service repair manual

1. SERVICE REPAIR
H80FT H90FT H100FT H110FT H120FT [U005]

2. Lift Truck Lifting Capacity
Model Weight
H4.0FT5, H4.0FT6 (H80FT) (U005) and S4.0FT (S80FT,
S80FTBCS) (J004)
3629 kg (8000 lb)
H4.5FTS5 (H90FT) (U005) 4082 kg (9000 lb)
H4.5FT6 (H100FT) (U005) and S4.5FT
(S100FT, S100FTBCS) (J004)
4536 kg (10000 lb)
H5.0FT (H110FT) (U005) 4989 kg (11000 lb)
H5.5FT (H120FT) (U005) and S5.5FT, S5.5FTS
(S120FT, S120FTS, S120FTPRS) (J004)
5443 kg (12000 lb)
NOTE: Load center at 500 mm (24 in.).
Counterweight Weights
Model Weight
S4.0FT (S80FT) (J004) 2249 kg (4958 lb)
S4.5FT (S100FT) (J004) 2552 kg (5626 lb)
S5.5FT, S5.5FTS (S120FT, S120FTS) (J004) 3170 kg (6988 lb)
S80FTBCS (J004) 2149 kg (4738 lb)
S100FTBCS (J004) 3205 kg (7066 lb)
S120FTPRS (J004) 3773 kg (8318 lb)
H4.0FT5 (H80FT) (U005) 2108 kg (4647 lb)
H4.0FT6 (U005) 2314 kg (5102 lb)
H4.5FTS5 (H90FT) (U005) 2455 kg (5412 lb)
H4.5FT6 (H100FT) (U005) 2642 kg (5825 lb)
H5.0FT (H110FT) (U005) 2936 kg (6473 lb)
H5.5FT (H120FT) (U005) 3226 kg (7112 lb)
8000 SRM 1903 Lift Truck Lifting Capacity
1

3. Tire Sizes
Truck Drive Tires Steer Tires
S4.0FT (S80FT, S80FTBCS) (J004) 22 x 9 x 16 18 x 7 x 12.12
S4.5FT, S5.5FT, S5.5FTS (S100FT, S100FTBCS,
S120FT, S120FTS, S120FTPRS) (J004)
22 x 12 x 16 18 x 8 x 12.12
S4.5FT, S5.5FT, S5.5FTS (S100FT, S100FTBCS,
S120FT, S120FTS, S120FTPRS) (J004)
22 x 7 x 16 Dual Tires 18 x 8 x 12.12
H4.0FT5, H4.5FTS5 (H80FT, H90FT) (U005) 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) (U005)
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 1903
2

4. Capacities
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) Ultra Low Sulfur ≤15
ppm Diesel No.2
Kubota 3.8L Diesel
(Long Wheel Base)
100.3 liter (26.5 gal) Ultra Low Sulfur ≤15
ppm Diesel No.2
8000 SRM 1903 Capacities
3

5. Item Quantity Specifications
Engine Oil
GM 4.3L 4.7 liter (5 qt) SAE J2362
API SL
ILSAC GF3
Kubota LPG 12.2 liter (12.9 qt) SAE J2362
API SL
ILSAC GF3
Kubota Diesel 13.2 liter (13.9 qt) −15°C (5°F) and above
SAE 15W-40
−25°C (−13°F)
SAE 10W-30
Below −25°C (-13°F)
SAE 5W-30
API CJ-4
Cooling System
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 LPG/Diesel 11 liter (11.6 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.
Capacities 8000 SRM 1903
4

6. Item Quantity Specifications
Hydraulic Tank Oil Capacity
GM 4.3L (Short Wheel Base) 62.0 liter (65.5 qt)
Drain and Fill CAUTION
Additives may damage the
hydraulic system. Before us-
ing additives, contact your lo-
cal Hyster dealer.
ISO VG-46 Hydraulic
Oil −15°C (5°F) and
above
GM 4.3L (Long Wheel Base) 78 liter (82.4 qt)
Drain and Fill CAUTION
Additives may damage the
hydraulic system. Before us-
ing additives, contact your lo-
cal Hyster dealer.
ISO VG-46 Hydraulic
Oil −15°C (5°F) and
above
Kubota Diesel (Short Wheel Base) 62.0 liter (65.5 qt)
Drain and Fill CAUTION
Additives may damage the
hydraulic system. Before us-
ing additives, contact your lo-
cal Hyster dealer.
ISO VG-46 Hydraulic
Oil −15°C (5°F) and
above
Kubota Diesel (Long Wheel Base) 78.0 liter (82.4 qt)
Drain and Fill CAUTION
Additives may damage the
hydraulic system. Before us-
ing additives, contact your lo-
cal Hyster dealer.
ISO VG-46 Hydraulic
Oil −15°C (5°F) and
above
8000 SRM 1903 Capacities
5

7. Item Quantity Specifications
Kubota LPG (Short Wheel Base) 62.0 liter (65.5 qt)
Drain and Fill CAUTION
Additives may damage the
hydraulic system. Before us-
ing additives, contact your lo-
cal Hyster dealer.
ISO VG-46 Hydraulic
Oil −15°C (5°F) and
above
Kubota LPG (Long Wheel Base) 78.0 liter (82.4 qt)
Drain and Fill CAUTION
Additives may damage the
hydraulic system. Before us-
ing additives, contact your lo-
cal Hyster dealer.
ISO VG-46 Hydraulic
Oil −15°C (5°F) and
above
Transmission
Basic Powershift Transmission 17 liter (18.0 qt) John Deere
JDM J20C
DuraMatch Transmission 17 liter (18.0 qt) John Deere
JDM J20C
Brake Oil (Master Cylinder) 0.35 liter (0.74 pt) Dexron III
Transmission and Wet Brake Drive Axle - Dana Axle Only
Lift Truck Model H4.0FT5/FT6, H4.5FTS, H4.5FT6, H5.0-5.5FT (H80-120FT) (U005)
Transmission and Planetary Carrier
Housing
28.3 liter (29.9 qt) John Deere
JDM J20C
Center Body (Dana Axle Only) 2.0 liter (2.1 qt) SAE 80W-90
Transmission and Wet Brake Drive Axle - Dana Axle Only
Lift Truck Model S4.0-4.5FT, S5.5FT, S5.5FTS (S80FT, S100FT, S120FT, S80FTBCS, S100FTBCS,
S120FTS, S120FTPRS) (J004)
Transmission and Planetary Carrier
Housing
26.8 liter (28.4 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
Capacities 8000 SRM 1903
6

8. Electrical System
Item GM 4.3L Kubota Diesel Kubota LPG
Battery 12-volt, negative ground 12-volt, negative ground 12-volt, negative ground
Spark Plugs AC-R44-LTS N/A NGK BKR6EIX
Spark Plugs Longlife Op-
tional
N/A N/A NGK 1FR6F8DN
Spark Plug Gap 0.889 mm (0.035 in.) N/A 0.7 to 0.8 mm (0.028 to
0.032 in.)
Ignition Timing:
Gas Not Adjustable N/A N/A
LPG Not Adjustable N/A Not Adjustable
Diesel N/A Not Adjustable N/A
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 @ 2470 rpm
Kubota 3.8L Diesel
Alternator Output (13.5 Volts) D DS
Low Idle 30 amps @ 800 rpm 25 amps @ 800 rpm
Governed Speed 80 amps @ 2200 rpm 45 amps @ 2200 rpm
Kubota 3.8L LPG
Alternator Output (13.5 Volts) LPG
Low Idle 30 amps @ 800 rpm
Governed Speed 87 amps @ 2400 rpm
8000 SRM 1903 Electrical System
7

9. Transmission Oil Pressures
1-Speed Transmission All Pressures at 2500 rpm and Oil at 50 to 65°C (120 to 150°F)
Port 1 Transmission Pump Port 2 Port 3 Port 5 Port 6
***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)
55 ±28 kPa
(8 ±4 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).
Transmission Oil Pressures 8000 SRM 1903
8

10. 2-Speed Transmission All Pressures at 2500 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)
55 ±28 kPa
(8 ±4 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). ***
8000 SRM 1903 Transmission Oil Pressures
9

11. Hydraulic System Relief Pressures
Table 1. 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 2. 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
(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 Relief Pressure at 800 rpms
(Kubota 3.8L LPG Engine)
10.3 ±0.3 MPa (1494 ±43.5 psi)
Steering Cylinder Stroke (Each Side)
(GM 4.3L and Kubota 3.8L/3.6L Diesel Engine)
200.85 mm (7.9 in.)
Steering Cylinder Stroke (Each Side)
(Kubota LPG Engine)
189.3 mm (7.4 in.)
Inside Steering Tire Angle
(GM 4.3L and Kubota 3.8L/3.6L Diesel Engine)
80°
Number of Turns to Lock
(GM 4.3L and Kubota 3.8L/3.6L Diesel Engine)
3.984
Inside Steering Tire Angle
(Kubota LPG Engine)
79.8°
Number of Turns to Lock (Kubota LPG Engine) 4.35
Turning Radius (±50 mm NO LOAD) Outside Inside
H4.0FT5 (H80FT) 2570 49
Hydraulic System Relief Pressures 8000 SRM 1903
10

12. Item Quantity
H4.0FT6 2599 49
H4.5FTS5 (H90FT) 2619 49
H4.5FT6 (H100FT) 2837 131
H5.0FT (H110FT) 2877 131
H5.5FT (H120FT) 2915 131
S4.0FT (S80FT) 2298 84
S80FTBCS 2102 84
S4.5FT (S100FT) 2447 103
S100FTBCS 2232 103
S5.5FT, S5.5FTS (S120FT, S120FTS) 2534 103
S120FTPRS 2375 103
Stall Speeds (in RPM ±100 rpm)
GM 4.3L
Transmission New Engine Broken-In Engine
Basic 2000 2100
DuraMatch 2000 2100
DuraMatch2 2000 2100
DuraMatch Plus2 Stall Speed Not Valid Stall Speed Not Valid
KUBOTA 3.6L DIESEL
Transmission New Engine Broken-In Engine
Basic 1950 2000
DuraMatch 1950 2000
DuraMatch2 1950 2000
DuraMatch Plus2 Stall Speed Not Valid Stall Speed Not Valid
KUBOTA 3.8L DIESEL
Transmission New Engine Broken-In Engine
Basic 1900 1970
DuraMatch 1900 1970
DuraMatch2 1900 1970
DuraMatch Plus2 Stall Speed Not Valid Stall Speed Not Valid
8000 SRM 1903 Steering System
11

13. 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

14. 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

15. 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

16. 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

17. 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

18. 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

19. 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

20. 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

21. 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

22. 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

23. 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

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25. 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

26. 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

27. 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