This document is a service and repair manual for Hyster R005 (H80FT, H90FT, H100FT, H110FT, H120FT) forklift models, specifically focusing on the drive axle and differential assembly with wet brakes (NMHG). It covers a range of models including S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; S80, 100FTBCS; S120FTS; S120FTPRS) [H004, J004] and H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) [R005, S005, U005].

The primary function of the components described in this manual is to provide the necessary drive and differential action for the forklift, enabling it to move and steer effectively. The wet brake system is an integral part of this assembly, providing reliable stopping power.

Important Technical Specifications:

The manual details the intricate components of the drive axle and differential assembly, including:

Reduction Gear Assembly: This includes the wheel hub coupler, bearing caps, O-rings, snap rings, retainer plates, bearing sets, wheel hub, wheel studs, seals, socket head capscrews, wheel bearing support, ring gear, planetary carrier, and planetary gears. These components work together to reduce the rotational speed from the transmission and increase torque to the wheels.
Wet Brake System: While the full details of the wet brake system are referenced in a separate manual (1800SRM1597), this manual covers the removal and installation of the parking brake cable and the disconnection of the brake line from the piston chamber. The wet brake design implies a sealed system where brake components operate in an oil bath, offering enhanced durability and consistent performance, especially in demanding environments.
Drive Axle Trumpet Arm: This structural component houses the reduction gear assembly and connects to the differential.
Differential Housing: This central component allows the drive wheels to rotate at different speeds, which is crucial for turning.
Input Pinion Carrier: Part of the differential, it transmits power from the driveshaft to the ring gear.
Bearings and Seals: Various types of bearings (tapered roller bearings, inboard and outboard bearing cones and cups) and seals are critical for smooth operation and preventing lubricant leakage.
Fasteners: A variety of capscrews, nuts, and snap rings are used throughout the assembly, with specific torque specifications provided for proper reassembly.

Usage Features:

The components described are fundamental to the forklift's mobility and safety. The drive axle and differential ensure that power is efficiently transmitted to the wheels, allowing the forklift to carry heavy loads and maneuver in various operational settings. The wet brake system is designed for robust and consistent braking performance, essential for operator safety and control.

Maintenance Features:

The manual provides comprehensive instructions for the maintenance and repair of the drive axle and differential assembly. Key maintenance features include:

Detailed Removal and Installation Procedures: Step-by-step guides are provided for removing and installing the drive axle, reduction gear assembly, and differential components. This includes specific instructions for supporting the lift truck, draining fluids, and handling heavy parts.
Disassembly and Assembly Instructions: Each major sub-assembly, such as the reduction gear and differential, has detailed instructions for disassembly, component inspection, and reassembly.
Cleaning and Inspection Guidelines: Emphasizes the importance of cleaning all parts and inspecting them for wear, cracks, or damage. Specific components like tapered roller bearings, ring gear, wheel hub, wheel hub support, planetary carrier, and planetary gears require thorough inspection. Replacement criteria are provided for damaged or worn parts.
Bearing Installation: Instructions include heating new inboard bearing cones to a specific temperature (80 to 90°C or 176 to 194°F) for proper installation and lubricating with multipurpose grease.
Seal Installation: Guidance on installing new seals using appropriate driver tools.
Wheel Stud Installation: Different procedures are outlined for installing wheel studs depending on the forklift model, including using a press or hammer, and applying Loctite 2760TM or 277TM with specific torque values (245 to 300 N·m or 181 to 221 lbf ft) for certain models.
Shimming Brake Disc Pack: A dedicated section for shimming the brake disc pack, indicating precision adjustments are required for optimal brake performance.
Torque Specifications: The manual includes a section dedicated to torque specifications for various fasteners, ensuring correct tightening and preventing damage or failure.
Special Tools: A list of special tools required for specific repair tasks is provided, highlighting the need for specialized equipment for proper maintenance.
Safety Precautions: The manual begins with a critical section on safety precautions, including warnings about lifting heavy parts, wearing safety glasses, disconnecting battery connectors, using proper blocking, keeping the work area clean, using correct tools, and handling flammable fuels. It also warns about compressed air and hot parts. The use of "WARNING" and "CAUTION" notes throughout the instructions underscores the importance of safety during maintenance.
Parts Replacement: Stresses the use of HYSTER APPROVED parts that meet or exceed original equipment manufacturer specifications for all repairs.
Fluid Management: Instructions for draining oil into suitable containers, indicating proper fluid handling is part of the maintenance process.

Hyster H90FT - Page 5

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