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Hyster R005 Service & Repair Manual
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Hyster R005 Service & Repair Manual

Hyster R005 Service & Repair Manual

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

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Summary of Contents for Hyster R005

  • Page 1 Hyster R005 (H80FT, H90FT, H100FT, H110FT, H120FT) Forklift Service Repair Manual...
  • Page 2 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...
  • Page 3 • 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.
  • Page 4 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 ©2015 HYSTER COMPANY...
  • Page 5 Table of Contents 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]...
  • Page 6 Thanks very much for your reading, Want to get more information, Please click here, Then get the complete manual NOTE: If there is no response to click on the link above, please download the PDF document first, and then click on it. Have any questions please write to me: admin@servicemanualperfect.com...
  • Page 7 Mast Repairs (S/N A513, A514, A613, A614, H5.0-5.5FT (H80, 90, 100, 110, 120FT) A702, A703, A704, A705, A706, A707, A751, (R005, S005, U005) A752, B513, B514, B586, B587, B588, B589, B590, B591, B749, B750, B751, B752, B753, 6. Remove the drive axle trumpet arm (right side) B754) 4000SRM1250.
  • Page 8 H4.5FTS5, H4.5FT6, H5.0-5.5FT (H80, 90, 100, 110, 120FT) H5.0-5.5FT (H80, 90, 100, 110, 120FT) (R005, S005, U005) (R005, S005, U005) 7. Remove the drain plugs to drain the oil into a 8. Remove the parking brake cable. Refer to the suitable container.
  • Page 9 4. FILL/LEVEL PLUG 2. FILL PLUG 5. BRAKE BLEEDER VALVE 3. OIL BREATHER 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)
  • Page 10 Figure 4. Brake Line and Piston Chamber 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 10. Place blocks under the axle assembly and con- MOUNTING FOR S4.0, 4.5, 5.5FT, S5.5FTS (S80, nect slings and lifting device.
  • Page 11 1400 SRM 1582 Drive Axle Removal 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;...
  • Page 12 Reduction Gear Assembly 1400 SRM 1582 NOTE: LEFT REDUCTION GEAR SHOWN. THE COMPONENTS FOR RIGHT SIDE ARE SAME. 1. CAPSCREW 9. WHEEL STUD 2. BEARING CAPS 10. SEAL 3. WHEEL HUB COUPLER 11. SOCKET HEAD CAPSCREW 4. O-RING 12. WHEEL BEARING SUPPORT 5.
  • Page 13 5. SNAP RING 13. RING GEAR 6. RETAINER PLATE 14. PLANETARY CARRIER 7. BEARING SET 15. PLANETARY GEAR 8. WHEEL HUB 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)
  • Page 14 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.
  • Page 15 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.
  • Page 16 Figure 14. Planetary Gears and Ring Gear bearing cup from wheel hub. Removal for Lift Truck Models H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-5.5FT (H80, 90, 100, 110, See Figure 15 for lift truck models 120FT) (R005, S005, U005) • S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; S80, 100FTBCS;...
  • Page 17 4. INBOARD BEARING CUP 5. INBOARD BEARING CONE H4.5FTS5, H4.5FT6, H5.0-5.5FT (H80, 90, 100, 110, 6. SEAL 120FT) (R005, S005, U005) 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;...
  • Page 18 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 STUD 2. WHEEL HUB Figure 18.
  • Page 19 For lift truck models H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-5.5FT (H80, 90, 100, 110, 120FT) Cleaning solvents can be flammable and toxic and (R005, S005, U005), place wheel hub as shown in can cause skin irritation. When using cleaning Figure 21. solvents, always follow the recommendations of the manufacturer.
  • Page 20 See Figure 24 for lift truck models Figure 21. Wheel Studs Install for Lift Truck Models S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; • H4.0FT5/FT6; H4.5FTS5, H4.5FT6, S80, 100FTBCS; S120FTS; S120FTPRS) (H004, H5.0-5.5FT (H80, 90, 100, 110, 120FT) J004) (R005, S005, U005)
  • Page 21 1400 SRM 1582 Reduction Gear Assembly 1. OUTBOARD BEARING CUP 3. INBOARD BEARING CUP 2. WHEEL HUB Figure 23. Bearing Cups Install for Lift Truck Models S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; S80, 100FTBCS; S120FTS; S120FTPRS) (H004, J004)
  • Page 22 H5.0-5.5FT (H80, 90, 100, 110, 120FT) (R005, S005, U005) 1. OUTBOARD BEARING CUP 3. INBOARD BEARING CUP 2. WHEEL HUB Figure 24. Bearing Cups Install for Lift Truck Models H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-5.5FT (H80, 90, 100, 110, 120FT) (R005, S005, U005)
  • Page 23 1400 SRM 1582 Reduction Gear Assembly 1. SNAP RING 5. WHEEL BEARING SUPPORT 2. OUTBOARD BEARING CONE 6. RING GEAR 3. WHEEL HUB 7. PLANETARY GEAR CARRIER 4. REDUCTION GEAR ASSEMBLY 8. PLANETARY GEAR Figure 25. Reduction Gear Assembly for Lift Truck Models S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; S80, 100FTBCS;...
  • Page 24 2. FORWARD BEARING CONE 6. RING GEAR 3. WHEEL HUB 7. PLANETARY GEAR CARRIER 4. REDUCTION GEAR ASSEMBLY 8. PLANETARY GEAR Figure 26. Reduction Gear Assembly for Lift Truck Models H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-5.5FT (H80, 90, 100, 110, 120FT) (R005, S005, U005)
  • Page 25 NOTE: REDUCTION GEAR FOR H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-5.5FT (H80, 90, 100, 110, 13. Install snap ring. 120FT) (R005, S005, U005) SHOWN. S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; S80, 100FTBCS; See Figure 25 for lift truck models S120FTS; S120FTPRS) (H004, J004) IS SIMILAR.

This manual is also suitable for:

H80ftH90ftH100ftH110ftH120ft