• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, andthat the load being lifted is balanced. Make sure the crane, cables, and chains have the capacityto support the weight of the load.
• Do not lift heavy parts by hand, use a lifting mechanism.
• Wear safety glasses.
• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electriclift trucks. Disconnect the battery ground cable on internal combustion lift trucks.
• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFTTRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance section.
• Keep the unit clean and the working area clean and orderly.
• Use the correct tools for the job.
• Keep the tools clean and in good condition.
• Always use HYSTER APPROVED parts when making repairs. Replacement parts must meetor exceed the specifications of the original equipment manufacturer.
• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using forceto remove parts.
• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if theunit needs repairs.
• Be sure to follow the WARNING and CAUTION notes in the instructions.
• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel areflammable. Be sure to follow the necessary safety precautions when handling these fuels andwhen working on these fuel systems.
• Batteries generate flammable gas when they are being charged. Keep fire and sparks away fromthe area. Make sure the area is well ventilated.
NOTE: The following symbols and words indicate safety information in thismanual:
WARNINGIndicates a condition that can cause immediate death or injury!
CAUTIONIndicates a condition that can cause property damage!
GeneralThis section has a description and the repair procedures for the planetary gear axle.
DescriptionThe planetary gear axle has an axle housing andtwo final drive assemblies. See Figure 1 and Fig-ure 2. Each final drive assembly is a planetary gearunit. The planetary gear assembly changes the finaldrive ratio which increases the torque to the drivewheels. Each unit has an axle shaft, sun gear, ring
gear hub, and ring gear. There are also three plane-tary pinions, a planetary gear carrier, and a housing.The differential is also installed in the axle housing.Service, parking, and auxiliary brake assemblies arealso installed on the drive axle. See the Brake sec-tion for your unit for repair of the brakes.
OperationThe rotation of the differential causes the axle shaftsand the sun gears to rotate. The sun gears thencause the planetary pinions to rotate. Rotation of
the pinions causes the planetary spiders to rotate thehubs and the drive wheels. The ring gear and thering gear hub do not rotate.
1. AXLE HOUSING2. AXLE SHAFT3. SLEEVE4. BRAKE ROTOR5. OIL SEAL6. BEARING CONE7. BEARING CUP8. HUB9. RING GEAR HUB10. RING GEAR
NOTE: The final drive assemblies can be removedwith the drive axle installed in the lift truck. If thedrive axle must be removed, do the following steps.If the drive axle will not be removed, do only Step 1and Step 2.
1. Put blocks under lift truck frame to raise drivewheels from ground.
2. Drain lubricant from axle as described in thesection Periodic Maintenance for the specificunit.
3. On units with drum brakes, remove air chambersas described in the section Brakes for the spe-cific unit.
4. If installed, remove mast assembly from lift truckas described in the section Mast for the specificunit.
5. Disconnect service brake lines on models thathave hydraulic brakes. Make sure to also discon-nect brake lines for auxiliary and parking brakesat drive line and differential. Disconnect coolingoil lines for units with oil-cooled brakes. Put capson all hydraulic lines and ports or fittings. SeeFigure 3.
6. Disconnect drive shaft at differential. On unitswith disc brakes mounted to differential housing,remove disc brake assemblies as described in thesection Brakes for the specific unit.
WARNINGMake sure the lifting device can lift 4500 kg(10,000 lb) when moving the drive axle.
7. Put the forks of a lift truck under axle to giveit support. Remove bolts and nuts that holdaxle to frame. Remove drive axle from lift truckframe. Clean all parts in solvent and dry withcompressed air.
DISASSEMBLE
1. Remove drive wheels and tires. See Figure 1,Figure 2, Figure 3, Figure 4, and Planetary Axle,Disassemble.
WARNINGCompletely remove the air pressure from thetires before removing the wheels from the lifttruck. Air pressure in the tires can cause thetire and rim parts to explode, causing seriousinjury or death.
Always wear safety glasses.
2. Remove air from tire. Remove valve core to makesure all air is out of inner tube. Push a wirethrough valve stem to make sure valve stem doesnot have a restriction.
WARNINGUse a correct lifting device to handle tiresand wheels. The tires and wheels on somelift trucks can weigh approximately 750 kg(1650 lb).
3. Remove wheel nuts and clamps, then use liftingdevice to remove tire and wheel from lift truck.
4. Drain oil from end of axle housing. On units withoil-cooled brakes, drain cooling oil from servicebrakes.
5. On units with disc brakes, remove brake calipersas follows:
a. Remove end plates from calipers. Removebrake pads from calipers.
b. Disconnect brake lines at calipers. Removecapscrews that hold calipers to axle housing.Make a note of the location of any shims thatare used at the caliper mount.
3
Planetary Gear Axle Repair 1400 SRM 47
Figure 3. Planetary Axle With Oil-Cooled Brakes
4
1400 SRM 47 Planetary Gear Axle Repair
Legend for Figure 3
1. AXLE HOUSING2. SPINDLE3. SEAL4. DRIVER5. OIL SEAL6. BEARING CONE7. BEARING CUP8. HUB9. RING GEAR HUB10. RING GEAR
Figure 4. Brake and Axle Assembly, Oil-Cooled Brake
5
Planetary Gear Axle Repair 1400 SRM 47
WARNINGBrake linings can contain dangerous fibers.Breathing the dust from these linings is a can-cer or lung disease hazard. Do not create dust!Do not clean brake parts with compressedair or by brushing. Use vacuum equipmentapproved for brake dust or follow the cleaningprocedure in this section. When the brakedrums are removed, do not create dust.
Do not sand, grind, chisel, hammer, or changelinings in any way that will create dust. Any
changes to linings must be done in a restrictedarea with special ventilation. Protective cloth-ing and a respirator must be used.
NOTE: Normally, the disc assembly (fixed and rotat-ing discs) of the oil-cooled brakes is replaced whenthe drive axle is disassembled.
6. Disassemble oil-cooled brake as described in thesection Oil-Cooled Brakes.
Planetary Axle, Disassemble
STEP 1.Remove cover from planetary gear carrier.
NOTE: Disc brake-type axle shown. Others similar.
1. HUB2. COVER3. PLANETARY GEAR CARRIER
6
1400 SRM 47 Planetary Gear Axle Repair
STEP 2.Put alignment marks on planetary gear carrier andhub. Remove planetary gear carrier capscrews. Re-move planetary gear carrier from hub. Use a pry baror put capscrews in puller holes in planetary gear car-rier. Remove ring gear from ring gear hub.
NOTE: Disc brake-type axle shown. Others similar.
1. PLANETARY GEAR CARRIER2. HUB3. RING GEAR
NOTE: Sun gear is part of the axle on axles with oil-cooled brakes. There is no thrust washer or snap ring.
STEP 3.Remove axle shaft, sun gear, and thrust washer fromhousing. If the sun gear is separate, remove it fromaxle shaft.
NOTE: Disc brake-type axle shown. Others similar.
1. HUB2. THRUST WASHER3. SUN GEAR4. SNAP RING
7
Planetary Gear Axle Repair 1400 SRM 47
STEP 4.Remove lock plate for adjustment nut. Remove ad-justment nut. Connect a lifting device to hub for sup-port. Use a puller to remove ring gear hub.
NOTE: Disc brake-type axle shown. Others similar.
1. HUB2. LOCK PLATE3. ADJUSTMENT NUT4. RING GEAR HUB
STEP 5.Attach a lifting device to hub. Carefully remove hub from spindle. Driver splines of hub engage brake discs ofoil-cooled brake. See Figure 4.
A. DRUM BRAKE-TYPE AXLE SHOWN. OTHERSSIMILAR.
B. DISC BRAKE-TYPE AXLE SHOWN. OTHERSSIMILAR.
1. HUB 2. SPINDLE
8
1400 SRM 47 Planetary Gear Axle Repair
STEP 6.Remove brake drum or brake rotor and bearings from hub of drum or disc brake axle as necessary. Removedriver from hub and brake housing, brake discs, piston assembly, and bearings from axle of oil-cooled brake asnecessary. See Figure 4.
A. DISC BRAKE-TYPE AXLE SHOWN. OTHERSSIMILAR.
B. DRUM BRAKE-TYPE AXLE SHOWN. OTHERSSIMILAR.
1. HUB2. BRAKE DRUM3. BRAKE ROTOR4. BEARING CONE
5. DUST SEAL6. OIL SEAL7. BEARING CUP
9
Planetary Gear Axle Repair 1400 SRM 47
STEP 7.Disassemble planetary gear carrier assembly as necessary. If setscrews are used to hold the pinions in position,put alignment marks on planetary gear carrier and pinion. Use a press to remove pinions.
1. PINION SHAFT2. PINION3. PLANETARY GEAR CARRIER
4. THRUST BUTTON5. THRUST WASHER6. SETSCREW
ASSEMBLE AND INSTALL
NOTE: Normally, the disc assembly (fixed and rotat-ing discs) of the oil-cooled brakes is replaced whenthe drive axle is disassembled.
1. Replace disc assembly and assemble oil-cooledbrake as described in the section Oil-CooledBrakes. See Figure 1, Figure 2, Figure 3, Fig-ure 4, and Planetary Axle, Assemble.
NOTE: During assembly and installation, see Table 2for torque specifications. Lubricate all parts withclean axle lubricant.
2. If the axle housing was removed, install it as de-scribed in Step 3 to Step 7. Assemble planetarygear carrier assemblies. See Planetary Axle, Dis-assemble.
3. Use a jack or the forks of a lift truck to putaxle under frame. Install nuts and bolts. In-stall plates on H7.00-12.50H (H150-275H),P7.00-9.00B (P150-200B), and H13.50-16.00B(H300-350B) models. Tighten nuts as shown inTable 1.
4. Install service, auxiliary, and parking brake com-ponents as described in the section Brakes forthe specific unit.
5. Connect drive shaft to differential or to transfercase.
6. Connect brake lines. On units with oil-cooledbrakes, also connect hydraulic lines for coolingoil of service brakes.
7. Install wheels. Tighten nuts according to speci-fications in Table 3.
8. Fill axle with lubricant as specified in the sectionPeriodic Maintenance for the specific unit.
Planetary Axle, Assemble
STEP 1.Install new disc set, spacer, piston, and seals in brake housing for oil-cooled brake as described in the sectionOil-Cooled Brakes. Install housing assembly on cover. Install bearings and dust shield in hub. Install driver,brake drum, or brake rotor on hub. Tighten capscrews according to specifications in Table 2.
NOTE: Assembly of axle for oil-cooled brake similar.
A. DISC BRAKE-TYPE ASSEMBLY SHOWN. B. DRUM BRAKE-TYPE ASSEMBLY SHOWN.
1. HUB2. BRAKE DRUM3. BRAKE ROTOR4. BEARING CONE
5. DUST SEAL6. OIL SEAL7. BEARING CUP
11
Planetary Gear Axle Repair 1400 SRM 47
STEP 2.Attach a lifting device to hub and install it on spindle. Install outer bearing cone and ring gear hub. Installadjustment nut.
NOTE: Assembly of axle for oil-cooled brake similar.
A. DISC BRAKE-TYPE ASSEMBLY SHOWN. B. DRUM BRAKE-TYPE ASSEMBLY SHOWN.
1. SPINDLE2. HUB3. BEARING CONE
4. RING GEAR HUB5. ADJUSTMENT NUT
12
1400 SRM 47 Planetary Gear Axle Repair
STEP 3.Tighten adjustment nut to 540 N•m (400 lbf ft)while rotating hub. Loosen nut and tighten it againto 540 N•m (400 lbf ft). Loosen adjustment nutuntil it just touches ring gear hub. Install a barand nut on hub as shown. Use a torque wrench tocheck rotating torque of hub. This is the initialvalue. Make sure hub is rotating while checkingthe torque. Tighten adjustment nut while checkingrotating torque again. Tighten adjustment nut sotorque value increases by the amount shown in thefollowing table. The final torque value must be theinitial value plus the value shown in the followingtable.
NOTE: Sun gear is part of the axle on axles with oil-cooled brakes. There is no thrust washer or snap ring.
STEP 4.Install ring gear, axle shaft, thrust washer, sun gear,and snap ring.
NOTE: Disc brake-type axle shown. Others similar.
1. HUB2. RING GEAR3. AXLE SHAFT4. THRUST WASHER5. SUN GEAR6. SNAP RING
14
1400 SRM 47 Planetary Gear Axle Repair
STEP 5.Assemble planetary gear carrier assembly. If the pinions have a flat side, the flat side must be toward theoutside of the hub circle. When installing the pinions, be sure to align the alignment marks. Use a press toinstall pinions. After the pinions are installed, install setscrews.
1. PINION SHAFT2. PINION3. PLANETARY GEAR CARRIER
4. THRUST BUTTON5. THRUST WASHER6. SETSCREW
STEP 6.Use a silicone gasket material between hub and plan-etary gear carrier assembly. Connect a lifting deviceto planetary gear carrier assembly and install it onhub. Align the marks between hub and planetarygear carrier assembly during installation. Tightennuts or capscrews as specified in Table 2.
NOTE: Disc brake-type axle shown. Others similar.
1. PLANETARY GEAR CARRIER2. HUB3. RING GEAR
15
Torque Specifications 1400 SRM 47
STEP 7.Use a silicone gasket material between cover andplanetary gear carrier. Align the marks and installcover. Tighten capscrews as specified in Table 2.
NOTE: Disc brake-type axle shown. Others similar.
1. HUB2. COVER3. PLANETARY GEAR CARRIER
Torque SpecificationsTable 2. Standard Torque Values for Axle Fasteners
Lock Nuts Capscrews and NutsSize
N•m lbf ft N•m lbf ft
1/4-201/4-28
UNCUNF
12 to 1513 to 18
9 to 1110 to 13
13 to 1813 to 18
10 to 1310 to 13
5/16-185/16-24
UNCUNF
24 to 3327 to 40
18 to 2420 to 30
27 to 4027 to 40
20 to 3020 to 30
3/8-163/8-24
UNCUNF
40 to 5448 to 68
30 to 4035 to 50
48 to 6848 to 68
35 to 5040 to 50
7/16-147/16-20
UNCUNF
68 to 8881 to 102
50 to 6560 to 75
81 to 10288 to 115
60 to 7565 to 85
9/16-129/16-18
UNCUNF
102 to 135115 to 155
75 to 10085 to 115
115 to 155135 to 175
85 to 115100 to 130
5/8-115/8-18
UNCUNF
150 to 195175 to 225
110 to 145130 to 165
175 to 225200 to 260
130 to 165150 to 190
5/8-115/8-18
UNCUNF
200 to 260245 to 310
150 to 190180 to 230
245 to 310285 to 365
180 to 230210 to 270
3/4-103/4-16
UNCUNF
265 to 475420 to 540
200 to 350310 to 400
420 to 540490 to 640
310 to 400360 to 470
NOTE: Torque values are for parts lubricated with a lightweight oil.
16
1400 SRM 47 Torque Specifications
Table 2. Standard Torque Values for Axle Fasteners (Continued)
Lock Nuts Capscrews and NutsSize
N•m lbf ft N•m lbf ft
7/8-97/8-14
UNCUNF
595 to 785680 to 880
440 to 580500 to 650
680 to 860780 to 1015
500 to 630575 to 750
1.0-81.0-121.0-14
UNCUNFUN
880 to 1185985 to 1290985 to 1290
650 to 875725 to 950725 to 950
1050 to 13551150 to 14901150 to 1490
775 to 1000850 to 1100850 to 1100
NOTE: Torque values are for parts lubricated with a lightweight oil.
