arm (left side). See Figure 12.
10. Remove and discard O-ring. See Figure 12 de-
pending on lift truck model.
1400 SRM 1582 Drive Axle Removal
5

NOTE: LEFT REDUCTION GEAR SHOWN. THE COMPONENTS FOR RIGHT SIDE ARE SAME.
1. CAPSCREW
2. BEARING CAPS
3. WHEEL HUB COUPLER
4. O-RING
5. SNAP RING
6. RETAINER PLATE
7. BEARING SET
8. WHEEL HUB
9. WHEEL STUD
10. SEAL
11. SOCKET HEAD CAPSCREW
12. WHEEL BEARING SUPPORT
13. RING GEAR
14. PLANETARY CARRIER
15. PLANETARY GEAR
Figure 7. Reduction Gear Assembly for Lift Truck Model S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; S80,
100FTBCS; S120FTS; S120FTPRS) (H004, J004)
Reduction Gear Assembly 1400 SRM 1582
6

NOTE: LEFT REDUCTION GEAR SHOWN. THE COMPONENTS FOR RIGHT SIDE ARE SAME.
1. CAPSCREW
2. BEARING CAPS
3. WHEEL HUB COUPLER
4. O-RING
5. SNAP RING
6. RETAINER PLATE
7. BEARING SET
8. WHEEL HUB
9. WHEEL STUD
10. SEAL
11. SOCKET HEAD CAPSCREW
12. WHEEL BEARING SUPPORT
13. RING GEAR
14. PLANETARY CARRIER
15. PLANETARY GEAR
Figure 8. Reduction Gear Assembly for Lift Truck Model H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-5.5FT
(H80, 90, 100, 110, 120FT) (R005, S005, U005)
1400 SRM 1582 Reduction Gear Assembly
7

1. WHEEL HUB COUPLER
2. CAPSCREWS
3. REMOVAL HOLES
4. WHEEL HUB
5. BEARING CAP
6. O-RING
Figure 9. Wheel Hub Coupler for Lift Truck Models
S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; S80,
100FTBCS; S120FTS; S120FTPRS) (H004, J004)
Figure 10. Wheel Hub Coupler for Lift Truck
Models H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
H5.0-5.5FT (H80, 90, 100, 110, 120FT) (R005, S005,
U005)
Legend for Figure 10
1. WHEEL HUB COUPLER
2. CAPSCREWS
3. REMOVAL HOLES
4. WHEEL HUB
5. BEARING CAP
6. O-RING
NOTE: RETAINING PLATE FOR LIFT TRUCK MOD-
ELS S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT;
S80, 100FTBCS; S120FTS; S120FTPRS) (H004,
J004) SHOWN. H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
H5.0-5.5FT (H80, 90, 100, 110, 120FT) (R005, S005,
U005) IS SIMILAR.
1. RETAINING PLATE
2. CAPSCREW
3. SNAP RING
Figure 11. Retaining Plate
Reduction Gear Assembly 1400 SRM 1582
8

NOTE: REDUCTION GEAR FOR H4.0FT5/FT6;
H4.5FTS5, H4.5FT6, H5.0-5.5FT (H80, 90, 100, 110,
120FT) (R005, S005, U005) SHOWN. S4.0, 4.5,
5.5FT, S5.5FTS (S80, 100, 120FT; S80, 100FTBCS;
S120FTS; S120FTPRS) (H004, J004) IS SIMILAR.
1. SOCKET HEAD CAPSCREW
2. O-RING
3. REDUCTION GEAR ASSEMBLY
4. DRIVE AXLE TRUMPET ARM (LEFT SIDE)
Figure 12. Removing Reduction Gear From Drive
Axle Trumpet Arm (Left Side) for Lift Truck
Models H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
H5.0-5.5FT (H80, 90, 100, 110, 120FT) (R005, S005,
U005)
DISASSEMBLE
1. Place reduction gear assembly in a soft jawed
vise.
2. Remove planetary gear carrier. See Figure 13.
3. Remove ring gear.
See Figure 13 for lift truck models
• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100,
120FT; S80, 100FTBCS; S120FTS;
S120FTPRS) (H004, J004)
See Figure 14 for lift truck models
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(R005, S005, U005)
4. Remove snap ring from planetary gear carrier
in front of planetary gear.
See Figure 13 for lift truck models
• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100,
120FT; S80, 100FTBCS; S120FTS;
S120FTPRS) (H004, J004)
See Figure 14 for lift truck models
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(R005, S005, U005)
1. REDUCTION GEAR ASSEMBLY
2. WHEEL HUB
3. WHEEL BEARING SUPPORT
4. RING GEAR
5. PLANETARY GEAR CARRIER
6. PLANETARY GEAR
7. SNAP RING
Figure 13. Planetary Gears and Ring Gear
Removal for Lift Truck Models S4.0, 4.5, 5.5FT,
S5.5FTS (S80, 100, 120FT; S80, 100FTBCS;
S120FTS; S120FTPRS) (H004, J004)
1400 SRM 1582 Reduction Gear Assembly
9

1. REDUCTION GEAR ASSEMBLY
2. WHEEL HUB
3. WHEEL BEARING SUPPORT
4. RING GEAR
5. PLANETARY GEAR CARRIER
6. PLANETARY GEAR
7. SNAP RING
Figure 14. Planetary Gears and Ring Gear
Removal for Lift Truck Models H4.0FT5/FT6;
H4.5FTS5, H4.5FT6, H5.0-5.5FT (H80, 90, 100, 110,
120FT) (R005, S005, U005)
5. Remove planetary gear.
See Figure 13 for lift truck models
• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100,
120FT; S80, 100FTBCS; S120FTS;
S120FTPRS) (H004, J004)
See Figure 14 for lift truck models
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(R005, S005, U005)
6. Repeat Step 4 through Step 6 for other two
planetary gears and bearings.
7. Remove thrust block if signs of wear are
present.
See Figure 13 for lift truck models
• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100,
120FT; S80, 100FTBCS; S120FTS;
S120FTPRS) (H004, J004)
See Figure 14 for lift truck models
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(R005, S005, U005)
NOTE: Perform following step with wheel hub un-
der a press on a suitable support, using appropriate
driver.
8. Pull wheel hub from wheel bearing support.
NOTE: The wheel bearing cone will remain on
wheel bearing support. The bearing cup will remain
in wheel hub.
NOTE: Step 9 and Step 10 need to be performed
with wheel hub on a flat surface.
9. Using appropriate bearing puller, remove in-
board bearing cone from wheel bearing support.
10. Using a pry bar, remove and discard seal ring.
See Figure 15.
11. Place wheel hub in a soft jawed vise.
NOTE: Inspect bearing cups before removal.
12. Using a drift and hammer remove outboard
bearing cup from wheel hub.
See Figure 15 for lift truck models
• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100,
120FT; S80, 100FTBCS; S120FTS;
S120FTPRS) (H004, J004)
See Figure 16 for lift truck models
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(R005, S005, U005)
13. Using a drift and hammer drive inboard bear-
ing cone from wheel hub.
See Figure 15 for lift truck models
• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100,
120FT; S80, 100FTBCS; S120FTS;
S120FTPRS) (H004, J004)
Reduction Gear Assembly 1400 SRM 1582
10

See Figure 16 for lift truck models
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(R005, S005, U005)
1. OUTBOARD BEARING CONE
2. OUTBOARD BEARING CUP
3. WHEEL HUB
4. INBOARD BEARING CUP
5. INBOARD BEARING CONE
6. SEAL
7. WHEEL BEARING SUPPORT
Figure 15. Wheel Hub Bearings, Seal, and Bearing
Support for Lift Truck Models S4.0, 4.5, 5.5FT,
S5.5FTS (S80, 100, 120FT; S80, 100FTBCS;
S120FTS; S120FTPRS) (H004, J004)
1. OUTBOARD BEARING CONE
2. OUTBOARD BEARING CUP
3. WHEEL HUB
4. INBOARD BEARING CUP
5. INBOARD BEARING CONE
6. SEAL
7. WHEEL BEARING SUPPORT
Figure 16. Wheel Hub Bearings, Seal, and Bearing
Support for Lift Truck Models H4.0FT5/FT6;
H4.5FTS5, H4.5FT6, H5.0-5.5FT (H80, 90, 100, 110,
120FT) (R005, S005, U005)
1400 SRM 1582 Reduction Gear Assembly
11

NOTE: Perform Step 14 only if necessary. If wheel
studs are removed they will need to be replaced
with new wheel studs. It is recommended to place
an oversized socket or spacer under wheel stud be-
ing removed to support wheel hub's flange and pre-
vent warping during wheel stud removal.
14. For lift truck models S4.0, 4.5, 5.5FT, S5.5FTS
(S80, 100, 120FT; S80, 100FTBCS; S120FTS;
S120FTPRS) (H004, J004), remove wheel studs
from wheel hub with a hammer or press. See
Figure 17.
Wheel studs for lift truck models H4.0FT5/FT6;
H4.5FTS5, H4.5FT6, H5.0-5.5FT (H80, 90, 100,
110, 120FT) (R005, S005, U005) can be removed
with correct size socket. See Figure 18.
1. WHEEL HUB
2. WHEEL STUD
Figure 17. Wheel Studs Removal for Lift Truck
Models S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT;
S80, 100FTBCS; S120FTS; S120FTPRS) (H004,
J004)
1. WHEEL STUD
2. WHEEL HUB
Figure 18. Wheel Studs Removal for Lift Truck
Models H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
H5.0-5.5FT (H80, 90, 100, 110, 120FT) (R005, S005,
U005)
Reduction Gear Assembly 1400 SRM 1582
12

CLEAN AND INSPECT
WARNING
Cleaning solvents can be flammable and toxic and
can cause skin irritation. When using cleaning
solvents, always follow the recommendations of
the manufacturer.
WARNING
Compressed air can move particles so that they
cause injury to the user or to other personnel.
Make sure that the path of the compressed air is
away from all personnel. Wear protective goggles
or a face shield to prevent injury to the eyes.
Clean and inspect following parts of reduction gear
assembly:
•Tapered roller bearings
- Inspect cup, cone, rollers, and cage of all ta-
pered roller bearings in assembly. If bearings
show signs of wear, cracks, or damage, re-
place with new bearing.
•Ring gear - Inspect ring gear for wear or
damage. If gear is worn or damaged it must
be replaced.
•Wheel hub and wheel hub support - In-
spect wheel hub and wheel hub support for
wear or damage. Parts that are damaged
must be replaced.
•Planetary carrier and parts - Inspect all
parts of planetary carrier for wear or dam-
age. Parts that are damaged must be re-
placed. If gears are replaced, new needle
bearings must be used. If any planet gear
needs to be replaced, all planet gears should
be replaced.
ASSEMBLE
1. For lift truck models S4.0, 4.5, 5.5FT, S5.5FTS
(S80, 100, 120FT; S80, 100FTBCS; S120FTS;
S120FTPRS) (H004, J004), support wheel hub.
It is recommended to use a steel ring (spacer)
with dimensions as shown in Figure 19, but
blocks may be used as well as long as there is
enough clearance to install wheel stud com-
pletely. Support wheel hub flange where wheel
stud is to be installed with an over sized socket
or spacer (as shown in Figure 20) to prevent
warping wheel hub flange.
For lift truck models H4.0FT5/FT6; H4.5FTS5,
H4.5FT6, H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(R005, S005, U005), place wheel hub as shown in
Figure 21.
Figure 19. Steel Ring
2. For lift truck models S4.0, 4.5, 5.5FT, S5.5FTS
(S80, 100, 120FT; S80, 100FTBCS; S120FTS;
S120FTPRS) (H004, J004), using a press or
hammer, install wheel studs. See Figure 20.
For lift truck models H4.0FT5/FT6; H4.5FTS5,
H4.5FT6, H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(R005, S005, U005) apply a coat of Loctite
2760TM or Loctite 277TM on to threads of wheel
stud ends threading into wheel hub and tighten
wheel studs to 245 to 300 N•m (181 to 221
lbf ft). See Figure 21.
3. Using appropriate driver tool install new seal
on to wheel bearing support. See Figure 22.
WARNING
Hot parts. Wear protective clothing and gloves to
prevent burns.
4. Place wheel bearing support on a flat surface.
Heat a new inboard bearing cone to 80 to
90°C (176 to 194°F). Using appropriate driver
tool install inboard bearing cone on to wheel
bearing support. Once inboard bearing cone is
cool, lubricate with multipurpose grease.
1400 SRM 1582 Reduction Gear Assembly
13

1. WHEEL STUD
2. WHEEL HUB
3. SOCKET OR SPACER
4. STEEL RING, SPACER, OR BLOCKS
Figure 20. Wheel Studs Install for Lift Truck
Models S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT;
S80, 100FTBCS; S120FTS; S120FTPRS) (H004,
J004)
Figure 21. Wheel Studs Install for Lift Truck
Models S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT;
S80, 100FTBCS; S120FTS; S120FTPRS) (H004,
J004)
Legend for Figure 21
1. WHEEL STUD
2. WHEEL HUB
1. SEAL
2. INBOARD BEARING CONE
3. WHEEL BEARING SUPPORT
Figure 22. Wheel Bearing Support
NOTE: A press or hammer used with appropriate
driver tool will be required for installation of bear-
ings, bearing cones, and bearing cups.
5. With wheel hub on a flat surface, install a new
inboard bearing cup into wheel hub.
See Figure 23 for lift truck models
• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100,
120FT; S80, 100FTBCS; S120FTS;
S120FTPRS) (H004, J004)
See Figure 24 for lift truck models
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(R005, S005, U005)
Reduction Gear Assembly 1400 SRM 1582
14