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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.

Содержание H100FT

Страница 1: ...Hyster R005 H80FT H90FT H100FT H110FT H120FT Forklift Service Repair Manual...

Страница 2: ...ENTIAL 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...

Страница 3: ...dic 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 ma...

Страница 4: ...ontrol 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...

Страница 5: ...tion 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 Cont...

Страница 6: ...ore 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 pl...

Страница 7: ...751 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...

Страница 8: ...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...

Страница 9: ...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 1...

Страница 10: ...ting 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...

Страница 11: ...nce 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 whee...

Страница 12: ...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 fo...

Страница 13: ...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 f...

Страница 14: ...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 E...

Страница 15: ...k 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...

Страница 16: ...rform 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 s...

Страница 17: ...ub 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 IN...

Страница 18: ...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 wit...

Страница 19: ...S 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 instal...

Страница 20: ...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 bearin...

Страница 21: ...RING CUP 2 WHEEL HUB 3 INBOARD BEARING CUP 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 1400 SRM 1582 Reduction Ge...

Страница 22: ...ft 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...

Страница 23: ...R ASSEMBLY 5 WHEEL BEARING SUPPORT 6 RING GEAR 7 PLANETARY GEAR CARRIER 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 S120F...

Страница 24: ...R ASSEMBLY 5 WHEEL BEARING SUPPORT 6 RING GEAR 7 PLANETARY GEAR CARRIER 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...

Страница 25: ...00 120FT S80 100FTBCS S120FTS S120FTPRS H004 J004 See Figure 26 for lift truck models H4 0FT5 FT6 H4 5FTS5 H4 5FT6 H5 0 5 5FT H80 90 100 110 120FT R005 S005 U005 14 Repeat Step 12 through Step 13 for...

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