This document is a service and repair manual for Hyster H006 (H135FT, H155FT) forklifts, specifically focusing on the drive axle and differential assembly repair for models equipped with wet brakes. It also covers H8.0FT, H8.0FT9, H9.0FT (H170FT, H175FT36, H190FT) [A299, B299, C299] series forklifts. The manual provides comprehensive guidelines for trained and experienced technicians to perform maintenance and service on these critical components.
Function Description:
The manual details the repair procedures for the drive axle and differential assembly, which are integral to the forklift's propulsion and steering. The drive axle transmits power from the transmission to the wheels, while the differential allows the wheels to rotate at different speeds, crucial for turning. The wet brake system, also covered, provides braking force through oil-immersed discs, offering consistent performance and extended life compared to dry brakes. The planetary reduction gear system, a key part of the drive axle, further reduces speed and increases torque at the wheels.
Important Technical Specifications (as inferred from the manual):
- Models Covered: H6.0FT, H7.0FT (H135FT, H155FT) [H006, J006, K006, L006]; H8.0FT, H8.0FT9, H9.0FT (H170FT, H175FT36, H190FT) [A299, B299, C299]. These designations indicate various forklift capacities and series.
- Brake Type: Wet Brake system. This implies an oil-immersed multi-disc brake design.
- Drive Axle Components: Includes planetary reduction gears, wheel hubs, axle shafts (outer and half shafts), bearings, seals, ring gears, sun gears, and planetary gear carriers.
- Differential Components: Bevel pinion, differential assembly.
- Hydraulic System Connections: Brake supply lines, accumulator/brake booster supply and return lines, transmission to drive axle cooling supply and return hoses.
- Fasteners: Various capscrews, socket head screws, retaining rings, and shoulder rings are used throughout the assembly.
- Special Tools: The manual includes a section for special tools, indicating specific equipment may be required for certain procedures.
- Torque Specifications: A dedicated section for torque specifications emphasizes the importance of precise tightening for all fasteners.
- Oil Capacity: Implied by the presence of fill, level, and drain plugs for the drive axle main housing and individual axle sides.
Usage Features:
This manual is not for end-user operation but for technicians performing service and repair. Key usage features for the technician include:
- Step-by-Step Procedures: Detailed instructions are provided for removal, disassembly, cleaning, inspection, assembly, and installation of components.
- Illustrations: Figures are extensively used to visually guide technicians through each step, showing component locations and assembly sequences. For example, Figure 1 shows the identification plate, Figure 2 illustrates drain and fill plugs for H6.0FT/H7.0FT models, Figure 3 depicts brake and cooling lines, Figure 4 shows drive axle mounting capscrews, Figure 5 details manifold and cooling hose removal, Figure 6 shows drain and fill plugs for H8.0FT/H9.0FT models, Figure 7 illustrates brake and cooling lines for H8.0FT/H9.0FT models, Figure 8 shows drive axle mounting capscrews for H8.0FT/H9.0FT models, Figure 9 provides an exploded view of the planetary reduction gear assembly for H6.0FT/H7.0FT models, and Figure 10 does the same for H8.0FT/H9.0FT models. Subsequent figures (STEP 1 through STEP 15) provide photographic guidance for specific disassembly steps of the planetary reduction gear.
- Safety Precautions: A dedicated section outlines critical safety measures, including proper lifting techniques, wearing safety glasses, disconnecting battery connectors, using correct blocks to prevent rolling/falling, maintaining a clean workspace, using correct tools, and handling flammable fuels and batteries safely.
- Warnings and Cautions: Specific warnings (hazardous situations leading to death or serious injury) and cautions (hazardous situations leading to minor injury or property damage) are highlighted throughout the instructions to ensure technician safety and prevent equipment damage.
- Model-Specific Instructions: Procedures are often differentiated by forklift model series, ensuring accuracy for the specific equipment being serviced. For instance, drain/fill plug locations and brake/cooling line configurations vary between the H6.0FT/H7.0FT and H8.0FT/H9.0FT series.
- Cross-Referencing: The manual refers to other relevant sections or manuals (e.g., "Mast Repairs" or "Brake System") for procedures outside its immediate scope, indicating a modular approach to documentation.
Maintenance Features:
The manual is entirely focused on maintenance and repair, providing detailed instructions for:
- Drive Axle Removal and Installation: Comprehensive steps for safely detaching and reattaching the entire drive axle assembly from the forklift frame.
- Planetary Reduction Gear Repair: Detailed procedures for disassembling, cleaning, inspecting, and assembling the planetary gears, carriers, ring gears, and associated components. This includes removal of retaining rings, planetary gears, ring gear, retaining screw, centering ring, planetary gear carrier, outer axle shaft, O-rings, capscrews, shoulder ring, and wheel hub support.
- Brake Repair: Instructions for servicing the wet brake system, including removal, disassembly, cleaning, inspection, assembly, and installation.
- Differential Repair: Procedures for the differential assembly, covering removal, disassembly, cleaning, inspection, assembly, and installation.
- Bevel Pinion Repair: Specific steps for the bevel pinion, including removal, disassembly, cleaning, inspection, assembly, and installation.
- Fluid Management: Instructions for draining and refilling drive axle oil, emphasizing the importance of proper fluid levels and types.
- Component Inspection: Emphasis on cleaning and inspecting components for wear, damage, or defects before reassembly.
- Use of Approved Parts: Strict recommendation to use "HYSTER APPROVED PARTS" to ensure quality and compatibility, highlighting the importance of using genuine components for reliable repairs.
- Regular Updates: A note indicates that manuals are regularly updated, suggesting that technicians should consult the latest versions and authorized dealers for the most current information.
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