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127(6

INTRODUCTION

GENERAL This section has the description and repair procedures for the differential, speed reducer, drive axle, wheel bearings, and the mounts for the axle housing.

The methods used to fasten the drive wheels to the hub are different for the three configurations. See FIGURE 3. When the drive axle is disassembled or assembled, small changes in the procedure must be made for the differences in the axles.

WARNING DESCRIPTION The mount brackets for the drive axle housing are fastened to the frame of the lift truck with six bolts on the E/J1.25–1.75XL (E25–35XL) models and eight bolts on the E2.00–3.00XL (E40–60XL), E2.00–3.20XM (E45–65XM), J2.00–3.00 (J40–60XL) and the N30XMH models. The outer ends of the axle housings are the spindles for the wheel bearings. The cups for the tapered roller bearings for the wheel bearings are pressed into the wheel hubs. The nut on the end of the spindle holds and adjusts the preload on the wheel bearings. The axle shafts are fastened to the hubs by capscrews. Studs and nuts fasten the wheel to the hub and brake drum. The back plate and brake assemblies are fastened to the mount brackets for the axle housing.

The lift truck must be put on blocks for some types of maintenance and repair. The removal of the following assemblies will cause large changes in the center of gravity: attachment, mast, drive axle, battery, and the counterweight.

When the lift truck is put on blocks, put additional blocks in the following positions: a. Before removing the mast and drive axle, put blocks under the counterweight so that the lift truck can not tip backward. b. Before removing the battery or counterweight, put blocks under the mast assembly so that the lift truck can not tip forward.

Put the lift truck on blocks only if the surface is solid, even, and level. Make sure that any blocks used to support the lift truck are solid, one piece units.

The transmission and differential are a single assembly.

(See FIGURE 6.) The transmission has a speed reducer gear that engages the splines on the shaft of the traction motor. A second speed reducer gear is fastened to the pinion shaft for the differential.

There are three configurations of drive wheel mounts used on the E/J1.25–1.75XL (E25–35XL) series of lift trucks because of the variations in tires that are available: E1.25–1.75XL (E25–35XL) standard solid tires wide tread solid tires J1.25–1.75XL pneumatic tires solid tires shaped like pneumatic tires (The pneumatic tires are available in standard and wide tread configurations, but the mount to the drive axle is the same.)

11547

FIGURE 1. PUTTING THE LIFT TRUCK ON BLOCKS

1

32

35 34 43

33

42*

31

27

33 8

25 20

32

19

31

15

37

38 39 12

14

2* 3*

40

16

5*

21

13 11 6*

41

9

12

4*

36*

44

22

10

7

25

8 13 17

28

18

12 9 23

7 1

8

24

E2.00–3.20XM (E45–65XM) DRIVE AXLE SHOWN. THE OTHER MODELS ARE SIMILAR. THE WHEEL CONFIGURATIONS FOR THE E/J1.25–1.75 (E25–35XL) ARE SHOWN IN FIGURE 3.

26 30

29

* NOT USED ON E2.00–3.20XM (E45–65XM) AND THE N30XMH 1. MOTOR, TRACTION 2. CAPSCREW, MOTOR MOUNT* 3. WASHER* 4. SPACER* 5. WASHER* 6. WASHER* 7. NUT 8. LOCKWASHER 9. CAPSCREW 10. O–RING 11. TRANSMISSION AND DIFFERENTIAL

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

23.

CAPSCREW WASHER AXLE HOUSING PLUG PLUG WASHER CAPSCREW BREATHER DIPSTICK O–RING SPINDLE NUT

24.

25.

26.

27.

28.

29.

30.

31.

32.

33.

WASHER HANGER CAPSCREW BRAKE, LEFT HAND LOCKWASHER CAPSCREW BRAKE, RIGHT HAND BEARING CONE BEARING CUP OIL SEAL

FIGURE 2. DRIVE AXLE ASSEMBLY 2

34. BRAKE DRUM 35. STUD 36. WHEEL/AXLE NUT* 37. WASHER 38. LOCKWASHER 39. NUT 40. AXLE 41. DOWL PIN 42. STUD* 43. WHEEL NUT 44. GREASE FITTING

4

5 6

2 1

3 8 7 11456

PNEUMATIC

STANDARD 1.

2.

3.

4.

LOCK NUT LOCK PLATE WASHER OUTER BEARINGS

WIDE TREAD 5.

6.

7.

8.

OIL SEAL INNER BEARING SEAL SPACER

FIGURE 3. DRIVE WHEEL MOUNTING (E/J1.25–1.75XL [E25–35XL])

REPAIRS REMOVAL OF THE DRIVE AXLE 1. Remove the battery as described in the PERIODIC MAINTENANCE section.

2. Remove the mast assembly as described in the section for THE MASTS. Drain the oil from the differential.

Remove the floor plates.

NOTE: The drive axle can be removed with the traction motor as one unit. Many service persons remove the traction motor before the drive axle is removed to reduce the weight of the unit. See THE FRAME section for procedures to remove the traction motor. The procedure in this section will describe removal of the drive axle after the traction motor has been removed.

3. Disconnect the brake lines to the wheel cylinders. Put caps on the open fittings.

4. E/J1.25–1.75XL (E35–35XL). Disconnect the hand lever assembly for the parking brake from the cowl.

Loosen the retainer that holds the hydraulic lines and cables near the floor plate. Carefully slide the hand lever assembly and cables past the hydraulic lines and electric wires so that the hand lever assembly and cables can be removed with the drive axle.

E/J2.00–3.00XL (E/J40–60XL). parking brake cables at the brakes.

Disconnect

the

E2.00–3.20XM (E45–65XM) and N30XMH. Disconnect the return spring from the park brake pedal.

Remove the park brake pedal. Disconnect the park brake assembly from the frame. Do not remove the mounting bolts from the park brake assembly. Remove the nuts and washers so that the bolts will keep the park brake assembly in one unit. After the park brake assembly has been removed from the frame bracket, put the nuts and washers on the bolts.

3

NOTE: Some early models of the electric XL series of lift trucks have M20 x 2.5 x 80 bolts instead of 7/8 x 14 UNF bolts.

7. Remove the mounting bolts for the hydraulic filter.

With the hoses still attached to the filter, move the filter to improve access to the mounting bolt for the transmission. Remove the mounting bolt that is located on the top of the transmission/differential assembly (see item 12, FIGURE 2.)

8. Slide the drive axle assembly from the lift truck. Use a crane and slings to move the drive axle to a work space.

Disassembly of the Drive Axle 11540

FIGURE 4. LOWER THE DRIVE AXLE TO THE SURFACE

1. Remove the capscrews that hold the axle shaft to the hub. There are two holes with threads in the flange of the axle shaft. Put capscrews (M12 x 1.75) in these holes to loosen the axle shaft from the hub.

2. Bend the lock plate so that the nut can be removed from the axle spindle. Remove the nut, lock plate, washer, and bearing cone. Carefully slide the hub and brake drum assembly from the spindle. Keep the spindle in the center of the hub and brake drum assembly during removal so that the oil seal in the hub is not damaged.

Do not permit oil or grease to get on the brake shoes.

3. Remove the inner bearing cone from the spindle.

[E/J1.25â&#x20AC;&#x201C;1.75XL (E25â&#x20AC;&#x201C;35XL) models also have a spacer between the grease seal and the shoulder of the wheel spindle.]

11541

FIGURE 5. REMOVE THE DRIVE AXLE FROM THE LIFT TRUCK 5. Remove the drive wheels and lower the lift truck so that the drive axle and the front of the frame is on the floor. (The steering wheels are on the floor and hold the end of the frame with the counterweight.)

6. Remove the 7/8 x 14 UNF bolts that hold the axle mounts to the frame. Turn the axle mounts forward so that there is additional clearance for removal of the drive axle.

4

4. If the brakes must be repaired, disassemble the brake assembly as described in the section for THE BRAKES. If disassembly of the brakes is not required, slide the brake assembly and the axle mount bracket from the axle spindle.

5. The axle spindles are not normally removed from the differential housing. If repairs are necessary, remove the 16 M12 x 1.75 x 35 capscrews that hold the axle spindles to the differential housing. Remove the axle spindles.

6. Remove the six M10 x 1.5 x 30 capscrews and washers and the two M10 x 1.5 x 40 capscrews and washers from the bottom of the differential housing.

Remove the transmission and differential assembly from the differential housing.

Disassembly of the Transmission and Differential 1. Remove the access plate from the top of the speed reducer. Use a small prybar to remove the hub cap from the end of the pinion shaft.

2. Disassemble only the parts of the transmission and differential that must be repaired. If the ring gear and pinion are not to be replaced, but parts of the differential must be replaced, check the contact pattern before disassembly. The pattern and the gear clearance are used as references for assembly. See the Assembly section for the procedures.

3. Loosen or remove the thrust screw for the ring gear.

Remove the lock plates for the adjusting nuts. Remove the bearing caps, adjusting nuts,bearing cups, and the differential assembly. Make sure that you do not change the parts from the right and left sides of the differential.

4. Use a sharp punch to raise the lock detent from the slot in the pinion shaft. Raise the lock detent carefully as possible so that there is minimum damage to the threads on the pinion shaft when the special lock nut is removed.

5. Use a piece of soft metal (copper or aluminum) to prevent the speed reducer gear from turning when the special lock nut is removed. Use the soft piece of metal between the speed reducer gears or between the speed reducer gear and the housing. Remove the special lock nut. (This special lock nut is tightened to 340 N.m [250 lbf ft].) Discard the special lock nut.

6. Remove the special washer with the key tab. Use a brass hammer to remove the pinion from the transmission case. The speed reducer gear and spacer will slide from the pinion shaft as it is removed from the transmission case. Make a note of the shim arrangement between the bearing and the spacer.

7. Remove the speed reducer gear and spacer from the transmission case.

8. Remove the spacer from the pinion shaft. Use a press to remove the bearing cone from the pinion. Make a note of the shim arrangement between the bearing cone and the pinion.

9. Use a press or a puller to remove the bearing cones from the differential case.

10. Remove the ring gear. Remove the 12 7/16 UNF x 1 inch bolts and the special hardened washers. Do not use a press or a hammer to remove the ring gear. Heat the differential in hot oil or water [82 to 100°C (180 to 212°F)] to loosen the ring gear.

11. Disassemble the differential. Remove the eight 3/8 UNF x 3â&#x20AC;&#x201C;1/2 inch capscrews and washers and separate the differential case. Remove the cross, spider gears, and axle gears.

12. Remove the bearing retainer for the input gear to the speed reducer. Remove the four M8 x 1.25 x 25 capscrews and washers. Remove the bearing retainer, gear and bearings. Make a note of the shim arrangement.

Use a puller to remove the inner bearing cup from the transmission case.

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9.

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TRANSMISSION HOUSING DOWEL PIN DOWEL PIN BEARING CAP WASHER CAPSCREW CAPSCREW LOCKWASHER RETAINER SHIM BEARING CUP BEARING CONE GEAR 25 HUB CAP SPECIAL LOCK NUT 24 WASHER BEARING CONE BEARING CUP 23 SHIM SPACER 21

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SPEED REDUCER GEAR SPACER PLATE LOCKWASHER CAPSCREW BEARING CUP BEARING CONE

SHIM RING GEAR AND PINION ADJUSTING NUT BEARING CONE BEARING CUP CAPSCREW LOCKWASHER

6 4

30 32

3 31

22 5

20

28

19

37

26 27

36 32

29

18 17

38

16 14

31

2

15

35

47

30 34 33

48 12

11

42

1

43

40

13

11527

41

12 11 10 7

35.

36.

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39.

8

39

40

44

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LOCKPLATE PLACEBOLT WASHER DIFFERENTIAL DIFFERENTIAL HOUSING

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48.

WASHER AXLE GEAR THRUST WASHER SPIDER GEAR CROSS CAPSCREW 42 WASHER THRUST SCREW JAM NUT

43

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FIGURE 6. TRANSMISSION AND DIFFERENTIAL 6

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45 39

CLEANING WARNING Always wear safety glasses.

Cleaning solvents may be flammable and toxic, and can cause severe skin irritation. When using cleaning solvents, always comply with the solvent manufacturerâ&#x20AC;&#x2122;s recommended safety precautions.

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 the parts of the drive axle with solvent. Dry the parts with compressed air.

INSPECTION 1. Check the pinion and ring gear for wear. Inspect the spider gears and axle gears for worn teeth. Inspect the cross for wear where the gears turn. The cross and the holes for the cross in the differential case must fit tightly.

2. Inspect the bearings and seals for wear or damage.

3. The mount brackets must turn freely on the axle housings. The splines for the axle shafts must not be damaged.

ASSEMBLY Assembly Of The Transmission And Differential INSTALLATION OF THE INPUT GEAR ASSEMBLY

1. Install the bearing cup in the end of the bore in the transmission case. Use a press to install bearing cones on each end of the input gear. Install the input gear and

bearings into the transmission case. Install the outer bearing cup.

2. Install the shims and the bearing retainer. Install the four M8 x 1.25 x 25 capscrews and washers. Tighten the capscrews to 19 N.m (14 lbf ft). Check the bearing clearance. Add or remove shims to adjust for zero bearing clearance. The input gear must turn smoothly with a maximum rotation torque of 0.133 N.m (1.2 lbf in).

INSTALLATION OF A NEW PINION ASSEMBLY

If the ring gear and pinion is worn or damaged, they must be replaced as a set. The ring gear and pinion must have the same reference numbers. When the pinion bearings are replaced or the ring gear and pinion are replaced, the shim arrangement must be adjusted for the new parts. Service persons must often make more than one adjustment before the clearances are correct. The transmission must be disassembled for shim adjustment and then assembled again for checks. The adjustments are correct when the gear clearance and contact pattern between the pinion and ring gear are correct and the preload on the pinion bearings is correct.

CAUTION Do not lock the special nut on the pinion shaft until the adjustments of the pinion are complete. The lock on the special nut will damage the threads on the pinion shaft if the the special nut must be removed several times for adjustments. If the threads are damaged on the pinion shaft, the pinion and ring gear must be replaced.

The dimension on the end of the pinion is the variation from the standard Gauge Distance. The Gauge Distance is the distance from the center of the ring gear to the bearing shoulder behind the pinion gear. Shims must be added between the pinion and the bearing to adjust for manufacturing tolerances.

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