Hyster D024 (S6.0FT Europe) Forklift Service Repair Manual

SERVICE REPAIR S6.0FT S7.0FT Europe [D024]

1400 SRM 1318

Drive Axle Removal

General This manual covers the repair of the drive axle, differential, and the wet disc brakes.

IDENTIFICATION PLATE See Figure 1.

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DANA PART NUMBER DANA SERIAL NUMBER HYSTER PART NUMBER AXLE OVERALL RATIO Figure 1. Identification Plate

Drive Axle Removal WARNING When putting the lift truck on blocks, make sure the surface is solid, even, and level. Any blocks used to support the lift truck must be solid, one-piece units.

1. Put blocks on each side (front and back) of the steering tires to prevent movement of the lift truck.

2. Raise the lift truck and put blocks under the frame so that the drive wheels do not touch the floor. Put blocks under the counterweight for stability.

3. Remove the mast assembly as described in the section Mast Repairs, 2- and 3-Stage Masts 4000 SRM 1250.

4. Remove the wheels.

5. Remove the planetary carrier cover fill/drain plugs on both sides of the drive axle and drain the oil into a suitable container. See Figure 2.

6. Remove the drive axle main housing center fill/ level plug. See Figure 2.

8. Remove the oil drain plugs on both sides of the drive axle and drain the oil into a suitable container. See Figure 2.

9. Remove the drive axle main housing center drain plug and drain the oil into a suitable container.

See Figure 2.

10. Remove the parking brake cables. Refer to the section Brake System 1800 SRM 1247.

11. Disconnect the brake supply line from the brake line cross fitting on the drive axle. See Figure 3.

12. Disconnect the brake booster supply line from the manifold on the drive axle. See Figure 3.

13. Disconnect the brake booster return line from the manifold on the drive axle. See Figure 3.

14. Disconnect the drive axle to transmission cooling return hose from the manifold on the drive axle.

See Figure 3.

15. Disconnect the transmission to drive axle cooling supply hose from the manifold on the drive axle.

See Figure 3.

7. Remove the oil fill plugs on both sides of the drive axle. See Figure 2.

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Drive Axle Removal

1400 SRM 1318

A. REAR VIEW SHOWN

B. FRONT VIEW SHOWN

1. DRIVE AXLE MAIN HOUSING CENTER DRAIN PLUG 2. PLANETARY CARRIER COVER FILL/DRAIN PLUG, RIGHT SIDE 3. OIL FILL PLUG, RIGHT SIDE 4. OIL FILL PLUG, LEFT SIDE 5. PLANETARY CARRIER COVER FILL/DRAIN PLUG, LEFT SIDE

6. OIL DRAIN PLUG, LEFT SIDE 7. DRIVE AXLE MAIN HOUSING CENTER FILL/LEVEL PLUG 8. OIL DRAIN PLUG, RIGHT SIDE 9. BREATHER

Figure 2. Drive Axle Drain and Fill/Level Plugs

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1400 SRM 1318 16. Place blocks under the axle assembly and connect slings and lifting device.

17. Place blocks under the transmission to support the transmission while removing the drive axle.

18. Remove the capscrews retaining the drive shaft and remove the drive shaft.

19. Remove the capscrews retaining the drive axle to the transmission mounting bracket. See Figure 4.

20. Remove the four mounting capscrews and washers from the drive axle. See Figure 5.

21. Remove blocks and lower the drive axle assembly. Pull axle forward and away from frame.

Drive Axle Removal 22. Place blocks under the differential assembly.

23. Disconnect the cooling hoses from the manifold and drive axle and remove the cooling hoses. See Figure 6.

24. Disconnect the brake cooling lines from the manifold and the drive axle and remove the brake cooling lines. See Figure 6.

25. Remove the socket head screws retaining the brake manifold to the drive axle and remove the manifold. See Figure 6.

26. Disconnect the brake lines from the drive axle and remove the brake lines with cross fitting as an assembly from the drive axle. See Figure 6.

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Drive Axle Removal

Figure 3. Drive Axle and Brake Cooling Lines and Brake Lines

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1400 SRM 1318

1400 SRM 1318

Drive Axle Removal Legend for Figure 3

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BRAKE SUPPLY LINE BRAKE BOOSTER RETURN LINE BRAKE COOLING LINE, RIGHT SIDE BRAKE LINE, RIGHT SIDE DRIVE AXLE COOLING RETURN HOSE, RIGHT SIDE 6. TRANSMISSION TO DRIVE AXLE COOLING SUPPLY HOSE

7. DRIVE AXLE TO TRANSMISSION COOLING RETURN HOSE 8. BRAKE BOOSTER SUPPLY LINE 9. DRIVE AXLE COOLING RETURN HOSE, LEFT SIDE 10. BRAKE LINE, LEFT SIDE 11. BRAKE COOLING LINE, LEFT SIDE

1. CAPSCREWS 2. MOUNTING BRACKET

3. TRANSMISSION 4. DRIVE AXLE

Figure 4. Drive Axle to Transmission Mounting Bracket

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Drive Axle Removal

1. CAPSCREW

1400 SRM 1318

2. WASHER

3. DRIVE AXLE

Figure 5. Drive Axle Mounting Capscrews Legend for Figure 6 1.

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SOCKET HEAD SCREWS BRAKE COOLING LINE, RIGHT SIDE BRAKE LINE, RIGHT SIDE DRIVE AXLE COOLING RETURN HOSE, RIGHT SIDE 5. MANIFOLD

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6. DRIVE AXLE COOLING RETURN HOSE, LEFT SIDE 7. BRAKE LINE, LEFT SIDE 8. BRAKE COOLING LINE, LEFT SIDE 9. CROSS FITTING

1400 SRM 1318

Drive Axle Removal

Figure 6. Manifold and Cooling Hoses Removal

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Planetary Reduction Gear Repair

Planetary Reduction Gear Repair REMOVE AND DISASSEMBLE Refer to Figure 7 for the following repair procedures.

Figure 7. Planetary Reduction Gear Assembly

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1400 SRM 1318

1400 SRM 1318

Planetary Reduction Gear Repair Legend for Figure 7

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OIL LEVEL PLUG PLANETARY CARRIER COVER SOCKET HEAD SCREW RETAINING RING PLANETARY GEAR SHIM WASHER SUN GEAR NUT SAFETY FLANGE THREADED STUD RING GEAR SUPPORT RING GEAR

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RETAINING RING BEARING O-RING WHEEL HUB WHEEL STUD BEARING SEAL AXLE SHAFT SOCKET HEAD SCREW WHEEL HUB MOUNT O-RING DRIVE AXLE HOUSING ARM

STEP 1.

Remove the oil level plug and drain oil in a suitable container.

1. OIL LEVEL PLUG STEP 2.

Remove the socket head screws retaining the planetary carrier cover to the wheel hub.

1. SOCKET HEAD SCREW AND SOCKET 2. PLANETARY CARRIER COVER

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Planetary Reduction Gear Repair

1400 SRM 1318

STEP 3.

Using a screwdriver or pry bar alternatively in the appropriate slots, disjoin the planetary carrier cover from the wheel hub.

1. PLANETARY CARRIER COVER STEP 4.

Remove the complete planetary carrier cover with planetary gears and sun gear.

1. PLANETARY CARRIER COVER 2. SUN GEAR STEP 5.

Remove the sun gear.

1. SUN GEAR

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1400 SRM 1318

Planetary Reduction Gear Repair

NOTE: The planetary gears and bearings must be replaced as an assembly.

STEP 6.

Remove the retaining rings retaining the planetary gears.

1. PLANETARY GEAR 2. RETAINING RING STEP 7.

Using an appropriate puller, remove the planetary gears and bearings.

1. PLANETARY GEAR STEP 8.

Check the condition of the shim washer.

1. SHIM WASHER

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Planetary Reduction Gear Repair

1400 SRM 1318

STEP 9.

Remove the ring gear safety flange retaining nuts.

1. NUT 2. RING GEAR STEP 10.

Remove safety flange.

1. SAFETY FLANGE STEP 11.

Using an appropriate puller, disengage the ring gear from the wheel hub.

1. RING GEAR

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1400 SRM 1318

Planetary Reduction Gear Repair

STEP 12.

Remove the ring gear.

1. RING GEAR STEP 13.

Connect an overhead lifting device to the wheel hub.

Using a plastic hammer, shift the wheel hub and the external bearing cone forward.

1. WHEEL HUB 2. EXTERNAL BEARING CONE STEP 14.

Remove the external bearing cone.

1. WHEEL HUB 2. BEARING CONE

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Planetary Reduction Gear Repair

1400 SRM 1318

STEP 15.

Remove the wheel hub and internal bearing cone from the wheel hub mount.

1. WHEEL HUB 2. SEAL 3. BEARING CONE NOTE: Make a note of the direction of the seal for proper installation of the new seal.

STEP 16.

Remove the seal from the wheel hub. Discard seal.

1. SEAL STEP 17.

Remove the internal bearing cone.

1. BEARING CONE

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1400 SRM 1318

Planetary Reduction Gear Repair

STEP 18.

Using a pin driver, remove the internal and external bearing cups.

1. BEARING CUP

CLEAN AND INSPECT WARNING Cleaning solvents can be flammable and toxic and can cause skin irritation. When using cleaning solvents, always follow the solvent manufacturer’s recommended safety precautions.

1. Clean all the parts with solvent.

2. Inspect the bearings and bearing cups for damage. If either bearing or bearing cup is damaged, replace both bearings and bearing cups.

3. Inspect the all parts for wear and damage. Replace parts as needed.

ASSEMBLE AND INSTALL Refer to Figure 7 for the following repair procedures.

STEP 1.

Position the wheel hub under a press.

Lubricate the seats of the internal and external bearing cones with John Deere JDM J20C. Using special tool T1, install the internal and external bearing cups into the wheel hub.

1. BEARING CUP 2. SPECIAL TOOL T1

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Planetary Reduction Gear Repair

1400 SRM 1318

STEP 2.

Lubricate the internal bearing cone with John Deere JDM J20C and install the internal bearing cone into the internal bearing cup.

1. BEARING CONE NOTE: Verify that the seal is correctly oriented.

STEP 3.

Position the seal in special tool T2.

1. SPECIAL TOOL T2 STEP 4.

Position special tool T2 on the wheel hub and press the seal into its seat.

1. WHEEL HUB 2. SPECIAL TOOL T2

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1400 SRM 1318

Planetary Reduction Gear Repair

NOTE: Using a plastic hammer, move the bearing cone to the limit stop by hammering lightly all around the edge of the wheel hub.

STEP 5.

Lubricate the wheel hub support with John Deere JDM J20C and install the wheel hub onto the support.

1. WHEEL HUB STEP 6.

If necessary, use a punch with a suitable diameter to finish seating the wheel hub and internal bearing.

NOTE: Using a plastic hammer, drive the bearing cone to the limit stop by hammering lightly all around the inner edge of the of the bearing.

STEP 7.

Lubricate the external bearing cone with John Deere JDM J20C and install the external bearing cone into the wheel hub.

1. EXTERNAL BEARING CONE

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Planetary Reduction Gear Repair

1400 SRM 1318

NOTE: In order to seat the flange, use a plastic hammer and alternatively hammer on several equivalent points.

STEP 8.

Install the ring gear.

1. RING GEAR STEP 9.

Install the safety flange.

1. SAFETY FLANGE STEP 10.

Apply LoctiteÂŽ 242 to the threads of the studs and install the retaining nuts.

1. NUT 2. RING GEAR

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1400 SRM 1318

Planetary Reduction Gear Repair

STEP 11.

Tighten the nuts in a crisscross pattern to 312 to 345 N•m (230 to 254 lbf ft).

1. NUT

CAUTION The jointed portion of the internal ring of the bearing must face the bottom of the pin.

STEP 12.

Fit the planetary gears onto the pins in the planetary cover. Using a suitable driver, seat the planetary gears on the pins, ensuring that the retaining rings can be installed.

1. PLANETARY GEAR STEP 13.

Install the retaining rings to lock the planetary gears in position.

1. PLANETARY GEAR 2. RETAINING RING

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Planetary Reduction Gear Repair

1400 SRM 1318

STEP 14.

Install the sun gear.

1. SUN GEAR STEP 15.

Lubricate a new O-ring with a lithium based grease and install the O-ring on the wheel hub.

1. O-RING STEP 16.

Using an overhead lift, install the planetary carrier cover with sun gear onto the wheel hub.

1. PLANETARY CARRIER COVER 2. SUN GEAR

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1400 SRM 1318

Planetary Reduction Gear Repair

STEP 17.

Install the socket head screws to retain the planetary carrier cover to the wheel hub. Tighten the socket head screws to 40 to 50 N•m (30 to 37 lbf ft).

1. SOCKET HEAD SCREW 2. PLANETARY CARRIER COVER STEP 18.

Install the oil level plug. Tighten the plug to 30 to 50 N•m (22 to 37 lbf ft).

1. OIL LEVEL PLUG

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Brake Repair

1400 SRM 1318

Brake Repair REMOVE AND DISASSEMBLE Refer to Figure 8 for the following procedures.

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SOCKET HEAD SCREW WASHER PARKING BRAKE LEVER O-RING SOCKET HEAD SCREW THRUST BUSHING O-RING ADJUSTING SCREW NUT CAP BLEEDER VALVE OIL FILL PLUG O-RING OIL BREATHER

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OIL DRAIN PLUG DRIVE AXLE MAIN HOUSING THRUST LEVER THRUST PINS O-RING O-RING PISTON RETURN SPRING SOCKET HEAD SCREW FRICTION PLATES BRAKE DISCS SOCKET HEAD/PIN SCREW AUTOMATIC REGULATION SPRING DOWEL PIN

Figure 8. Brake Assembly

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1400 SRM 1318

Brake Repair

STEP 1.

Insert the socket through the relative holes and remove the socket head screws retaining the planetary reduction gear assembly to the axle housing.

STEP 2.

Place a sling as shown around the planetary reduction gear assembly and remove the planetary reduction gear assembly from the axle housing complete with friction plates, brake discs, and the axle shaft.

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Brake Repair

1400 SRM 1318

STEP 3.

Remove the axle shaft.

CAUTION If the brake discs and friction plates are not being replaced, avoid switching their positions.

NOTE: Make a note of the order of the brake discs and friction plates to ensure proper assembly.

STEP 4.

Remove the friction plates and brake discs.

1. BRAKE DISC 2. FRICTION PLATE STEP 5.

Remove and discard the O-ring.

1. O-RING

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1400 SRM 1318

Brake Repair

STEP 6.

Mark the position of the piston.

STEP 7.

Remove the socket head screws and return springs from the piston.

1. SOCKET HEAD SCREW 2. RETURN SPRING STEP 8.

Remove the socket head/pin screws that guide the piston.

1. SOCKET HEAD/PIN SCREW

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Brake Repair

1400 SRM 1318

WARNING 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.

CAUTION Hold onto the piston as it may be suddenly ejected and damaged.

STEP 9.

Slowly apply compressed air through the brake fluid port to extract the entire piston.

1. PISTON NOTE: The O-rings must be replaced each time the unit is disassembled.

STEP 10.

Remove and discard the O-rings from the piston.

1. O-RING 2. O-RING

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