Hyster D187 (S60XM) Forklift Service Repair Manual

S40XM S45XM S50XM S55XM S60XM S65XM [D187]

General

Thissectionhasthedescriptionandrepairproceduresforthedriveaxle,wheelbearings,and mountsfortheaxlehousing.Informationforthe

differentialandtheringandpiniongearsisinthe section Single-SpeedPowershiftTransmission, TroubleshootingandRepair 1300SRM501.

Description

Thedriveaxleisheldtothelifttruckbyaxlemounts. SeeFigure1.Theseaxlemountsarefastenedto theframeofthelifttruckbynutsandbolts.The differentialhousingandspindlescanrotateasmall amountintheaxlemounts.Theouterendsofthe spindlesarethemountsforthewheelbearings.The wheelbearingsaretaperedrollerbearingswiththe cupspressedintothehub/brakedrum.Thenuton theendofthespindleholdsandadjuststhewheel

REMOVEANDDISASSEMBLE

WARNING

bearings.Theaxleshaftsarefastenedtothehubs bycapscrews.

Thebackplateandbrakeassemblyarefastenedto theaxlehousingmounts.Theaxlehousingmounts arealsothehangersforthemast.

Theouterwheelbearingislubricatedwithgearoil fromthedifferentialhousing.Theinnerwheelbearingislubricatedwithwheelbearinggrease.

DriveAxleRepair

Neverloosenthenutsthatholdtheinnerand outerwheelhalvestogetherwhenthereisair pressureinthetire.

Whenputtingthelifttruckonblocks,make surethesurfaceissolid,even,andlevel.Any blocksusedtosupportthelifttruckmustbe solid,one-pieceunits.

1. Putblocksoneachside(frontandback)ofthe steeringtirestopreventmovementofthelift truck.SeeFigure1.

2. Raisethelifttruckandputblocksunderthe framesothatthedrivewheelsjusttouchthe floor.Putblocksunderthecounterweightfor stability.

3. Removethemastassemblyasdescribedinthe section Mast, Repairs 4000SRM522.

4. Draintheoilfromthedifferential.

WARNIN G

DeflatetheH2.00-3.20XM(H40-65XM)tires completelybeforeremovingthemfromthelift truck.Airpressureinthetirescancausethe tireandrimpartstoexplodecausingserious injuryordeath.

5. Removethewheels.Removethecapscrewsthat holdtheaxleshaftstothebrakedrums.Remove theaxleshafts.

6. Bendthelockplateandremovethenutfromthe spindle.Removethewasherandbearingcone. Slidethehub/brakedrumfromthespindle.Ifthe assemblycannotberemovedeasily,loosenthe brakeshoes.Putascrewdriverthroughthehole inthebackplatetoturntheadjusterwheeland loosenthebrakeshoes.Pulltheactuatoraway fromtheadjusterwheelwhiletheadjusterwheel isturnedup.

7. Disconnectthebrakelinestothewheelcylinders. Disconnecttheparkingbrakecablesattheparkingbrakelever.Loosenthecableclampsforthe parkingbrakecables.

8. Putblocksunderthedifferentialhousing.Removetheboltsandnutsthatholdtheaxlehousingmountstotheframeofthelifttruck.Remove theaxlehousingmounts.

Figure1.DriveAxleParts

9. Removethecapscrewsthatholdthespindlesto thedifferentialhousing.Removethespindle. SeeFigure2.

10. Disassemblethebrakeassemblyasdescribedin thesection BrakeSystem 1800SRM506.Removethebackplatefromthemountsfortheaxle housing.

CLEANANDINSPECT

WARNING

Cleaningsolventscanbeflammableandtoxic andcancauseskinirritation.Whenusing cleaningsolvents,alwaysfollowthesolvent manufacturer’srecommendedsafetyprecautions.

1. Cleanallthepartsofthedriveaxlewithsolvent.

2. Inspectthebearingsandsealsfordamage.The spindlesmustturnfreelyinthemounts.The splinesfortheaxleshaftsmustnotbedamaged.

ASSEMBLEANDINSTALL

1. InstallnewO-ringsonthespindles.SeeFigure1 andFigure3.Installthespindleintothedifferentialhousing.Installthecapscrewsandlockwashers.Tightenthecapscrewsasshowninthe TorqueSpecifications.

2. Assemblethebrakeassemblytothemountfor theaxlehousingasdescribedinthesection BrakeSystem 1800SRM506.

3. LubricatethespindleswithNeverSeez® and slidethemountswiththebrakeassemblyonthe spindle.SeeFigure4.Installandtightenthe boltsandnutsasshownintheTorqueSpecifications.

4. Installnewgreasesealsinthehub.SeeFigure5.Installtheoutersealwiththeliptoward

theouterbearing.Installtheinnerbearingand seal.SeeFigure6.Putwheelbearinggreasein thebearingthatisbetweentheseals.

5. Installthehub/brakedrumassemblyontheaxle housing.

6. Installtheouterbearingconeontheaxlehousing.Installthewasherandlockplate.Install thenut.Tightenthenutto205N•m(150lbfft) torquewhilerotatingthehub.Loosenthenut untilthehubturnsfreely.Thetorquemustbe lessthan25N•m(20lbfft).Tightenthenut to35N•m(25lbfft)oruntilthefirstalignment positionafter35N•m(25lbfft).Bendthelock plateoverthenut.SeeFigure7.

Figure2.SpindleRemoval

Figure3.O-RingInstallation

Figure4.SpindleLubrication

7. Adjusttheclearanceofthebrakeshoesasdescribedinthesection BrakeSystem 1800SRM 506.

8. Installthewheelsandnutsandtightenthenuts forthewheelsasshownintheTorqueSpecifications.

9. Putsealantontheflangeoftheaxleshaft.Installtheaxleshaftsandcapscrews.Tightenthe capscrewsasshownintheTorqueSpecifications.

10. Installandtightenthedrainplug.FillthedifferentialhousingwithSAE90EPgearoilthrough thefillhole.Installthefillplug.Connectthe brakelinesandparkingbrakecables.Remove theairfromthebrakesystemasdescribedinthe section BrakeSystem 1800SRM506.

11. Installthemastasdescribedinthesectionfor Mast, Repairs 4000SRM522.

Figure5.HubAssembly

TorqueSpecifications

BackPlatetoAxleMountCapscrews 225N•m(166lbfft)

WheelCylinderCapscrews 18to27N•m(13to20lbfft)

SpindletoDifferentialHousing 66N•m(49lbfft)

AxleShaftCapscrews 98N•m(75lbfft)

AxleMountstoFrame

325to380N•m(240to280lbfft)Torque wrenchonheadofcapscrew.

WheelNuts 490to510N•m(361to376lbfft)

BackPlatetoAxleMountCapscrews 255N•m(188lbfft)

WheelCylinderCapscrews 18to27N•m(13to20lbfft)

SpindletoDifferentialHousing 90N•m(66lbfft)

AxleShaftCapscrews 90N•m(66lbfft)

AxleMountstoFrame 473N•m(350lbfft)Torquewrenchonnut.

WheelNuts 237to305N•m(175to225lbfft)

Figure6.OilSealInstallation

Figure7.LockPlateInstallation

H2.00-3.20XM(H40-65XM)

S2.00-3.20XM(S40-65XM)

Troubleshooting

PROBLEMPOSSIBLECAUSEPROCEDUREORACTION

Thelifttruckwillnotmove.Anaxleshaftisbroken.Installnewaxleshaft.

Thedriveaxlehasleaks.Thedrainorfillplugislooseormissing. Repairthreads.Tightenplug.Install missingpart.

Thesealshavedamage.Installnewseals.

TheO-ringshavedamage.InstallnewO-rings.

Thedriveaxlemakesnoise.Thebearingshavedamage.Installnewparts.

Thebrakeassemblyisdamaged.Repairbrakeassembly. Theoillevelistoolow.Fillasrequired.Checkforleaks. Theaxlecapscrewsareloose.Tightencapscrewstospecified torque.

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General

Thissectionhasthedescriptionandrepairproceduresforthesteeringaxle.Seethefollowingsections foradditionalinformationonthepartsofthesteeringsystem:

•SteeringControlUnit(RossHGF) 1600SRM 257forlifttruckmodelsS/E2.00-3.20XL(S/E4060XL)(A187,B187,C187,andC108)

•SteeringHousingandControlUnit 1600SRM 720forlifttruckmodelsE2.00-3.20XM(E45-65Z) (G108),E2.00-3.20XM(E45-65XM 2)(F108),and V30ZMD(D210/E210)

•SteeringHousingandControlUnit 1600 SRM512forlifttruckmodelsE2.00-3.20XM (E45-65XM)(F108),S2.00-3.20XM(S40-65XM) (D187),andN30XMH,N30XMH 2H (A210,C210)

•HydraulicSystemandGearPump 1900SRM 130forlifttruckmodelsS2.00-3.20XL(S40-60XL) (A187,B187,andC187)

•HydraulicSystem 1900SRM286forlifttruck modelsE2.00-3.20XL(E40-60XL)(C108)

•HydraulicSystem 1900SRM513forlifttruck modelsS2.00-3.20XM(S40-65XM)(D187)

•HydraulicSystem 1900SRM559forlifttruck modelsN30XMH,N30XM 2H(A210,C210), V30ZMD(D210/E210),E2.00-3.20XM(E45-65XM, E45-65XM 2 (F108)andE2.00-3.20XM(E45-65Z) (G108)

•SteeringSystem 1600SRM459forlifttruck modelsS2.00-3.20XL(S40-60XL)(A187,B187, andC187)

•SteeringSystemforElectricLiftTrucks 1600 SRM485forlifttruckmodelsE2.00-3.20XL(E4060XL)(C108),E2.00-3.20XM(E45-65XM 2)(F108), andN30XMH,N30XM 2H(A210,C210)

•SteeringSystemforACElectricLiftTrucks 1600SRM1054forlifttruckmodelsV30ZMD (D210/E210)andE2.00-3.20XM(E45-65Z)(G108)

Description

Thesteeringaxleassemblyincludesanaxleframe, steeringcylinder,andtwospindleassemblies.See Figure1.Thesteeringaxleisarticulatedandisconnectedtotheframebycenterpivotmounts.Thecenterpivotmountspermitthesteeringaxletomove intheframemountwhenthelifttrucktravelsover roughsurfaces.

Theendcapsofthesteeringcylinderarealsothe mountsforthecylinderandareheldtotheshellby themountcapscrews.ThereareO-rings,seals,and wipersintheendcapstosealthecapstotheshell androd.Theendsofthepistonrodextendfromboth endsofthecylinder.Asinglepistonandthesealare atthecenteroftherod.Oilpressureononesideof thepistonmovesthepistoninthebore.Thepiston pushesanequalamountofoilfromtheoppositeside ofthecylinder.

Whenthepistonreachestheendofthestroke,areliefvalveinthesteeringcircuitcontrolstheoilpressure.Thetierodsthatconnectthespindlearmsto thecylinderarenotadjustable.

Eachspindleturnsontwotaperedrollerbearingsin mountsintheaxleframe.Thepreloadonthebearingsiscontrolledbyshimsatthelowerbearingcap. Thewheelsrotateontwotaperedrollerbearingsand areheldonthespindlesbyacastlenut.Thebearing preloadofthewheelsisadjustedbythecastlenut. Thegreasesealsprotectthebearingsfromdirtand water.

1.SPINDLEASSEMBLY

4.RUBBERMOUNT

5.STEERINGCYLINDER

6.NUTANDBOLT

2.AXLEFRAME

3.BRACKET

Figure 1.SteeringAxle

SteeringAxleAssemblyReplacement

REMOVE WARNING

PUTTINGTHELIFTTRUCKONBLOCKS

Thelifttruckmustbeputonblocksforsome typesofmaintenanceandrepair.Theremoval ofthemast,driveaxle,battery,orcounterweightassemblieswillcauselargechanges inthecenterofgravity.Whenthelifttruck isputonblocks,putadditionalblocksinthe followingpositions:

•Ifthemastanddriveaxleareremoved,put blocksunderthecounterweightsothelift truckcannotfallbackward.

•Ifthebattery(electriclifttrucks)orcounterweightisremoved,putblocksunderthemast sothatthelifttruckcannotfallforward.

Putthelifttruckonblocksonasolid,even,and levelsurface.Makesuretheblocksorstands haveenoughcapacitytoholdthelifttruck.Use additionalblocksnexttothetiresasnecessary topreventmovementofthelifttruck.Make suretheliftingdevicesusedduringrepairscan lifttheweightofthepartsandassemblies.

SeetheOperatingManualorPeriodicMaintenancesectionforyourlifttruckmodel,forthe procedurestoputthelifttruckonblocks.

Thesteeringaxlecanberemovedwithoutremoving thecounterweight;thejobiseasierwiththecounterweightremoved.SeeFigure1.

1. Installaneyeboltintopofcounterweight.Removecounterweight.Seethesections

•Frame 100SRM558forlifttruckmodels

E2.00-3.20XM(E45-65XM,E45-65XM 2 (F108), N30XMH,N30XM 2H(A210,C210),V30ZMD (D210/E210),andE2.00-3.20XM(E45-65Z) (G108)

•Frame 100SRM284forlifttruckmodels E2.00-3.20XL(E40-60XL)(C108)

•Frame 100SRM505forlifttruckmodels

S2.00-3.20XM(S40-65XM)(D187)

•Frame 100SRM254forlifttruckmodels

S2.00-3.20XL(S40-60XL)(A187,B187,and C187)

forprocedurestoremovethecounterweight.

2. Makesurewheelsaresetforstraighttravel.Put lifttruckonstandssothesteeringaxlewillhave enoughclearancetoberemoved.Thetopofthe axleframemusthaveclearanceunderthebottomoftheframeattherearofthelifttruck.

3. Disconnecthydrauliclinesatsteeringcylinder. Installplugfittingsincylinderandputcapson hydrauliclines.Plugfittingswillpreventspindlesfromturningasaxleisremovedfromunder thelifttruck.

4. Slidefloorjackorforksofanotherlifttruckunder steeringaxle.Raiseliftingdeviceuntilitholds theweightoftheaxleassembly.Removefour capscrewsandnutsthatfastentwobracketsunderrubbermounts.Removebracketsandslowly loweraxleassemblyontowheels.Carefullyroll axleassemblyawayfromlifttruck.

INSTALL

1. Installrubbermountsonaxle.Makesureface ofrubbermountwiththepartnumberisaway fromtheaxle.Makesurepartnumberwillbe rightsideupafteraxleassemblyisinstalled.See Figure1.

2. Applylubricantthatisapprovedforusewith rubbertorubbermount.Thelubricantisused wheremountandframejoin.

3. Usefloorjackoranotherlifttrucktoputsteering axleintopositioninframe.Makesurerubber mountsfitinsideframebracketsformounts.

4. Installbottombrackets.Tightenfourbracket boltsandnutsto88N•m(65lbfft).

5. Removeplugsandcapsandconnecthydraulic linestosteeringcylinder.

6. Operatesteeringsystemtoremoveairfromsystem.Turnsteeringwheelseveraltimesfromone stoptotheother.Checkforhydraulicleaks.

WheelsRepair

REMOVEANDDISASSEMBLE

1. Putaxleonblockssowheelsjusttouchthefloor. Removegreasecap.Removecotterpinandcastlenut.Removebearingcone.Slidewheelfrom spindle.Removeinnerbearingconeandseal fromspindle.SeeFigure2.

2. Ifthebearingsmustbereplaced,useabrassdrift toremovebearingcupsandwearsleeve.

3. Repeatprocedureforotherwheel.

CLEAN WARNING

Cleaningsolventscanbeflammableandtoxic andcancauseskinirritation.Whenusing cleaningsolvents,alwaysfollowthesolvent manufacturer’srecommendedsafetyprocedures.

Cleanallpartswithsolvent.Makesurebearingsare clean.

INSPECT

Inspectthespindleandmakesurethatitdoesnot haveanyroughorsharpareasthatwouldprevent thebearingsfrombeingcorrectlyinstalled.Ifnecessary,smoothanyroughorsharpareasbeforeinstalling thebearings.

ASSEMBLE ANDINSTALL

1. Ifnecessary,useapresstoinstallnewbearing cupsinwheel.SeeFigure2orFigure3.Ifnecessary,installnewwearsleeveinwheel.Install

greasesealonspindle.Lubricatebearingcones withgrease.Makesurebearingsarefilledwith grease.Installinnerbearingconeonspindle.

CAUTION

Donotdamagethesealsduringinstallation.

2. Carefullyslidewheelontospindle.Installouter bearingcone,andinstallthewasher.

NOTE: Ifthelifttruckisanoldermodel,gotoStep8.

3. Installcastlenut.Tightencastlenutto68N•m (50lbfft),whilerotatingthehubinbothdirectionstoproperlysetbearings.Loosennutby1/4 turn.Tightennutto3N•m(27lbfin).

4. Pullonthewheelaxiallytoensurethatthereis noendplay.Ifthereisendplay,repeatStep1 throughStep3.

5. Adjustcastlenutleftorrighttoclosestspindle holealignmentposition.Locknutinplacewith cotterpin.Ifcotterpincannotbeinstalled,or thereisnotatleastonefullthreadvisiblepast thenut,thenrepositionthewasherandrepeat Step3throughStep5.

6. Installgreasecap.

7. Repeatprocedurefortheotherwheel.

8. Installcastlenut.Tightencastlenutto200N•m (150lbfft).Loosennuttolessthan27N•m (20lbfft).Tightennutto34N•m(25lbfft). Tightencastlenutuntilcotterpincanbeinstalled.Installcotterpin.

Figure2.SpindleandTieRodAssembly(EarlyModels)

Spindles,Bearings,andTieRodsRepair

REMOVEANDDISASSEMBLE

1. Removethetiresandwheels.SeetheWheels RepairsectioninthisSRM.

CAUTION

Donothitthethreadsorthenutofthetierod.

2. Ifthetierodistobereplaced,removethecotter pinandcastlenut.Removepin,insidethedust cover,securingtierodtothesteeringcylinder.

3. Useaspecialpullertoremovethetaperedstud fromthespindlearm.Toloosenthestud,use anotherhammerbehindthearmtoholdthearm. Hitthespindlearmwithalargehammer.

4. Removethegreasecapfromthespindle.Remove thecapscrewsfromthebearingcap.Removethe bearingcapandshims.Ifnecessary,removethe bearingcupfromthebearingcapasshownin Figure4.

5. Tiltthespindleandliftthespindlefromtheaxle. SeeFigure5orFigure6.Ifnecessary,removethe bearingandsealsfromthespindle.Ifnecessary, removethewearsleeveandbearingcupfromthe axleframe.

6. Repeattheprocedurefortheotherspindleand tierod.

Figure3.SpindleandTieRodAssembly(LaterModels)