Hyster r005 (h80 ft) forklift service repair manual

SERVICE REPAIR
H80FT H90FT H100FT H110FT H120FT [R005]

Lift Truck Lifting Capacity
Model Weight
H4.0FT5, H4.0FT6 (H80FT) (R005) 3629 kg (8000 lb)
H4.5FTS5 (H90FT) (R005) 4082 kg (9000 lb)
H4.5FT6 (H100FT) (R005) 4536 kg (10000 lb)
H5.0FT (H110FT) (R005) 4989 kg (11000 lb)
H5.5FT (H120FT) (R005) 5443 kg (12000 lb)
NOTE: Load center at 500 mm (24 in.).
Counterweight Weights
Model Weight
H4.0FT5 (H80FT) (R005) 2172 kg (4788 lb)
H4.0FT6 (R005) 2370 kg (5225 lb)
H4.5FTS5 (H90FT) (R005) 2504 kg (5520 lb)
H4.5FT6 (H100FT) (R005) 2709 kg (5972 lb)
H5.0FT (H110FT) (R005) 3009 kg (6634 lb)
H5.5FT (H120FT) (R005) 3294 kg (7262 lb)
8000 SRM 1559 Lift Truck Lifting Capacity
1

Tire Sizes
Truck Drive Tires Steer Tires
H4.0FT5, H4.5FTS5 (H80FT,
H90FT) (R005)
250 x 15
250 x 70 x R15
28 x 12.5 to 15
29 x 8 Dual
7.00 x 15 Dual
7.00 x R15 Dual
7.00 x 12
28 x 9 to 15
H4.5FT6, H5.0FT, H5.5FT
(H100FT, H110FT, H120FT)
(R005)
300 x 15
315 x 70 x R15
32 x 12.1 to 15
355 x 65 x 15
355 x 50 x 20
8.25 x 15 Dual
8.25 x R15 Dual
7.00 x 12
28 x 9 to 15
Tire Sizes 8000 SRM 1559
2

Capacities
Table 1. H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (R005)
Item Quantity Specifications
Fuel Capacity
Gas (Short Wheel Base) 79 liter (20.8 gal) 86 Octane
Gas (Long Wheel Base) 100.3 liter (26.5 gal) 86 Octane
LPG 15.1 - 20.4 kg (33.5 - 45.0 lb)
Full
LPG-HD 5, HD 10
Kubota 3.6L Diesel
(Short Wheel Base)
79 liter (20.8 gal) Diesel No. 2
Kubota 3.6L Diesel (Long Wheel Base) 100.3 liter (26.5 gal) Diesel No. 2
Kubota 3.8L Diesel
(Short Wheel Base)
79 liter (20.8 gal) Low Sulfur ≤500 ppm or
Ultra Low Sulfur ≤15
ppm Diesel No.2
Kubota 3.8L Diesel (Long Wheel Base) 100.3 liter (26.5 gal) Low Sulfur ≤500 ppm or
Ultra Low Sulfur ≤15
ppm Diesel No.2
Engine Oil
PSI (GM) 4.3L 4.7 liter (5 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 IL-
SAC GF4
Kubota Diesel 13.2 liter (13.9 qt)
−25°C (−13°F) and above
SAE 10W-30
Below −25°C (−13°F)
SAE 5W-20
−15°C (5°F) and above
SAE 15W-40
API CF or CI-4
8000 SRM 1559 Capacities
3

Table 1. H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (R005) (Continued)
Cooling System
PSI (GM) 4.3L 15.1 liter (15.9 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 or deionized water.
Kubota Diesel 11 liter (11.6 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 or deionized water.
Hydraulic Tank Oil Capacity
PSI (GM) 4.3L (Short Wheel Base)
62.0 liter (65.5 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
PSI (GM) 4.3L (Long Wheel Base)
78 liter (84 qt)
Drain and Fill
CAUTION
cal Hyster dealer.
ISO VG-46 Hydraulic
above
Capacities 8000 SRM 1559
4

Table 1. H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (R005) (Continued)
Kubota Diesel (Short Wheel Base)
62.0 liter (65.5 qt)
Drain and Fill
CAUTION
cal Hyster dealer.
ISO VG-46 Hydraulic
above
Kubota Diesel (Long Wheel Base)
78.0 liter (82.4 qt)
Drain and Fill
CAUTION
cal Hyster dealer.
ISO VG-46 Hydraulic
above
Transmission (Dry Brake)
Basic Powershift Transmission 20 liter (21.0 qt) John Deere
JDM J20C
DuraMatch Transmission 20 liter (21.0 qt) John Deere
JDM J20C
Brake Oil (Master Cylinder) 0.35 liter (0.74 pt) Dexron III
Differential and Drive Axle Oil
(Dry Brake)
8.0 liter (8.5 qt) SAE 80W-90 or 85W-140
Transmission and Wet Brake Drive Axle - Dana Axle Only
Transmission and Planetary Carrier
Housing
31.3 liter (33.0 qt) John Deere
JDM J20C
Center body (Dana Axle Only) 2.0 liter (2.1 qt) SAE 80W-90
Wet Brake Drive Axle - NMHG Axle Only
New or Rebuilt Axle 10.3 liter (10.9 qt) John Deere
JDM J20C
Service Fill 9.3 liter (9.9 qt) John Deere
JDM J20C
8000 SRM 1559 Capacities
5

Electrical System
Item PSI (GM) 4.3L Kubota Diesel
Battery 12-volt, negative ground 12-volt, negative ground
Spark Plugs AC-R44-LTS N/A
Spark Plug Gap 0.889 mm (0.035 in.) N/A
Ignition Timing:
Gas Not Adjustable N/A
LPG Not Adjustable N/A
Diesel N/A Not Adjustable
PSI (GM) 4.3L
Alternator Output (14 Volts) G and LPG GS and LPS
Idle 50 amps @ 750rpm 38 amps @ 750rpm
Governed Speed 65 amps @ 2400 rpm 45 amps @ 2400 rpm
Kubota 3.6L Diesel
Alternator Output (13.5 Volts) D
Low Idle 30 amps @ 850 rpm
Governed Speed 80 amps @ 2400 rpm
Kubota 3.8L Diesel
Alternator Output (13.5 Volts) D DS
Low Idle 30 amps @ 825 rpm 25 amps @ 825 rpm
Governed Speed 80 amps @ 2325 rpm 45 amps @ 2325 rpm
Electrical System 8000 SRM 1559
6

Transmission Oil Pressures
1-Speed Transmission 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)
*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). ***High pressure port is used when
the lift truck is equipped with a dry brake system. The low pressure port is used when the lift truck is
equipped with a wet brake system.
8000 SRM 1559 Transmission Oil Pressures
7

2-Speed Transmission 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 Port 6
***Low
Pressure
***High
Pressure
Reverse
Clutch
Forward
Low Clutch
Forward
High
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)
983
±58** kPa
(142.5
±8.5 psi)
738 ±52 kPa
(107
±7.5 psi)
138 ±34.5 kPa
(20 ±5 psi)
*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). ***High pressure port is used when
the lift truck is equipped with a dry brake system. The low pressure port is used when the lift truck is
equipped with a wet brake system.
Transmission Oil Pressures 8000 SRM 1559
8

Hydraulic System Relief Pressures
Table 3. Hydraulic Systems With Hydraulic Gear Pump
Item Specification
Oil Temperature for Setting Relief Pressure 50 to 65°C (122 to 149°F)
Primary Relief Valve Pressure (High Idle) 22.1 ±0.48 MPa (3205 ± 70 psi)
Secondary Relief Valve Pressure (High Idle) 15.51 ±0.48 MPa (2250 ±70 psi)
Table 4. Hydraulic Systems With Variable Displacement Pump
Item Specification
Oil Temperature for Setting Relief Pressure 50 to 65°C (122 to 149°F)
Primary Relief Valve Pressure (High Idle) 23.7 ±0.50 MPa (3437 ± 72.5 psi)
Secondary Relief Valve Pressure (High Idle) 15.50 ±0.50 MPa (2248 ±72.5 psi)
Maximum Allowable Leakage at 1A Port to Tank 22.7 cc @ 19.3 MPa (2799 psi)
Steering System
Item Quantity
Oil Temperature 50 to 65°C (122 to 149°F)
Steering Relief Pressure at 800 rpms (PSI (GM) 4.3L
and Kubota 3.8L Diesel Engine)
12.4 ±0.3 MPa (1798 ±43.5 psi)
Steering Relief Pressure at 850 rpms (Kubota 3.6L
Diesel Engine)
12.4 ±0.3 MPa (1798 ±43.5 psi)
Steering Cylinder Stroke (Each Side) 200.85 mm (7.9 in.)
Inside Steering Tire Angle 80°
Number of Turns to Lock 3.984
Turning Radius (±50 mm NO LOAD) Outside Inside
H4.0FT5 (H80FT) 2570 49
H4.0FT6 2599 49
H4.5FTS5 (H90FT) 2619 49
H4.5FT6 (H100FT) 2837 131
H5.0FT (H110FT) 2877 131
H5.5FT (H120FT) 2915 131
8000 SRM 1559 Hydraulic System Relief Pressures
9

Stall Speeds (in RPM ±100 rpm)
PSI (GM) 4.3L GAS
Transmission New Engine Broken-In Engine
Basic 2160 2210
DuraMatch 2160 2210
DuraMatch2 2160 2210
DuraMatch Plus2 Stall Speed Not Valid Stall Speed Not Valid
PSI (GM) 4.3L LPG
Basic 2070 2170
DuraMatch 2070 2170
KUBOTA 3.6L DIESEL
Basic 1950 2000
DuraMatch 1950 2000
KUBOTA 3.8L DIESEL
Basic 1900 1970
DuraMatch 1900 1970
Stall Speeds (in RPM ±100 rpm) 8000 SRM 1559
10

1400 SRM 1245 Drive Axle Repair
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 Repairs, 2- and 3-Stage Masts
4000 SRM 1250.
4. Remove the fill plug and O-ring. Discard O-ring.
5. Remove the drain plug and O-ring to drain the
oil from the drive axle into a suitable container.
Discard O-ring. See Figure 1.
6. Remove the wheels.
7. Disconnect the brake line connecting the master
cylinder to the brake manifold located on top of
the differential housing assembly.
8. Remove the parking brake cable. Refer to the
section Brake System 1800 SRM 1247.
9. Place blocks under the axle assembly and connect
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. See Figure 7.
13. Remove the four mounting capscrews from the
drive axle. See Figure 2.
14. Remove blocks and lower the drive axle assembly.
Pull axle forward and away from frame.
15. Place blocks under the differential assembly.
16. Remove the axle shafts, hub/brake drum assem-
bly, and back plates. Refer to the section Brake
System 1800 SRM 1247.
17. Remove the capscrews and washers retaining the
hanger assembly to the internal gear and differ-
ential housing.
18. Remove the planetary gear assembly from the
differential housing.
1. DIFFERENTIAL HOUSING ASSEMBLY
2. O-RING
3. OIL FILL PLUG
4. OIL DRAIN PLUG
5. O-RING
Figure 1. Drain Plug
1

Drive Axle Repair 1400 SRM 1245
Figure 2. Drive Axle
2

Legend for Figure 2
1. BRAKE MANIFOLD
2. INPUT SHAFT (YOKE)
3. OUTER SEAL
4. BEARING CONE
5. BEARING CUP
6. INNER SEAL
7. HUB/BRAKE DRUM ASSEMBLY
8. BEARING CUP
9. BEARING CONE
10. WHEEL BEARING WASHER
11. LOCK PLATE
12. LOCK NUT
13. AXLE SHAFT
14. CAPSCREW
15. CAPSCREW
16. BRAKE ASSEMBLY
17. BRAKE LINE
18. CAPSCREW
19. WASHER
20. CAPSCREW
21. WASHER
22. HANGER ASSEMBLY
23. INTERNAL GEAR
24. PLANETARY GEAR ASSEMBLY
25. SUN GEAR
19. Remove the internal gear from the differential
housing.
20. Remove the sun gear from the differential hous-
ing.
21. Remove the outer snap ring retaining the ball
bearing. See Figure 3.
22. Remove ball bearing.
23. Remove inner snap ring.
2. INNER SNAP RING
3. BALL BEARING
4. OUTER SNAP RING
Figure 3. Planetary Gear Disassembly/Assembly
CAUTION
When removing the planetary gear, ensure that
the needle bearings are not lost. Losing any
needle bearing could result in damage to the
equipment.
24. Remove pin retaining the thrust washer, plane-
tary gear, spacer, and needle bearings. See Fig-
ure 4.
2. PIN
3. THRUST WASHER
4. SPACER
5. NEEDLE BEARINGS (QTY 48)
6. PLANETARY GEAR
Figure 4. Planetary Gear and Needle Bearings
3

Drive Axle Repair 1400 SRM 1245
25. Remove planetary gear, thrust washers, and nee-
dle bearings from housing.
26. Remove the 48 needle bearings (24 on each side of
spacer) and spacer from the planetary gear. Re-
peat this step on the remainder planetary gears.
27. Remove the thrust washer from the inside
of planetary gear assembly. Repeat Step 19
through Step 27 for the opposite side. See Fig-
ure 5.
2. THRUST WASHER
Figure 5. Planetary Gear Assembly and Thrust
Washer
CLEAN AND INSPECT
WARNING
Cleaning solvents can be flammable and toxic
and can cause skin irritation. When using
cleaning solvents, always follow the solvent
manufacturer’s recommended safety precau-
tions.
1. Clean all the parts of the drive axle with solvent.
2. Inspect the planetary gears, spacers, needle
bearings, and thrust washers for damage. If
planetary gears, spacers, needle bearings, or
thrust washers show signs of wear or damage,
replace the components as needed.
3. Inspect the internal gears for wear and damage.
Replace as needed. Clean silicone from mating
surfaces.
4. Inspect the sun gear for wear or damage. If the
sun gears show signs of wear or damage, replace
the sun gear. The splines of the sun gears must
not be damaged.
5. 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 dam-
aged.
ASSEMBLE AND INSTALL
1. Install thrust washer inside the planetary gear
assembly.
2. Apply a light coat of grease on the inside of the
planetary gear and slowly install 24 needle bear-
ings on each side of the spacer into planetary gear
to be flush with the gear face.
NOTE: Spacer should split the needle bearings into
two separate sections for one planetary gear assem-
bly.
3. Apply a light coat of grease on thrust washer and
install the thrust washer on the ends of the plan-
etary gear.
4. Install the thrust washers, planetary gear, and
needle bearings as an assembly into the plane-
tary gear assembly.
5. Ensure flat surface of the pin is toward the center
of the carrier and install pin in alignment with
the planetary gear. Repeat Step 2 through Step 5
for remainder planetary gears.
6. Install inner snap ring to retain pins.
7. Install ball bearing.
8. Install outer snap ring to retain the ball bearing.
9. Install the sun gear in the differential housing.
Repeat steps Step 1 through Step 9 for the oppo-
site side.
10. Apply RTV High Performance sealant, Hyster
Part No. 1584621 or equivalent, to the mating
surface of the internal gear. Install the internal
gear on the differential housing.
11. Install planetary gear assembly into the differ-
ential housing assembly.
4

12. Place the hanger assembly in position on the dif-
ferential housing assembly. Apply Loctite® 242
to the capscrews and install capscrews and lock-
washers to retain differential housing assembly.
Tighten capscrews in sequence shown in Figure 6
to 225 to 248 N•m (166 to 183 lbf ft). Repeat
steps Step 10 through Step 12 for the opposite
side.
NOTE: Apply Loctite® 515 or High Performance RTV
Silicone Gasket Maker on the axle shaft flange when
installing.
13. Install the back plates, hub/brake drum assem-
blies, and axle shafts. Refer to the section Brake
System 1800 SRM 1247.
14. 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 be-
tween the frame and the drive axle mount, and will
ensure even weight distribution.
15. Position the drive axle in the lift truck.
NOTE: It is recommended to use a torque multiplier
to achieve the torque specification in Step 16.
16. Install the four mounting capscrews and wash-
ers. Tighten the capscrews to 820 to 902 N•m
(605 to 665 lbf ft).
17. Place the drive shaft in position and install the
retaining capscrews. Tighten the drive shaft cap-
screws to 50 to 66 N•m (37 to 49 lbf ft).
Figure 6. Hanger Assembly Tightening
Sequence
18. 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 Figure 7.
19. Remove blocks from under the transmission.
20. Install parking brake cable. Make sure the brake
cable is routed properly and has no interference.
Verify that the parking brake operates properly.
Refer to the section Brake System 1800 SRM
1247.
21. Connect the brake line connecting the master
cylinder to the brake manifold located on top of
the differential housing assembly.
NOTE: When tightening the wheel nuts, DO NOT use
any lubricant on the studs or nuts.
22. Install the wheel and nuts and tighten the nuts
to 610 to 680 N•m (450 to 502 lbf ft).
23. Apply multipurpose grease to new O-ring and in-
stall O-ring on the drain plug.
24. Install the O-ring and drain plug, and tighten to
14 to 27 N•m (10 to 20 lbf ft).
1. TRANSMISSION
3. ISOLATOR, TRANSMISSION
4. WASHER
5. LOCKWASHER
6. CAPSCREW
Figure 7. Transmission to Differential Housing
Assembly Mounting Bolts
5

Differential Repair 1400 SRM 1245
25. Fill the drive axle to the proper level with 7.5 to
8.0 liter (7.9 to 8.4 qt) of SAE 80W-90 gear oil
through the fill hole as shown in Figure 8.
26. Apply multipurpose grease to new O-ring and in-
stall O-ring on the fill plug.
27. Install the O-ring, fill plug, and tighten to 14 to
27 N•m (10 to 27 lbf ft).
28. Remove the air from the brake system as de-
scribed in the section Brake System 1800 SRM
1247.
29. Install the mast assembly as described in the sec-
tion Mast Repairs, 2- and 3-Stage Masts 4000
SRM 1250.
30. Raise the lift truck and remove blocks from under
frame and from under the counterweight. Lower
the lift truck.
31. Remove the blocks on each side (front and back)
of the steering tires.
32. Operate the lift truck and check for proper oper-
ation and leaks.
1. OIL FILL PLUG
2. OIL DRAIN PLUG
3. OIL FILL LEVEL
Figure 8. Oil Fill Level
Differential Repair
REMOVE
For the following repair procedures, the drive axle
must be removed and disassembled. Refer to the sec-
tion Drive Axle Repair.
Support Differential Assembly From
Differential Housing Assembly
1. Remove input shaft (yoke).
2. Remove the dust cover.
3. Remove the oil seal. See Figure 9.
4. Remove capscrew and lockwasher retaining
brake manifold bracket to the differential as-
sembly support. See Figure 10.
5. Remove brake manifold bracket.
6. Remove capscrews and lockwashers retaining
the differential assembly support to the differ-
ential housing.
Using two of the M8 × 1.25 × 40 capscrews re-
moved from the differential assembly support,
push the differential assembly support from the
differential housing. If the capscrews do not have
enough threaded length, use a pry bar to finish
removing the differential assembly support.
7. Remove differential assembly support from the
differential housing assembly. See Figure 10.
6

1400 SRM 1245 Differential Repair
2. OIL SEAL
3. DUST COVER
4. INPUT SHAFT (YOKE)
Figure 9. Drive Axle Yoke
1. DIFFERENTIAL HOUSING
2. DIFFERENTIAL ASSEMBLY SUPPORT
3. BRAKE MANIFOLD BRACKET
4. LOCKWASHERS
5. CAPSCREWS
6. CAPSCREW
7. LOCKWASHER
Figure 10. Differential Housing Assembly
Section Disassembly
7

Differential Assembly From Differential Assembly Support
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.
NOTE: If the lift truck was manufactured prior to October 2006 and the retaining rings have not been replaced,
go to STEP 1. 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 2.
STEP 1.
Remove differential assembly retainer ring cotter
pins. Using a retainer ring special tool, Hyster P/N
1581188, loosen the retainer rings. If necessary,
loosen the bearing cap capscrews to allow the re-
tainer rings to turn freely.
1. COTTER PIN
2. RETAINER RING
1. RETAINER RING SPECIAL TOOL
8

STEP 2.
Remove differential assembly retainer ring cotter
pins. Using a retainer ring special tool, Hyster P/N
1663599, loosen the retainer rings. If necessary,
loosen the bearing cap capscrews to allow the re-
tainer rings to turn freely.
1. COTTER PIN
2. RETAINER RING
1. RETAINER RING SPECIAL TOOL
9

STEP 3.
Remove the retainer rings.
2. RETAINER RINGS
STEP 4.
Mark one differential carrier leg and bearing cap
to correctly match the parts when assembling dif-
ferential assembly support. Mark the part using a
center punch and hammer. Remove the capscrews
and washers retaining the bearing caps. Remove the
bearing caps.
2. BEARINGS
3. BEARING CAPS
4. WASHERS
5. CAPSCREWS
10

STEP 5.
Remove the differential assembly from the differen-
tial assembly support.
2. TAPERED ROLLER BEARING AND CUP
3. DIFFERENTIAL ASSEMBLY
Differential Assembly Support from Drop Box
STEP 1.
Remove the capscrews and lockwashers retaining the
pinion cover plate.
Remove pinion cover plate.
2. PINION COVER PLATE
3. CAPSCREWS
4. LOCKWASHERS
5. DROP BOX ASSEMBLY
11

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.
NOTE: When removing the pinion, be sure to retain the shims.
STEP 2.
Use a small, flat chisel to unstake the pinion nut.
Remove the pinion nut, washer, bearing cone, and
shims.
2. SHIMS
3. BEARING CONE
4. WASHER
5. PINION NUT
STEP 3.
Remove the capscrews, washers, and clamp retaining
the drop box housing.
Using two of the M8 × 1.25 × 50 capscrews removed
from the drop box housing, push the drop box housing
from the differential assembly support. If the cap-
screws do not have enough threaded length, use a pry
bar to finish removing the drop box housing.
2. DROP BOX HOUSING
3. CLAMP
4. LOCKWASHERS
5. CAPSCREWS
12

Drive Pinion and Pinion Gear, from Differential Assembly Support
NOTE: When removing the pinion, be sure to retain the shims.
STEP 1.
Carefully remove pinion assembly from the differen-
tial assembly support. Using a press and a bearing
puller, remove the shims and inner bearing from the
pinion.
2. INNER BEARING
3. SHIMS
4. PINION
STEP 2.
Remove drive gear and driven gear.
2. DRIVE GEAR
3. DRIVEN GEAR
13

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DISASSEMBLE
Differential Assembly
STEP 1.
Remove the bearing cups. Using a suitable bearing
puller, remove the bearings from the differential as-
sembly.
1. BEARING CUP
2. TAPERED ROLLER BEARING
STEP 2.
Remove the capscrews retaining the ring gear to the
differential assembly. Remove the ring gear.
1. RING GEAR
3. CAPSCREW
14

NOTE: Mark each side of the case halves before separating to ensure alignment at reassembly.
STEP 3.
Remove the capscrews retaining the case halves to-
gether and separate the case halves.
Inspect the case halves for wear or damage. If wear
or damage is present, the entire differential assem-
bly must be replaced.
1. CAPSCREWS
2. CASE HALF
3. SPIDER ASSEMBLY
4. CASE HALF
STEP 4.
Remove the side gears and thrust washers from the
case halves.
1. CASE HALF
2. THRUST WASHER
3. SIDE GEAR
4. SPIDER ASSEMBLY
5. CASE HALF
15

STEP 5.
Remove the spherical washers and spider gears from
the cross.
Inspect the spider gears for wear or damage. Replace
as needed.
1. SPHERICAL WASHER
2. SPIDER GEAR
3. CROSS
Drop Box Housing
STEP 1.
Using a bearing puller, remove outer bearing from
the drop box housing.
1. OUTER BEARING
2. DROP BOX HOUSING
16

Hyster r005 (h80 ft) forklift service repair manual

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