SERVICE REPAIR H4.5FT6 H5.0FT H5.5FT Europe [P005]
General
Thissectionhastherepairproceduresforthedriveaxleanddifferentialassembly.
DriveAxleRepair
REMOVEANDDISASSEMBLE
WARNING
Whenputtingthelifttruckonblocks,make surethesurfaceissolid,even,andlevel.Any blocksusedtosupportthelifttruckmustbe solid,one-pieceunits.
1. Putblocksoneachside(frontandback)ofthe steeringtirestopreventmovementofthelift truck.
2. Raisethelifttruckandputblocksunderthe framesothatthedrivewheelsdonottouchthe floor.Putblocksunderthecounterweightfor stability.
3. Removethemastassemblyasdescribedinthe section MastRepairs, 2and3-StageMasts 4000SRM1250.
4. RemovethefillplugandO-ring.DiscardO-ring.
5. RemovethedrainplugandO-ringtodrainthe oilfromthedriveaxleintoasuitablecontainer. DiscardO-ring.SeeFigure1.
6. Removethewheels.
7. Disconnectthebrakelineconnectingthemaster cylindertothebrakemanifoldlocatedontopof thedifferentialhousingassembly.
8. Removetheparkingbrakecable.Refertothe section BrakeSystem 1800SRM1247.
9. Placeblocksundertheaxleassemblyandconnectslingsandliftingdevice.
10. Placeblocksunderthetransmissiontosupport thetransmissionwhileremovingthedriveaxle.
11. Removethecapscrewsretainingthedriveshaft andremovethedriveshaft.
12. Removethetransmissionisolatormountingbolt locatedontopoftheassembly.SeeFigure7.
13. Removethefourmountingcapscrewsfromthe driveaxle.SeeFigure2.
14. Removeblocksandlowerthedriveaxleassembly.Pullaxleforwardandawayfromframe.
15. Placeblocksunderthedifferentialassembly.
16. Removetheaxleshafts,hub/brakedrumassembly,andbackplates.Refertothesection Brake System 1800SRM1247.
17. Removethecapscrewsandwashersretainingthe hangerassemblytotheinternalgearanddifferentialhousing.
18. Removetheplanetarygearassemblyfromthe differentialhousing.
1400SRM1245 DriveAxleRepair
1.DIFFERENTIALHOUSINGASSEMBLY 2.O-RING 3.OILFILLPLUG 4.OILDRAINPLUG 5.O-RING
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Figure1.DrainPlug
DriveAxleRepair 1400SRM1245
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Figure2.DriveAxle
19. Removetheinternalgearfromthedifferential housing.
20. Removethesungearfromthedifferentialhousing.
21. Removetheoutersnapringretainingtheball bearing.SeeFigure3.
22. Removeballbearing.
23. Removeinnersnapring.
CAUTION
Whenremovingtheplanetarygear,ensurethat theneedlebearingsarenotlost.Losingany needlebearingcouldresultindamagetothe equipment.
24. Removepinretainingthethrustwasher,planetarygear,spacer,andneedlebearings.SeeFigure4.
1.PLANETARYGEARASSEMBLY 2.PIN
3.THRUSTWASHER
4.SPACER
5.NEEDLEBEARINGS(QTY48)
6.PLANETARYGEAR
Figure4.PlanetaryGearandNeedleBearings
1400SRM1245 DriveAxleRepair
1.BRAKEMANIFOLD 2.INPUTSHAFT(YOKE) 3.OUTERSEAL 4.BEARINGCONE 5.BEARINGCUP 6.INNERSEAL 7.HUB/BRAKEDRUM ASSEMBLY 8.BEARINGCUP 9.BEARINGCONE 10.WHEELBEARINGWASHER 11.LOCKPLATE 12.LOCKNUT 13.AXLESHAFT 14.CAPSCREW 15.CAPSCREW 16.BRAKEASSEMBLY 17.BRAKELINE 18.CAPSCREW 19.WASHER 20.CAPSCREW 21.WASHER 22.HANGERASSEMBLY 23.INTERNALGEAR 24.PLANETARYGEARASSEMBLY 25.SUNGEAR 26.DIFFERENTIALHOU SINGASSEMBLY
LegendforFigure2
1.PLANETARYGEARASSEMBLY 2.INNERSNAPRING 3.BALLBEARING 4.OUTERSNAPRING
Figure3.PlanetaryGearDisassembly/ Assembly
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25. Removeplanetarygear,thrustwashers,andneedlebearingsfromhousing.
26. Removethe48needlebearings(24oneachsideof spacer)andspacerfromtheplanetarygear.Repeatthisstepontheremainderplanetarygears.
27. Removethethrustwasherfromtheinside ofplanetarygearassembly.RepeatStep19 throughStep27fortheoppositeside.SeeFigure5.
4. Inspectthesungearforwearordamage.Ifthe sungearsshowsignsofwearordamage,replace thesungear.Thesplinesofthesungearsmust notbedamaged.
5. Inspecttheaxleshaftsforwearandcracksatthe flange,shaft,andsplines.Ifaxleshaftsshow signsofwearordamage,replacetheaxleshafts. Thesplinesfortheaxleshaftsmustnotbedamaged.
ASSEMBLEANDINSTALL
1. Installthrustwasherinsidetheplanetarygear assembly.
2. Applyalightcoatofgreaseontheinsideofthe planetarygearandslowlyinstall24needlebearingsoneachsideofthespacerintoplanetary geartobeflushwiththegearface.
NOTE: Spacershouldsplittheneedlebearingsinto twoseparatesectionsforoneplanetarygearassembly.
3. Applyalightcoatofgreaseonthrustwasherand installthethrustwasherontheendsoftheplanetarygear.
1.PLANETARYGEARASSEMBLY
2.THRUSTWASHER
Figure5.PlanetaryGearAssemblyandThrust Washer
CLEANANDINSPECT
WARNING
Cleaningsolventscanbeflammableandtoxic andcancauseskinirritation.Whenusing cleaningsolvents,alwaysfollowthesolvent manufacturer’srecommendedsafetyprecautions.
1. Cleanallthepartsofthedriveaxlewithsolvent.
2. Inspecttheplanetarygears,spacers,needle bearings,andthrustwashersfordamage.If planetarygears,spacers,needlebearings,or thrustwashersshowsignsofwearordamage, replacethecomponentsasneeded.
3. Inspecttheinternalgearsforwearanddamage. Replaceasneeded.Cleansiliconefrommating surfaces.
4. Installthethrustwashers,planetarygear,and needlebearingsasanassemblyintotheplanetarygearassembly.
5. Ensureflatsurfaceofthepinistowardthecenter ofthecarrierandinstallpininalignmentwith theplanetarygear.RepeatStep2throughStep5 forremainderplanetarygears.
6. Installinnersnapringtoretainpins.
7. Installballbearing.
8. Installoutersnapringtoretaintheballbearing.
9. Installthesungearinthedifferentialhousing. RepeatstepsStep1throughStep9fortheoppositeside.
10. ApplyRTVHighPerformancesealant,Hyster PartNo.1584621orequivalent,tothemating surfaceoftheinternalgear.Installtheinternal gearonthedifferentialhousing.
11. Installplanetarygearassemblyintothedifferentialhousingassembly.
DriveAxleRepair 1400SRM1245
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12. Placethehangerassemblyinpositiononthedifferentialhousingassembly.ApplyLoctite® 242 tothecapscrewsandinstallcapscrewsandlockwasherstoretaindifferentialhousingassembly. TightencapscrewsinsequenceshowninFigure6 to225to248N•m(166to183lbfft).Repeat stepsStep10andStep11fortheoppositeside.
NOTE: ApplyLoctite® 515orHighPerformanceRTV SiliconeGasketMakerontheaxleshaftflangewhen installing.
13. Installthebackplates,hub/brakedrumassemblies,andaxleshafts.Refertothesection Brake System 1800SRM1247.
14. Connectslingsandliftingdevicetodriveaxle.
NOTE: Wheninstallingthedriveaxle,ensurethe driveaxleisheldwiththeuppersurfaceofthedrive axleagainsttheframe.Thiswillpreventanygapbetweentheframeandthedriveaxlemount,andwill ensureevenweightdistribution.
15. Positionthedriveaxleinthelifttruck.
NOTE: Itisrecommendedtouseatorquemultiplier toachievethetorquespecificationinStep16.
16. Installthefourmountingcapscrewsandwashers.Tightenthecapscrewsto820to902N•m (605to665lbfft).
17. Placethedriveshaftinpositionandinstallthe retainingcapscrews.Tightenthedriveshaftcapscrewsto50to66N•m(37to49lbfft).
18. Installthetransmissionisolatormountingbolt locatedontopoftheassembly.Tightentheboltto 225to250N•m(166to184lbfft).SeeFigure7.
19. Removeblocksfromunderthetransmission.
20. Installparkingbrakecable.Makesurethebrake cableisroutedproperlyandhasnointerference. Verifythattheparkingbrakeoperatesproperly. Refertothesection BrakeSystem 1800SRM 1247.
21. Connectthebrakelineconnectingthemaster cylindertothebrakemanifoldlocatedontopof thedifferentialhousingassembly.
NOTE: Whentighteningthewheelnuts,DONOTuse anylubricantonthestudsornuts.
22. Installthewheelandnutsandtightenthenuts to610to680N•m(450to502lbfft).
23. ApplymultipurposegreasetonewO-ringandinstallO-ringonthedrainplug.
24. InstalltheO-ringanddrainplug,andtightento 14to27N•m(10to20lbfft).
1400SRM1245 DriveAxleRepair
Figure6.HangerAssemblyTightening Sequence
1.TRANSMISSION 2.DIFFERENTIALHOUSINGASSEMBLY 3.ISOLATOR,TRANSMISSION 4.WASHER 5.LOCKWASHER 6.CAPSCREW
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Figure7.TransmissiontoDifferentialHousing AssemblyMountingBolts
25. Fillthedriveaxletotheproperlevelwith7.5to 8.0liter(7.9to8.4qt)ofSAE80W-90gearoil throughthefillholeasshowninFigure8.
26. ApplymultipurposegreasetonewO-ringandinstallO-ringonthefillplug.
27. InstalltheO-ring,fillplug,andtightento14to 27N•m(10to27lbfft).
28. Removetheairfromthebrakesystemasdescribedinthesection BrakeSystem 1800SRM 1247.
29. Installthemastassemblyasdescribedinthesection MastRepairs, 2and3-StageMasts 4000 SRM1250.
30. Raisethelifttruckandremoveblocksfromunder frameandfromunderthecounterweight.Lower thelifttruck.
31. Removetheblocksoneachside(frontandback) ofthesteeringtires.
32. Operatethelifttruckandcheckforproperoperationandleaks. 1.OILFILLPLUG 2.OILDRAINPLUG 3.OILFILLLEVEL
DifferentialRepair REMOVE
Forthefollowingrepairprocedures,thedriveaxle mustberemovedanddisassembled.RefertothesectionDriveAxleRepair.
SupportDifferentialAssemblyFrom DifferentialHousingAssembly
1. Removeinputshaft(yoke).
2. Removethedustcover.
3. Removetheoilseal.SeeFigure9.
4. Removecapscrewandlockwasherretaining brakemanifoldbrackettothedifferentialassemblysupport.SeeFigure10.
5. Removebrakemanifoldbracket.
6. Removecapscrewsandlockwashersretaining thedifferentialassemblysupporttothedifferentialhousing.
UsingtwooftheM8×1.25×40capscrewsremovedfromthedifferentialassemblysupport, pushthedifferentialassemblysupportfromthe differentialhousing.Ifthecapscrewsdonothave enoughthreadedlength,useaprybartofinish removingthedifferentialassemblysupport.
7. Removedifferentialassemblysupportfromthe differentialhousingassembly.SeeFigure10.
DifferentialRepair 1400SRM1245
Figure8.OilFillLevel
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1400SRM1245 DifferentialRepair 1.DIFFERENTIALHOUSINGASSEMBLY 2.OILSEAL 3.DUSTCOVER 4.INPUTSHAFT(YOKE)
1.DIFFERENTIALHOUSING 2.DIFFERENTIALASSEMBLYSUPPORT 3.BRAKEMANIFOLDBRACKET 4.LOCKWASHERS 5.CAPSCREWS 6.CAPSCREW 7.LOCKWASHER
Figure9.DriveAxleYoke
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Figure10.DifferentialHousingAssembly SectionDisassembly
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DifferentialAssemblyFromDifferentialAssemblySupport
NOTE: Beforeworkingonthedifferentialassembly,inspectthehypoidgearsetfordamage.Ifinspectionshows nodamage,thesamegearsetcanbeusedagain.Usingadialindicator,measurethebacklashofthegearset andmakearecordofthedimension.
NOTE: IfthelifttruckwasmanufacturedpriortoOctober2006andtheretainingringshavenotbeenreplaced, gotoSTEP1.IfthelifttruckwasmanufacturedafterOctober2006ortheretainingringshavebeenreplaced inalifttruckmanufacturedpriortoOctober2006,gotoSTEP2.
STEP1. Removedifferentialassemblyretainerringcotter pins.Usingaretainerringspecialtool,HysterPart No.1581188,loosentheretainerrings.Ifnecessary,loosenthebearingcapcapscrewstoallowthe retainerringstoturnfreely.
DifferentialRepair 1400SRM1245
1.COTTERPIN
2.RETAINER RING
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1.RETAINERRINGSPECIALTOOL
STEP2. Removedifferentialassemblyretainerringcotter pins.Usingaretainerringspecialtool,HysterPart No.1663599,loosentheretainerrings.Ifnecessary,loosenthebearingcapcapscrewstoallowthe retainerringstoturnfreely.
1400SRM1245 DifferentialRepair
1.COTTERPIN
2.RETAINERRING
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1.RETAINERRINGSPECIALTOOL
STEP3. Removetheretainerrings.
1.DIFFERENTIALASSEMBLYSUPPORT
2.RETAINERRINGS
STEP4. Markonedifferentialcarrierlegandbearingcap tocorrectlymatchthepartswhenassemblingdifferentialassemblysupport.Markthepartusinga centerpunchandhammer.Removethecapscrews andwashersretainingthebearingcaps.Removethe bearingcaps.
1.DIFFERENTIALASSEMBLYSUPPORT
2.BEARINGS
3.BEARINGCAPS
4.WASHERS
5.CAPSCREWS
DifferentialRepair 1400SRM1245
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STEP5.
Removethedifferentialassemblyfromthedifferentialassemblysupport.
DifferentialAssemblySupportfromDropBox
STEP1.
Removethecapscrewsandlockwashersretainingthe pinioncoverplate.
Removepinioncoverplate.
1.DIFFERENTIALASSEMBLYSUPPORT 2.PINIONCOVERPLATE
3.CAPSCREWS
4.LOCKWASHERS
5.DROPBOXASSEMBLY
1400SRM1245 DifferentialRepair
1.DIFFERENTIALASSEMBLYSUPPORT 2.TAPEREDROLLERBEARINGANDCUP 3.DIFFERENTIALASSEMBLY
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CAUTION
Whenremovingthepinionnut,makesurethestakedareasdonottouchthepinionthreads.The stakedareascancausedamagetothepinionthreads,makingthepinionunserviceable.
NOTE: Whenremovingthepinion,besuretoretaintheshims.
STEP2.
Useasmall,flatchiseltounstakethepinionnut.
Removethepinionnut,washer,bearingcone,and shims. 1.DIFFERENTIALASSEMBLYSUPPORT 2.SHIMS
STEP3.
Removethecapscrews,washers,andclampretainingthedropboxhousing.
UsingtwooftheM8×1.25×50capscrewsremoved fromthedropboxhousing,pushthedropboxhousing fromthedifferentialassemblysupport.Ifthecapscrewsdonothaveenoughthreadedlength,usea prybartofinishremovingthedropboxhousing. 1.DIFFERENTIALASSEMBLYSUPPORT 2.DROPBOXHOUSING 3.CLAMP 4.LOCKWASHERS 5.CAPSCREWS
DifferentialRepair 1400SRM1245
3.BEARINGCONE 4.WASHER 5.PINIONNUT
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DrivePinionandPinionGear,fromDifferentialAssemblySupport
NOTE: Whenremovingthepinion,besuretoretaintheshims.
STEP1.
Carefullyremovepinionassemblyfromthedifferentialassemblysupport.Usingapressandabearing puller,removetheshimsandinnerbearingfromthe pinion.
1.DIFFERENTIALASSEMBLYSUPPORT
2.INNERBEARING
3.SHIMS
4.PINION
STEP2. Removedrivegearanddrivengear.
1.DIFFERENTIALASSEMBLYSUPPORT
2.DRIVEGEAR
3.DRIVENGEAR
1400SRM1245 DifferentialRepair
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