1400575, OPR, HYSTER, Hyster2, SRM

//-->.pos {position:absolute; z-index: 0; left: 0px; top: 0px;}INTRODUCTIONGENERALThis section has the description and repair proceduresfor the differential, speed reducer, drive axle and themounts for the axle housing.to the reduction gear. The reduction gear is engaged withthe drive gear on the differential.1DESCRIPTIONThe drive unit assembly is fastened to the frame of thelift truck by the axle mounts. The outer ends of the axlehousings are the spindles for the wheel bearings. Thecups for the wheel bearings are pressed into the wheelhubs. The nut on the end of the spindle holds and adjuststhe preload on the wheel bearings. The axle shafts arefastened to the hubs by capscrews. Studs and nuts fastenthe wheel to the hub and brake drum. The back plate andbrake assemblies are fastened to the axle mounts.The speed reducer and differential are assembled as asingle unit. See FIGURE 5. The pinion in the speedreducer engages the splines on the shaft of the tractionmotor. The cluster gear transfers power from the pinion541.2.3.4.5.DIFFERENTIALSPINDLE (AXLE HOUSING)AXLE MOUNTSPEED REDUCERTRACTION MOTOR32FIGURE 1. DRIVE UNIT ASSEMBLYREPAIRSREMOVALNOTE:The traction motor can be removed as aseparate unit. See the section for the FRAME.WARNINGThe lift truck must be put on blocks for sometypes of maintenance and repair. The removal ofthe following assemblies will cause large changesin the center of gravity: attachment, mast, driveaxle, battery, and the counterweight. When the lifttruck is put on blocks, put additional blocks in thefollowing positions:12892a. Before removing the drive axle, put blocks underthe counterweight so that the lift truck can not tipbackward.b. Before removing the battery or counterweight,put blocks under the mast assembly so that the lifttruck can not tip forward.Put the lift truck on blocks only if the surface is solid,even, and level. Make sure that any blocks used tosupport the lift truck are solid, one piece units.FIGURE 2. PUT THE LIFT TRUCK ON BLOCKS1. Disconnect the battery connector.2. Remove the mast assembly as described in the sectionfor the MASTS.3. Use a crane and chains to put the lift truck on blocks asshown in FIGURE 2. Make sure the crane has thecapacity to lift the weight of the lift truck. See theNameplate for the weight of the lift truck.14. Remove the floor plates. Remove the drive wheels.Disconnect the brake lines to the wheel cylinders. Putcaps on the open fittings.5. Disconnect the parking brake cables at the levers atthe service brakes. Drain the oil from the differential.6. Put a floor jack under the drive unit assembly. Makesure the drive unit assembly has stability, then removethe nuts and bolts from the axle mounts. Remove thealignment pins from the frame. The alignment pins canbe a tight fit. See the procedures in FIGURE 3. Slide thedrive unit assembly from the lift truck.METHOD 1:1. Use a grade 8 bolt the maximum diameter pos-sible and long enough to go through the spacer(cup) and pin. Put a washer and nut on the threadedend against the alignment pin. The washer and nutmust be smaller than the holes in the frame andaxle mount.15122. Install the spacer and bolt through the pin from theframe side. Use a wrench to pull the alignment pinout of (removal), or into (installation) the axle mountand frame members.1525334REMOVAL51. FRAME2. AXLE MOUNT3. BOLTMETHOD 2:1. Use a threaded rod (bolt) as described inMethod 1, but long enough to go through thespacer, hydraulic cylinder with a hollow pistonand alignment pin. The washer and nut on theend of the bolt must be smaller than the holesin the frame and axle mount when the pin isremoved.3412121824INSTALLATION4. SPACER (CUP)5. ALIGNMENT PIN6. HYDRAULIC CYLINDER2. Install the spacer, hydraulic cylinder andthreaded rod assembly through the pin from theframe side. Operate the hydraulic cylinder in thedirection away from the frame and pull the pinout of (removal) or into (installation) the axlemount and frame members.3126REMOVAL246INSTALLATION12358FIGURE 3. AXLE MOUNT ARRANGEMENT2DISASSEMBLY(See FIGURE 4. and FIGURE 5.)1. Remove the axle shafts. If necessary, remove thebrake assemblies as described in the section for theBRAKE SYSTEM.2. Remove the capscrew that holds the right hand axlemount to the speed reducer housing. Remove the axlemounts from the axle housing.3. Remove the expansion plug from the differentialhousing. Remove the nuts and washer from thereduction gear.4. Remove the capscrews that hold the speed reducerhousing to the differential housing. Separate thehousings.14151712161.2.3.4.5.6.7.OIL LEVEL PLUGDRIVE AXLE HOUSINGO–RINGSPINDLERIGHT–HAND AXLE MOUNTALIGNMENT PINWASHER313451239118.9.10.11.ISOLATORSPACERSPEED REDUCER HOUSINGNUTS AND BOLT (MOTORSUPPORT)12. TRACTION MOTOR13. LEFT–HAND AXLE MOUNT81086614.15.16.17.7GREASE FITTINGBUSHINGDIFFERENTIAL HOUSINGBREATHERFIGURE 4. PARTS OF THE DRIVE UNIT341819207812341756781. DRIVE GEAR2. DIFFERENTIAL3. DIFFERENTIALBEARING CAP4. ADJUSTMENT NUT5. CAPSCREW AND LOCKPLATE6. SPEED REDUCERHOUSING7. BEARING CUP8. BEARING CONE916159.10.11.12.13.14.15.16.17.18.19.20.712CLUSTER GEARSHIMSBEARING CAPO–RINGREDUCTION GEARPINIONALIGNMENT PINDIFFERENTIAL HOUSINGEXPANSION PLUGLOCK NUTLOCK RINGBEARING LOCK NUT61011141312FIGURE 5. SPEED REDUCER AND DIFFERENTIAL ASSEMBLY5. Remove the bearing caps from the speed reducerhousing. Remove the capscrews that hold the halves ofthe speed reducer housing together. Separate thehousings.6. Remove the gears, bearings and shims from the speedreducer housing.7. Remove the lock plates for the adjustment nuts for thedifferential. Remove the capscrews for the differentialbearing caps. Remove the bearing caps and adjustmentnuts.8. Remove the drive gear from the differential case. Ifnecessary, disassemble the differential. See FIGURE 6.412324151. DIFFERENTIALCASE2. THRUST WASHER23. PINION4. SIDE GEAR5. SPIDERFIGURE 6. DIFFERENTIALCLEANINGWARNINGAlways wear safety glasses.Cleaning solvents may be flammable and toxic, andcan cause severe skin irritation. When usingcleaning solvents, always comply with the solventmanufacturer’s recommended safety precautions.Compressed air can move particles so that theycause injury to the user or to other personnel. Makesure that the path of the compressed air is away fromall personnel. Wear protective goggles or a faceshield to prevent injury to the eyes.Clean the parts of the drive axle with a cleaning solvent.Dry the parts with compressed air.1. SIDE GEAR2. THRUST WASHER3. DIFFERENTIALCASE12312882INSPECTION1. Check the gears for wear or damage. Inspect thespider gears and axle gears for worn teeth. Inspect thecross for wear where the gears turn. The cross and theholes for the cross in the differential case must fittightly.2. Inspect the bearings and bearing surfaces for damage.3. The mounts must turn freely on the axle housing. Thesplines for the axle shafts must not be damaged.FIGURE 7. INSTALL THE SIDE GEAR ANDTHRUST WASHER3. Install the spider (cross), differential pinions andthrust washers into the differential case as shown inFIGURE 8.1. SPIDER,DIFFERENTIALPINIONS, ANDTHRUSTWASHERS1ASSEMBLY1WARNINGHot parts. Wear protective clothing and gloves toprevent burns.1. If the drive gear was removed from the differentialcase, put the drive gear in hot water that is 82 to105°C(180 to 220°F) for approximately 10 minutes. Removethe drive gear from the water and put it on thedifferential case. Do not use a press or a hammer toinstall the drive gear. Install the twelve capscrews andspecial hardened washers. Tighten the capscrews to 111N.m (82 lbfft). Make sure the drive gear is in the correctposition against the flange of the differential case.2. Lubricate and install a side gear and thrust washer inthe differential case as shown in FIGURE 7. Make surethe side of the thrust washer with dents is toward the sidegear.12882FIGURE 8. INSTALL THE SPIDER (CROSS),PINIONS AND THRUST WASHERS4. Install the second side gear and thrust washer over thespider and differential pinions as shown in FIGURE 9.Put the second half of the differential case over the firsthalf and the gears as shown in FIGURE 9. Make sure themarks are aligned. Install four of the capscrews in across pattern. Tighten the capscrews to 50 N.m (37 lbfft). Install the remaining capscrews and tighten them ina cross pattern.5

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