Hyster F019 (H330HD) Forklift Service Repair Manual 1

General

Thissectioncontainsdescriptionandrepairproceduresforthedifferential.ThereisaSpecificationssection andaTroubleshootingsectionattheendofthissection.

Description

Thisdifferentialisfastenedtothedriveaxlehousingofthelifttruck.Thedifferentialprovidesasingle-speedreductionforanincreaseintorquetothe drivewheels.Thereisahousing,aringandpinion gearset,andthedifferentialassembly.Theringgear

transferspowerfromthepinionthroughthedifferentialassemblytotheaxles.Thedifferentialassembly permitsthedrivewheelstorotateatdifferentspeeds duringaturn.SeeFigure1.

Figure1.TypicalDifferentialAssembly

DifferentialRepair REMOVE

NOTE: Therepairprocedurescoverallunitsunless otherwiseindicated.

DifferentialCarrierFromAxleHousing, Remove

NOTE: Thedifferentialassemblycannormallybe removedwithoutremovingthedriveaxle.Onsome trucks,includingtheH7.00-12.50H(H150-275H), thedriveaxlemustberemovedtoremovethedifferentialassembly.Ifremovalofthedriveaxleis necessary,seethe DriveAxle servicemanualfor yourlifttruckmodel.

1. Removethemast.Seethe Mast sectionforyour lifttruckmodelfortheremovalprocedures.

2. Raisetheendofthevehiclewheretheaxleis mounted.Useajackorotherliftingtool,and placesafetystandsundereachsideoftheaxle. SeeFigure2.

WARNING

Blockthewheelstopreventthelifttruck frommoving.Supportthelifttruckwith safetystands.DONOTworkunderalifttruck

supportedonlybyjacks.Jackscanslipand fallover.Seriouspersonalinjurycanresult.

3. Placejackstandsundereachspringseatofthe axle,toholdthelifttruckintheraisedposition.

1.SAFETYSTANDS

Figure2.LiftTruckSupport

4. Removeplugfromthebottomoftheaxlehousing anddraintheoilfromtheaxleassembly.

5. Disconnectthedriveshaftatthedifferential.If aspeedreducerorgearboxisinstalled,remove thespeedreducerorgearbox.

6. Someunitshaveadrumordiscbrakeattachedto theoutputyoke.Disconnectanybrakelinkageor brakelines.Seethe Brake sectionforyourunit.

7. Disconnectthedrivelineuniversaljointfromthe pinioninputyokeorflangeonthedifferential carrier.SeeFigure3.

8. Removetheaxleshaftsfromtheaxlehousing. Seethe DriveAxle sectionforyourmodeloflift truckfortheprocedures.

a. OnStraddleTrucks™,disconnectthedrive axleuniversaljointsatthedifferential yokes.Removethecapscrewsthatfastenthe bearingretainerstothedifferentialhousing.Pulltheyoke,stubshaftandbearing retainerfromthehousing.

9. Placeatransmissionjackunderthedifferential carrierforsupport.SeeFigure4.

Figure3.TypicalDrivelineUniversalJoint

Figure4.DifferentialCarrierSupport

16. Usealiftingdeviceandliftthedifferentialcarrierbytheinputyokeorflangeandplacetheassemblyonarepairstand.SeeFigure5.

CAUTION

Whenusingaprybar,becarefulnottodamagethedifferentialcarrierorhousingflange. Damagetothesesurfaceswillcauseoilleaks.

1.DIFFERENTIALCARRIER

2.REPAIRSTAND

Figure5.DifferentialCarrierStand

Different ialandRingGearFrom DifferentialCarrier,Remove

NOTE: Someofthepartsdescribedbelowarenot foundonsomedifferentialcarriermodels.SeeFigure1.

NOTE: Beforeworkingonthedifferentialcarrier,inspectthehypoidgearsetfordamage.Ifinspection showsno damage,thesamegearsetcanbeused again.Measurethebacklashofthegearsetand makearecordofthedimension.SeethesectionRing GearBacklash,Adjust.Duringdifferentialreassembly,adjustthebacklashtotheoriginalrecordeddimensionwhenthegearsetisinstalledintothedifferentialcarrier.

10. Removeallbutthetoptwodifferentialcarrier housingcapscrews.SeeFigure4.

11. Loosenthetoptwodifferentialcarrierhousing capscrewsandleavethemattachedtotheassembly.Thecapscrewswillholdthedifferentialcarrierinthehousing.

12. Loosenthedifferentialcarrierintheaxlehousing.Usealeathermallettohitthemounting flangeofthedifferentialcarrieratseveralpoints.

13. Afterthedifferentialcarrierisloosened,remove thetoptwocapscrews.

14. Removethedifferentialcarrierfromtheaxle housing.Useaprybarwitharoundend,tohelp removedifferentialcarrierfromhousing.

15. Removethedifferentialcarrierassemblyfrom underthelifttruck.

1. Loosen thejamnutsonthethrustscrew.

2. Remove thethrustscrewandjamnutfromthe differentialcarrier.SeeFigure6.

4. Markonedifferentialcarrierlegandbearingcap tocorrectlymatchthepartsduringdifferential carrierassembly.Markthepartsusingacenter punchandhammer.SeeFigure7.

5. Removethecotterpinsthatholdthebearingadjustingringsinposition.Somedifferentialcarriermodelshavedowelpinsorlockplatesholdingthebearingadjustingringsinposition.Each lockplateisheldinpositionbytwocapscrews. SeeFigure8.

6. Removecapscrewsandwashersholdingthetwo bearingcapsonthedifferentialcarrier.SeeFigure8.

Figure8.BearingAdjustingRingRemoval

7. Removethebearingcapsandbearingadjusting ringsfromthedifferentialcarrier.SeeFigure9.

Figure6.ThrustScrewandJamNutRemoval

3. Rotatethedifferentialcarrieruntiltheringgear isatthetopoftheassembly.

1.BEARINGCAP

2.DIFFERENTIALCARRIERLEG

3.MATCHMARKS

Figure7.MarkDifferentialCarrierLegand BearingCap

1.COTTERPIN2.LOCKPLATE

NOTE:

1. Fastenayokeorflangebartotheinputyokeor flange.Whenthenutisremoved,thebarwill holdthedrivepinioninposition.SeeFigure11.

2. Removethenutandwasherfromthedrivepinion.

3. Removetheyokeorflangebar.

CAUTION

Donotuseahammerormallettoloosenand removetheyokeorflange.Ahammerormalletcandamagethepartsandcausedriveline runoutordrivelineimbalanceproblemsafter carriertodrivelineassembly.

4. Removetheyokeorflangefromthedrivepinion. Iftheyokeorflangeistightonthepinion,usea pullerforremoval.SeeFigure12.

5. Removethecapscrewsandwashersthatholdthe pinioncarrierinthedifferentialcarrier.SeeFigure13.

8. Usealiftingdeviceandliftthemaindifferential andringgearassemblyfromthedifferentialcarrier.SeeFigure10.

Figure10.MainDifferentialandRingGear AssemblyRemoval

1.FLANGEBAR2.YOKEBAR

Figure11.FlangeandYokeBar

A. YOKEPULLER B. FLANGEPULLER

WARNING

Useabrassorleathermalletforassemblyand disassemblyprocedures.Donothitsteelparts withasteelhammer.Piecesofapartcanbreak offandcauseseriouspersonalinjury.

CAUTION

Donotuseaprybartoremovethepinioncarrierfromthecarrier.Aprybarcandamagethe bearingcase,shims,anddifferentialcarrier.

6. Removethedrivepinion,pinioncarrier,and shimsfromthedifferentialcarrier.SeeFigure13.Ifthepinioncarrieristightonthe differentialcarrier,hitthepinioncarrieratseveralpointsaroundtheflangeareawithaleather, plasticorrubbermallet.

7. Inspecttheshims.Iftheyareingoodcondition, keeptheshimstogetherforuseduringdifferentialcarrierassembly.

8. Iftheshimsaretobereplaced,firstmeasurethe totalthicknessofthepack.Makeanoteofthe dimension.Thedimensionwillbeneededtocalculatethedepthofthedrivepinioninthedifferentialcarrierwhenthegearsetisinstalled.

DISASSEMBLE

DifferentialandRingGearAssembly, Disassemble

NOTE: Someofthepartsdescribedbelowarenot foundonsomedifferentialcarriermodels.SeeFigure1.

NOTE: Makesuretherearematchingmarksonthe casehalvesofthedifferentialassembly.SeeStep4 inthesectionDifferentialandRingGearFromDifferentialCarrier,Remove.SeeFigure7.

WARNING

Useabrassorleathermalletforassemblyand disassemblyprocedures.Donothitsteelparts withasteelhammer.Piecesofapartcanbreak offandcauseseriouspersonalinjury.

1. Removethecapscrewsandwashersthathold thecasehalvestogetherandseparatethecase halves.Ifnecessary,useabrass,plastic,or leathermallettoloosentheparts.

Figure12.YokeandFlangePullerTools

Figure13.PinionCarrierRemoval

2. Removethedifferentialspider,fourpiniongears, twosidegears,andsixthrustwashersfrominsidethecasehalves.SeeFigure14.

c. Presstherivetsthroughholesinthering gearandflangecasehalf.Pressfromthe drilledrivethead.

1.THRUSTWASHER

2.SIDEGEAR

3.SPIDER,PINIONS,ANDTHRUSTWASHERS

Figure14.RingGearDisassembly

3. Iftheringgearneedstobereplaced,remove bolts,nuts,andwashersholdingtheringgearto theflangecasehalf.

CAUTION

Donotremovetherivetsorrivetheadswitha chiselandhammer.Usingaflatedgetoolcan causedamagetotheflangecase.SeeFigure15.

4. Ifyourdifferentialmodelusesrivetstoholdthe ringgeartotheflangecasehalf,removetherivetsasfollows:

a. Centerpuncheachrivetheadinthecenter, ontheringgearsideoftheassembly.

b. Drilleachrivetheadontheringgearsideof theassemblytoadepthequaltothethicknessofonerivethead.Useadrillbitthatis 1/32ofaninchsmallerthanthebodydiameteroftherivets.SeeFigure15.

A. CORRECTDRILLINGRIVETSFROMHEAD

B. WRONGCHISELINGRIVETSFROMHEAD Figure15.RivetRemoval

WARNING

Observeallwarningsandcautionsprovided bythepressmanufacturertoavoiddamageto componentsandseriouspersonalinjury.

5. Separatethecasehalfandringgearusinga press.Supporttheassemblyundertheringgear withmetalorwoodblocksandpressthecase halfthroughthegear.SeeFigure16.

Figure16.CaseHalfandRingGearSeparation

6. Ifthedifferentialbearingsneedtobereplaced, removethebearingconesfromthecasehalves. Useabearingpullerorpress.SeeFigure17.

WARNING

Observeallwarningsandcautionsprovided bythepressmanufacturertoavoiddamageto componentsandseriouspersonalinjury.

NOTE: Someofthepartsdescribedbelowarenot foundonsomedifferentialcarriermodels.SeeFigure1.

1. Placedrivepinionandpinioncarrierinapress. Thepinionshaftmustbetowardthetopofthe assembly.Addsupportsforthepinioncarrier undertheflangearea.SeeFigure18.

2. Pressthedrivepinionthroughthepinioncarrier. SeeFigure18.

WARNING

Useabrassorleathermalletforassemblyand disassemblyprocedures.Donothitsteelparts withasteelhammer.Piecesofapartcanbreak offandcauseseriouspersonalinjury.

NOTE: Theinnerbearingconeandbearingspacer willremainonthepinionshaft.SeeFigure19.

3. Ifapressisnotavailable,usealeather,plastic orrubbermallettodrivethepinionthroughthe pinioncarrier.

CAUTION

Whenremovingtheoilseal,Donotdamagethe wallofthebore.Damagetotheborewallcan resultinoilleaks.

NOTE: Alwaysreplacetheoilsealwithanewseal duringreassembly.

4. Removetheoilsealfromthepinioncarrier.See Figure19.

A. PULLER B. PRESS

Figure17.DifferentialBearingsReplacement

DrivePinionandPinionCarrier, Disassemble

1.PRESS 2.DRIVEPINION 3.OILSEAL 4.PINIONCARRIER

5.SUPPORT 6.SPIGOTBEARING 7.FLANGESUPPORT

Figure18.DrivePinionDisassembly

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5. Inspectthepinionbearingsandreplaceifnecessary.Ifthepinionbearingsneedtobereplaced, performthefollowing:

a. Removetheinnerandouterbearingcups fromtheinsideofthecage.Useeitherapress andsleeve,bearingpuller,orasmalldrift pin.SeeFigure17andFigure20.Ifapress isused,providesupportforthepinioncarrierundertheflangeareawithmetalorwood blocks.

CAUTION

Thepullermustfitundertheinnerraceof theconetoremovetheconecorrectlywithout damage.

b. Removetheinnerbearingconefromthe drivepinionwithapressorbearingpuller. SeeFigure21.

6. Ifthespigotbearingneedstobereplaced,place thedrivepinioninavise.Installasoftmetal coverovereachvisejawtoprotectthedrivepinion.

7. Removethesnapringfromtheendofthedrive pinion.SeeFigure22.

NOTE: Somespigotbearingsarefastenedtothedrive pinionwithaspecialpeeningtool.SeeFigure23.

NOTE: Somespigotbearingsareatwo-pieceassembly.Removetheinnerracefromthepinionwitha bearingpuller.Removetheouterrace/rollerassemblyfromthepinioncarrier withadriftorapress.See Figure24.

8. Removethespigotbearingfromthedrivepinion withabearingpuller.

A. BEARINGDRIVER B. BEARINGPULLER

Figure20.PinionBearingReplacement

1.PRESS 2.DRIVEPINION 3.BEARINGPULLER

4.SUPPORTS 5.INNERBEARING CONE

Figure21.PinionBearingReplacement

1.SPIGOTBEARING2.SNAPRING

Figure22.SnapRingRemoval

1.PEENINGPOINTS

Figure23.SpigotBearingPeeningPoints

1.REMOVEOUTERRACEANDROLLER ASSEMBLYFROMCARRIER

2.REMOVEINNERRACEFROMPINION Figure24.Two-PieceSpigotBearing

CLEANANDINSPECT

WARNING

Cleaningsolventscanbeflammableandtoxic andcancauseskinirritation.Whenusing cleaningsolvents,alwaysfollowtherecommendationsofthemanufacturer.

WARNING

Compressedaircanmoveparticlessothatthey causeinjurytotheuserortootherpersonnel. Makesurethatthepathofthecompressedair isawayfromallpersonnel.Wearprotective gogglesorafaceshieldtopreventinjurytothe eyes.

Cleanandinspectthefollowingpartsofthedifferential:

•Yoke-Cleanthesurfaceoftheyokejournalwitha cleaningsolventandinspecttheoriginalyokeseal surfaceforanygrooves.

•Driveaxle-Cleanthepartsoftheaxlewithsolventanddrywithcompressedair.Inspectallmachinedsurfacesandbearingsforwearanddamage.

•TaperedRollerBearings-Inspectthecup,cone, rollers,andcageofalltaperedrollerbearingsinthe assembly.Ifbearingsshowsignsofwear,cracks,or damage,replacewithnewbearing.

•PinionsandGears-Inspectthepinionsandgears forwearordamage.Gearsthatarewornordamagedmustbereplaced.

•Axleshafts-Inspecttheaxleshaftsforwearand cracksattheflange,shaftandsplines.Ifaxle shaftsshowsignsofwearordamage,replacethe axleshafts.

•Maindifferentialassembly-Inspectallpartsof themaindifferentialassemblyforwearordamage. Partsthataredamagedmustbereplaced.SeeFigure25forpartstoinspect.

Figure25.MainDifferentialAssembly Inspection

ASSEMBLE

Pinion,Bearings,andPinionCarrier, Assemble

NOTE: Someofthepartsdescribedbelowarenot foundonsomedifferentialcarriermodels.SeeFigure1.

1. Putdifferentialoilonthebearingsandcups.Installthecupsinthepinioncarrier.SeeFigure1.

2. Installtheinnerbearingandspigotbearing againstthepinionshoulders.Useasleeveand presstopushagainsttheinnerbearingrace.

CAUTION

Ifanewpinionisinstalled,anewringgear mustalsobeinstalled.Thepinionandring gearareaset(seeFigure32)andmustbeinstalledtogether.

NOTE: Duringassemblyatthefactory,onespaceris used.Twothinnerspacersareusedifthepinionor bearingsarereplaced.Thesespacersareselectedfor correctbearingpreload.

NOTE: Somespigotbearingsarefastenedtothepinionwithasnapring,andsomearefastenedwitha punch.Otherscanhaveatwo-piecebearing.SeeFigure24.

3. Installthespigotbearingwasherandsnapring. Putthepinionassemblyinthepinioncarrier.Installthespacersonthepinion.SeeFigure19.

4. Useapresstoinstalltheouterbearingagainst thespacer.Rotatethecarriertomakesurethe bearingsareinstalledcorrectly.

5. UseeitherthePressMethodortheYokeor FlangeMethod,andapplythecorrectpreload. SeeSpecifications,Table6.Checkthebearing preloadasdescribedinPinionBearings,Adjust Preloadofthissection.

PinionBearings,AdjustPreload

PressMethod

WARNING

Observeallwarningsandcautionsprovided bythepressmanufacturertoavoiddamageto componentsandseriouspersonalinjury.

NOTE: Ifapressisnotavailable,orthepressdoes nothaveapressuregauge,usetheYokeorFlange Methodtoadjustpinionbearingpreload.

1. Placethedrivepinionandcarrierassemblyina presswiththegearhead(teeth)towardthebottom.

2. Installasleeveofthecorrectsizeagainsttheinnerraceoftheouterbearing.SeeFigure19.

3. Applyandholdthecorrectamountofpressureto thepinionbearings.SeeSpecifications,Table6. Aspressureisapplied,rotatethepinioncarrier severaltimessothatthebearingsmakenormal contact.

4. Whilepressureisheldagainsttheassembly, wrapacordseveraltimesaroundthepinion carrier.FastenaNewtonorpoundscaletothe cord.SeeFigure26.

1.PRESS

2.SLEEVE

3.PINION BEARING

Figure26.BearingPreloadCheck

5. Pullthescaletounwindthecord.Check thereadingonthescaleasthecordunwinds smoothly.Donotreadstartingtorque.Read onlythetorquevalueafterthepinioncarrier startstorotate.Thestartingtorquewillprovide afalsereading.

CAUTION

OnH7.00-12.50H(H150-275H)trucks,DONOT usethewasherthatisonthenewpinion.Use thethickerspacer(HysterPN125277).The threadscanbedamagedorthenutcanloosen ifthewasherisused.

6. Thescalereadingmustindicate2.2to7.0kg(5 to15lb).

Apinioncarrierthathasa76.2mm(3in.)radiusanda2.2kg(5lb)scalereadingisequal to1.70N•m(15lbfin).Selectabearingspacer setforthecorrectpreload.Athinnersetwillincreasethepreload.Athickerbearingspacerset willdecreasepreload.

7. Usethefollowingproceduretocalculatethebearingpreload(torque):

• Poundspulled×radius(inches)=lb-inpreload.

-Preload×0.113=N•mpreload.

• Kilogramspulled×radius(cm)=kg-cmlb-in preload

-Preload×0.098=N•mpreload. OR

EXAMPLES:

• Readingfromspringscale=3.4kg(7.5lb).

• Diameterofpinioncarrier=16.8cm(6.62in.).

• Radiusofpinioncarrier=8.4cm(3.31in.).

7.5lb×3.31in=24.8in-lbpreload.

Preload×0.113=2.8N•mpreload. OR

3.4kg×8.4cm=28.6kg-cmpreload. Preload×0.098=2.8N•mpreload.

YokeorFlangeMethod WARNING

Observeallwarningsandcautionsprovided bythepressmanufacturertoavoiddamageto componentsandseriouspersonalinjury.

CAUTION

Donotinstalltightfityokesorflangesonshafts usingahammerormallet.Ahammerormallet willdamagetheyokeorflange.

NOTE: Useapresstoinstalltheyokeorflange.

1. Installtheinputyokeorflange,nut,andwasher onthedrivepinion.Theyokeorflangemust beseatedagainsttheouterbearingforproper preload.

2. Temporarilyinstallthedrivepinionandpinion carrierassemblyintothedifferentialcarrier.Do notinstallshimsunderthepinioncarrier.See Figure34.

3. Installthepinioncarriertothedifferentialcarrierbyinstallingthecapscrewsandtightening thembyhand.Donotinstallthewashers,they arenotrequired.

4. Fastenayokeorflangebartotheinputyokeor flange.SeeFigure11.Thebarwillholdthedrive pinioninpositionwhenthenutistightened.

5. Tightenthenutonthedrivepiniontothecorrect torquevalueasshowninSpecifications,Table6. Removetheyokeorflangebar.

6. Attachatorquewrenchonthedrivepinionnut. Rotatethedrivepinionandreadthevalueindicatedonthewrench.SeeFigure27.

7. Ifthepreload(torque)ofpinionbearingsisnot withinspecifications,removethepinionand pinioncarrierfromthedifferentialcarrier.PerformStepaandStepbbelow,thenrepeatStep1 throughStep6.

Figure27.TorqueValueReading