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HYSTER K019 (H13XM-6 Europe) Forklift Service Repair Manual

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HYSTER K019 (H13XM-6 Europe) Forklift Service Repair Manual

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  1. SERVICE REPAIR H13XM-6 H14XM-6 H16XM-6 H10XM-12 H6XM-12EC H7XM-12EC Europe [K019] PART NO. 1652525 8000 SRM 1320

  2. 8000 SRM 1937 Counterweight Weights Counterweight Weights Unit Main Counterweight 3051 kg (6,726 lb) 3366 kg (7,420 lb) 4276 kg (9,426 lb) 4451 kg (9,812 lb) 5131 kg (11,311 lb) 5295 kg (11,673 lb) 5930 kg (13,073 lb) 6985 kg (15,399 lb) H190HD/H8.00XM H210HD/H9.00XM H230HD/H10.00XM-6 H250HD H280HD/H12.00XM H300HD/H13.00XM H330HD/H14.00XM/H10.00XM-12EC H360HD/H16.00XM-6/H12.00XM-12EC/H360HD-EC Table 1. Counterweight Weights Model Weight H8XM-6 (H190HD2) H9XM-6 (H210HD2) H10XM-6 (H230HD2) H10XMS (H250HD2/H230HD2S) H12XM-6 (H280HD2) H13XM-6 (H300HD2) H14XM-6/H10XM-EC (H330HD2) H16XM-6/H12XM-EC (H360HD2 H360HD2-EC) 3051 kg (6,726 lb) 3366 kg (7,420 lb) 4276 kg (9,426 lb) 4451 kg (9,812 lb) 5131 kg (11,311 lb) 5295 kg (11,673 lb) 5930 kg (13,073 lb) 6985 kg (15,399 lb) 1

  3. Lift Truck Weights 8000 SRM 1937 Lift Truck Weights Table 2. Basic Truck Model "MIN" Weight 9,400 kg (20,723 lb) 9,700 kg (21,384 lb) 10,700 kg (23,589 lb) 10,900 kg (24,030 lb) 11,550 kg (25,463 lb) 12,500 kg (27,557 lb) 13,200 kg (29,101 lb) 14,250 kg (31,415 lb) "MAX" Weight 10,150 kg (22,376 lb) 10,450 kg (23,038 lb) 11,450 kg (25,242 lb) 11,600 kg (25,573 lb) 12,300 kg (27,116 lb) 13,700 kg (30,203 lb) 14,350 kg (31,636 lb) 15,400 kg (33,951 lb) H190HD2 H8-XM-6 H210HD2 H8-XM-6 H230HD2 H10-XM-6 H250HD2 H280HD2 H12-XM-6 H300HD2 H13-XM-6 H330HD2 H14-XM-6 H360HD2 H16XM-6 NOTE: Add 90 kg (198.4 lb) for a completely topped off fuel tank. NOTE: The minimum weight indicates the weight for trucks with an open cab and pneumatic tires. The maximum weight indicates the weight for trucks with an open cab and solid tires. To calculate the total weight of the basic truck include the weight of following options: • Add 200 kg (440.9 lb) for a closed cab. • Add 50 kg (110 lb) for air conditioning. • Add 90 kg (198.4 lb) for a completely topped up fuel tank. Capacities Item Quantity Engine Oil Tier 3, QSB6.7L Tier 4, QSB4.5L Tier 4, QSB6.7L 16 liter (16.9 qt) 10.5 liter (11.0 qt) 14 liter (14.8 qt) 2

  4. 8000 SRM 1937 Capacities Item Quantity Cooling System Tier 3, QSB6.7L Tier 4, QSB4.5L Tier 4, QSB6.7L Hydraulic Tank (FULL mark) 25.5 liter (27 qt) 22.4 liter (23.6 qt) 21 liter (22.2 qt) 125 liter (33 gal) Hydraulic System (Total Capacity) 8 to 12 ton 13 to 16 ton 151 liter (39.9 gal) 172 liter (45.4 gal) 27 liter (28.5 qt) Transmission ZF Drive Axle and Differential 8 to 12 ton 13 to 16 ton 19 liter (5 gal) 21 liter (5.5 gal) Planetary Gears 8 to 12 ton 13 to 16 ton 4.4 liter (4.7 qt) 5.5 liter (5.3 qt) Fuel Tank 8 to 9 ton 10 to 12 ton 13 to 16 ton 108 liter (28.5 gal) 140 liter (37 gal) 158 liter (41.7 gal) 18.9 liter (5 gal) Diesel Exhaust Fluid (DEF) Electrical System All Models 24 Volt, Negative Ground Alternator Output at 24°C (75°F) 21 amps at 750 rpm 76 amps at 2200 rpm All Engines 3

  5. Engine Specifications 8000 SRM 1937 Engine Specifications Table 3. Cummins QSB4.5 Item Specification Cummins QSB4.5 4 1-3-2-4 107 mm (4.2 in.) 120 mm (4.7 in.) Type Number of Cylinders Firing Order Bore Stroke Displacment 4.5 liter (275 in.3) 17.2:1 52 kPa (7.5 psi) 69 kPa (10 psi) 2450 rpm with load ± 50 rpm no load 800 rpm ±2% 2016 + 100/-50 rpm Compression Ratio Oil Pressure (Minimum, at Low Idle) Oil Pressure (At low idle) Governed Speed (Full power at Normal Operating Temperature) Idle Speed Stall Speed (Broken-in Engine) Thermostat Begin to open Fully open Valve Clearance (Cold) Intake Exhaust Minimum Cranking Speed Weight (Dry) 82°C (179°F) 95°C (203°F) 0.25 mm (0.01 in.) 0.51 mm (0.02 in.) 120 rpm 371 kg (818 lb) Table 4. Cummins QSB6.7 Item Specification Cummins QSB6.7 6 1-5-3-6-2-4 102 mm (4.02 in.) 120 mm (4.62 in.) Type Number of Cylinders Firing Order Bore Stroke Displacement 6.7 liter (409 in.3) 17.2:1 69-380 kPa (10-55 psi) Compression Ratio Oil Pressure (Minimum, at 2500 rpm and normal op- erating temperature) 4

  6. 8000 SRM 1937 Engine Specifications Table 4. Cummins QSB6.7 (Continued) Item Specification 52 kPa (7.5 psi) 2300 rpm with load 2450 ±30 no load 800 rpm ±2% 1966 to 2116 rpm Oil Pressure (At low idle) Governed Speed (Full power at Normal Operating Temperature) Idle Speed Stall Speed (Broken-in Engine) Thermostat Begin to open Fully open Valve Clearance (Cold) Intake Exhaust Minimum Cranking Speed Weight (Dry) 82°C (179°F) 95°C (203°F) 0.25 mm (0.01 in.) 0.51 mm (0.02 in.) 125 rpm 485 kg (1069 lb) Mast Speeds Lifting and Lowering Speeds 90 cc/Rev @2050 rpm @2050 rpm m/ sec ft/ min m/ sec Rated Load 0.47 92.5 0.54 0.32/0.30 62.9/59 0.37/0.35 72.8/68.8 0.37/0.32 105 cc/Rev 120 cc/Rev @2050 rpm m/ sec Rated Load 0.55 Unit ft/ min ft/ min Rated Load H190HD2 H8XM 2 STG NFL 3 STG FFL (2ND/FREE) 2 STG NFL 3 STG FFL (2ND/FREE) 2 STG NFL 3 STG FFL (2ND/FREE) 2 STG NFL 3 STG FFL (2ND/FREE) 106 108 72.8/63 H210HD2 H9XM 0.47 92.5 62.9/59 0.54 106 0.55 108 72.8/63 0.32/0.30 0.37/0.35 72.8/68.8 0.37/0.32 H230HD2 H10XM 0.36 70.8 59/57 0.41 80 0.42 82.7 77/67 0.30/0.29 0.38/0.36 74.8/70.8 0.39/0.34 H250HD2 0.36 70.8 59/57 0.41 80 0.42 82.7 77/67 0.30/0.29 0.38/0.36 74.8/70.8 0.39/0.34 5

  7. Mast Speeds 8000 SRM 1937 Lifting and Lowering Speeds 90 cc/Rev @2050 rpm @2050 rpm m/ sec ft/ min m/ sec Rated Load 0.36 70.8 0.41 0.30/0.29 59/57 0.38/0.36 74.8/70.8 0.39/0.34 105 cc/Rev 120 cc/Rev @2050 rpm m/ sec Rated Load 0.42 Unit ft/ min ft/ min Rated Load H280HD2 H12XM 2 STG NFL 3 STG FFL (2ND/FREE) 2 STG NFL 3 STG FFL (2ND/FREE) 2 STG NFL 3 STG FFL (2ND/FREE) 2 STG NFL 3 STG FFL (2ND/FREE) 2 STG NFL 3 STG FFL (2ND/FREE) 2 STG NFL 3 STG FFL (2ND/FREE) 2 STG NFL 3 STG FFL (2ND/FREE) 2 STG NFL 2 STG NFL 2 STG NFL 80 82.7 77/67 H300HD2 0.28 55 - - - - 0.34 66.9 59/57 0.25/0.24 49.2/47.2 0.30/0.29 H13XM 0.28 55 - - - - 0.34 66.9 59/57 0.25/0.24 49.2/47.2 0.30/0.29 H330HD2 0.28 55 - - - - 0.34 66.9 59/57 0.25/0.24 49.2/47.2 0.30/0.29 H14XM 0.28 55 - - - - 0.34 66.9 59/57 0.25/0.24 49.2/47.2 0.30/0.29 H360HD2 0.28 55 - - - - 0.34 66.9 59/57 0.25/0.24 49.2/47.2 0.30/0.29 H16XM 0.28 55 - - - - 0.34 66.9 59/57 0.25/0.24 49.2/47.2 0.30/0.29 H6XM-12EC H360XM2-EC H7XM-12EC - - - - - - - - - - - - 0.52 0.52 0.52 102.36 102.36 102.36 Tire Sizes NOTE: Refer to Truck Nameplate for correct tire pressure. Model Tire Size 9.00 × 20-14 ply 10.00 × 20-16 ply 12.00 × 20-16 ply 12.00 × 20-16 ply Tire Pressure 900 kPa (130 psi) 900 kPa (130 psi) 1000 kPa (145 psi) 1000 kPa (145 psi) H8.00-9.00XM-6 (H190-210HD2) H10.00-12.00XM-6 (H230-280HD2) H10.00-12.00XM-EC (H360HD2-EC) H13-14XM-6 (H300-330HD2); H16XM-6 (H360HD2) All Michelin XZM Radial Tires 1000 kPa (145 psi) 6

  8. 8000 SRM 1937 Tire Sizes Hydraulic System Item Quantity Cummins Diesel Hydraulic Pump Capacity @ 2300 rpm 90 cc (3 oz) 120 cc (4 oz) 25 cc (0.8 oz) Wet Brake Cooling Pump Relief Pressures * Main Control Valve Steering Circuit 196 liter/min (51.7 gal/min) 262 liter/min (69.2 gal/min) 57 liter/min (15.0 gal/min) 22.5 MPa (3262.5 psi) 16 ±1 MPa (2320 ±145 psi) *Oil temperature 20°C (68°F) Torque Specifications, General TRANSMISSION ZF Capscrews, Torque Converter Bell Housing to Transmission Housing 46 N•m (34 lbf ft) Nuts, Locking System Pressure Tubes Into Rear Transmission Cover 42 N•m (31 lbf ft) Capscrews, Transmission Oil Filter Head 23 N•m (21 lbf ft) Screw, Holding Segment on Pressure Tubes 23 N•m (17 lbf ft) Capscrews, Torque Converter Housing to Fly- wheel Housing 46 N•m (34 lbf ft) Capscrews, Screen Into Front Transmission Cover 23 N•m (17 lbf ft) Capscrews, Hydraulic Pumps to Transmis- sion 25 N•m (18 lbf ft) Capscrews, Tubes and Suction Tube Into Front Transmission Cover 23 N•m (17 lbf ft) See the section Transmission Repair (ZF- WG161) 1300SRM1456 for other torque values. Capscrews, Rear Transmission Cover to Front Transmission Cover 4 N•m (34 lbf ft) DRIVELINE AND AXLE Capscrews, Output Flange to Transmission Housing 34 N•m (25 lbf ft) Capscrews, Universal Yoke 50 N•m (37 lbf ft) Bolts, Axle to Frame 920 N•m (679 lbf ft) Capscrews, Torque Converter Bell Housing to Transmission Housing 46 N•m (34 lbf ft) COUNTERWEIGHT Top Capscrews 1500 N•m (1106 lbf ft) Oil Fill Tube with Dipstick and Oil Drain Plug 80 N•m (59 lbf ft) 7

  9. Torque Specifications, General 8000 SRM 1937 HYDRAULIC SYSTEM Rear Capscrews 1500 N•m (1106 lbf ft) Priority Valve (A) 217to 231 N•m (160 to 170 lbf ft) DIFFERENTIAL Check Valve (K) 27 to 34 N•m (20 to 25 lbf ft) See the section Drive Axle1400SRM1931. BRAKES - WET Check Valve (L) 122 to 136 N•m (90 to 100 lbf ft) See the sections Brake and Hydraulic Cooling System 1800SRM1933. Check Valve (Q) 9 to 12 N•m (7 to 9 lbf ft) STEERING Shuttle Valves 26 to 30 N•m (34 to 40 lbf ft) Nut, Steering Wheel 68 N•m (50 lbf ft) Full Flow Relief Valve (C) and (G) 217to 231 N•m (160 to 170 lbf ft) Capscrews, Steer Cylinder Mount 435 N•m (321 lbf ft) Pilot Supply Valve (F) 45 to 50 N•m (33 to 37 lbf ft) Capscrews, Bearing Cap 75 N•m (55 lbf ft) Load Sense Selector Valve (D) 35 to 40 N•m (26 to 30 lbf ft) Nut, Wheel Bearing Initial 203 N•m (150 lbf ft) Final 34 N•m (25 lbf ft) Coil Retaining Nut for Load Sense Selector Valve (D) 4 to 6 N•m (35 to 53 lbf in) Note: Torque lock nut to Initial torque while rotating wheel hub. Back off lock nut until wheel hub turns freely with no end play. (Torque at this point should be less than 27 N•m (20 lbf ft)). Retorque to Final torque and lock in place at first alignment position which occurs at or above final torque spec. Lift Pressure Selector Valve (B) 35 to 40 N•m (26 to 30 lbf ft) Coil Retaining Nut for Lift Pressure Selector Valve (B) 4 to 6 N•m (35 to 53 lbf in) Solenoid Capscrews 6.3 N•m (56 lbf in) Capscrews, Steer Axle Mount 270 N•m (199 lbf ft) Mount Capscrews 14 N•m (124 lbf in) WHEEL NUTS Drive Wheels (Final Torque Value) 615 to 710 N•m (454 to 524 lbf ft) Pump Flangehead Screws 46 to 49 N•m (34 to 36 lbf ft) Steer Wheels (Final Torque Value) 615 to 710 N•m (454 to 524 lbf ft) Pump to Motor Capscrews 25 N•m (221 lbf in) 8

  10. 8000 SRM 1937 Torque Specifications, General Suction Hose Adapter to Hydraulic Pump 91 to 100 N•m (67 to 74 lbf ft) Nut, Sideshift Cylinder Rod 675 N•m (498 lbf ft) TILT CYLINDERS Pressure Line Fitting to Hydraulic Pump 49 to 59 N•m (36 to 44 lbf ft) Nut, Cylinder Rod H13-14XM-6 (H360HD2); H10-12XM-12EC (H360HD2-EC) 949 to 983 N•m (700 to 725 lbf ft) H13-16XM-6 (H300-360HD2) 1105 to 1140 N•m (815 to 841 lbf ft) (H300-330HD2); H16XM-6 Counterbalance Valves 60 N•m (44.3 lbf ft) MAST Capscrews, Pivot Pin 435 N•m (321 lbf ft) Retainer H8-12XM-6 (H170-280HD2) 542 to 610 N•m (400 to 450 lbf ft) H13-14XM-6 (H300-330HD2); (H360HD2); H10-12XM-12EC (H360HD2-EC) 610 to 675 N•m (450 to 498 lbf ft) Capscrew, Bearing Block 9 N•m (7 lbf ft) H16XM-6 Capscrews, Bearing Block Bracket 44 N•m (32 lbf ft) Lock Nut, Rod End 66 N•m (49 lbf ft) Nuts, Wear Plate 53 N•m (39 lbf ft) Capscrew, Pin Anchor 165 N•m (122 lbf ft) Retainer, Lift Cylinder H8-9XM-6 (H170-210HD2) 400 to 475 N•m (295 to 350 lbf ft) H10-12XM-6 (H230-280HD2) 475 to 550 N•m (350 to 406 lbf ft) H13-14XM-6 (H300-330HD2); (H360HD2); H10-12XM-12EC (H360HD2-EC) 550 to 625 N•m (406 to 461 lbf ft) WIPER ARMS, FRONT Capscrews, Bracket to Cab 20 to 25 N•m (14.7 to 18.4 lbf ft) H16XM-6 Capscrews, Arm to Bracket 22 to 27 N•m (16.2 to 19.9 lbf ft) CARRIAGE Capscrews, Blade to Arm 8 to 10 N•m (6 to 7.4 lbf ft) Capscrew, Bearing Block 9 N•m (7 lbf ft) Capscrew, Arm Set 35 to 45 N•m (25.8 to 33.2 lbf ft) Capscrews, Bearing Block Bracket 44 N•m (32 lbf ft) Torque Specifications, Cummins Diesel LUBRICATION SYSTEM 80 N•m (59 lbf ft) Plug, Oil Sump, Steel Oil Pan All other Torque Specifications are found in Cummins Engine Manual. Contact Cummins Engine for any torque specifications not listed for this engine. 9

  11. 1400 SRM 1931 General General This manual contains the description and repair procedures for the components of the planetary gear drive axle and the drive shaft as equipped on L007 and K019 series lift trucks. The main parts of the drive axle include the differential, planetary gear assembly, and the brake housings. The main parts of the drive shaft are two universal joints and a slip yoke. See Figure 1 and Figure 5. • • Periodic Maintenance 8000SRM1939 2-Stage Mast 4000SRM1647 Before making repairs to the drive axle it is important to put the lift truck on blocks. Identification Plate The exact axle model specification tag is located on the axle housing. See Figure 2. Refer to the following resources for additional information: 1. 2. 3. PLANETARY GEAR SERVICE BRAKE AXLE HOUSING 4. 5. DIFFERENTIAL PARKING BRAKE Figure 1. Drive Axle 1

  12. General 1400 SRM 1931 Figure 2. Planetary Drive Axle Identification The AxleTech Model Number in the axle type plate provides the exact specification of the axle and is as follows: P 1) R 2) C 3) 48 4) 5 5) W3H 6) 123456 Example: 7) P– Planetary R– Rigid C– Integral Cast 48– Wheel End Designation (Model Number) 5– Carrier Designation for Base Model Number W3H– Wet Disc Brake type • W – Wet Disc Brake • 3 – Housing Diameter (3 = 320 mm (13 in.) • H – Hydraulic Actuation 123456– Exact Specification 1. 2. 3. 4. 5. 6. 7. 2

  13. 1400 SRM 1931 Description and Operation Description and Operation The ring gear is connected with the ring gear hub. The ring gear hub keeps the ring gear stationary and supports the outer wheel bearing on the spin- dle. The wheel bearing adjustment nut pushes against the ring gear hub, providing the required bearing pre-load. DRIVE AXLE Planetary Gear Assembly The planetary gear assembly increases torque from the axle shaft to the drive wheels. The axle shaft is connected with the sun gear through splines. A thrust button keeps the axle shaft secured at its lo- cation. The sun gear is connected with three plane- tary gears, which rotate on shafts that are installed in the planetary gear carrier. The standard drive axle has four planetary gears. All other drive axles have six planetary gears. The planetary gears are connected with the stationary ring gear. The ring gear causes the planetary gear carrier to rotate when the axle shaft turns. The planetary gear car- rier and drive wheels are installed on the wheel hub. See Figure 3. The wheel hub rotates on two wheel bearings and has a splined extension to the service brakes on which the brake friction discs are installed. The oil seal behind the inner wheel bearing keeps the gear oil in the wheel hub separate from the brake cool- ing oil. Brake cooling oil is retained by the toric ring face seal between the wheel hub and brake housing. 3

  14. Description and Operation 1400 SRM 1931 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. SET SCREW 11. SUN GEAR THRUST WASHER 12. SUN GEAR 13. SNAP RING 14. THRUST BUTTON 15. PLANETARY GEAR SHAFT TORIC RING FACE SEAL INNER BEARING WHEEL STUD OUTER BEARING LOCK RING RING GEAR HUB NEEDLE ROLLER SPACER O-RING 16. SPIRAL RETAINING RING 17. MAGNETIC DRAIN PLUG 18. PLANETARY GEAR 19. RING GEAR 20. SPINDLE NUT 21. PLANETARY SPIDER 22. WHEEL HUB 23. O-RING 24. MACHINE SCREW 25. WET BRAKE DISC HOUSING 26. WET BRAKE PISTON HOUSING 27. SPINDLE 28. AXLE SHAFT 29. WEAR SLEEVE 30. OIL SEAL Figure 3. Wheel End Cross Section 4

  15. 1400 SRM 1931 Description and Operation Differential Legend for Figure 4 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. DIFFERENTIAL CASE TAPERED ROLLER BEARINGS DIFFERENTIAL CARRIER NOSE BEARING SIDE GEAR DIFFERENTIAL PINION DRIVE AXLE HOUSING AXLE SHAFT RING GEAR DRIVE PINION The differential permits the left-hand and right- hand drive wheels to rotate at a different speed. The components of the differential are installed in the differential carrier that is bolted in the drive axle housing. Main components of the differential are the ring gear and pinion, and the differential case that contains two side gears and four differen- tial pinions. See Figure 4. Torque from the pinion is transferred to the ring gear, which is attached to the differential case. The differential case transfers torque through the dif- ferential pinions to the side gears. Splines in the side gears mesh with the drive shaft, and the drive shaft transfers torque to the planetary gear assem- blies. The pinion shaft is additionally supported by a nose bearing. A thrust screw limits ring gear de- flection in extreme situations. DRIVE SHAFT The drive shaft transfers power and torque from the transmission to the drive axle. The drive shaft includes two universal joints to bridge the different axis of rotation of the transmission output shaft and drive axle input shaft. The drive shaft slip yoke allows changes in the drive shafts length. See Fig- ure 5. A seal prevents dirt from entering and retains grease inside the bearing blocks and the slip yoke. Lubricate the bearings and slip yoke periodically. 1. 2. 3. DRIVE AXLE UNIVERSAL JOINT SLIP YOKE 4. 5. SPLINED STUB TRANSMISSION Figure 5. Drive Shaft Figure 4. Differential Cross-Section 5

  16. Remove and Replace 1400 SRM 1931 Remove and Replace PRECAUTIONS DRIVE SHAFT Putting the Lift Truck on Blocks Remove WARNING When putting the lift truck on blocks, make sure the surface is solid, even, and level. Any blocks used to support the lift truck must be solid, one- piece units. CAUTION The drive shaft for this truck is a two piece model, consisting of a male splined drive shaft, a female splined slip yoke and a universal joint on both ends where it connects to the drive axle and transmission. Before putting the lift truck on blocks, check the presence of components, hoses or wires mounted under the frame, to prevent damage to these parts. Drive shafts are balanced and configured at the time of manufacture. It is recommended that an alignment mark is made on the drive shaft indicat- ing the position of the universal joint and drive shaft prior to removal. 1. Place the lift truck on a solid, level surface. 2. Lower the carriage and forks, stop the engine, and apply the parking brake. During removal, it may be possible for the drive shaft to split apart into two pieces. Reassemble the drive shaft using the alignment mark made prior to removal. 3. Put blocks on each end (front and back) of the steering tires to prevent movement of the lift truck. Incorrect assembly and/or install of the drive shaft may lead to: • Vibration of the drive shaft and/or truck • Premature failure of the universal joints on the drive shaft • Excessive vibration levels in the transmis- sion • Excessive vibration levels in the drive axle. 4. Put a jack under the drive axle and lift the truck. 5. Put blocks under the frame behind the tires. 6. Lower the jack and move it away from the truck. See Figure 6. NOTE: The drive shaft does not have to be re- moved when repairing the wheel hub and only needs to be removed when repairing the drive shaft or the differential. Use a marker of some type to indicate position and orientation of drive shaft prior to removal. 1. Place the lift truck on a solid, level surface. 2. Apply the parking brake. 3. Lower the mast completely. 4. Tilt the mast completely forward. Figure 6. Putting Truck Front on Blocks 6

  17. 1400 SRM 1931 Remove and Replace 5. Shut down the engine. 9. Attach a sling to each end of the drive shaft. Use a lifting device to support the weight of the drive shaft. 6. Place blocks in front of and behind the tires to prevent movement of the lift truck. 10. Remove the cap screws at each end of the drive shaft that retain the universal joints to the drive axle flange and transmission flange. If needed, use a soft, rubber hammer to loosen the universal joints from the mounting flanges. See Figure 7. 7. Raise (side tilt) the cab to the fully open posi- tion to gain access to the drive shaft. CAUTION drive 25 kg (55 lb). Dents and damage to the drive shaft can cause premature failure. The shaft weighs approximately 11. Lower the drive shaft on the pallet. 12. Lower the pallet with the drive shaft and move away from the truck. 8. Place a pallet truck with a pallet underneath the truck to support the drive shaft. 1. 2. 3. DRIVE AXLE CONNECTION CAP SCREW SLIP YOKE 4. 5. SPLINED STUB UNIVERSAL JOINT Figure 7. Drive Shaft Assembly 7

  18. Remove and Replace 1400 SRM 1931 Disassemble Clean and Inspect NOTE: If any component of the universal joint is damaged or worn, the universal joint must be re- placed as an assembly. NOTE: Replace the universal joint if it fails any of the following inspections. 1. Inspect the bearing seals for damage. 1. Remove the four cap screws at each universal joint. 2. Rotate the universal joint back and forth, checking the universal bearings for backlash or irregular resistance. If there is any backlash or irregular resistance, the universal joints must be replaced. 2. Repeat Step 1 for the remaining universal joint. 3. Make alignment marks on the drive shaft as- sembly for correct alignment during assembly. See Figure 8. NOTE: Replace the drive shaft if it fails any of the following inspections. 4. Separate the slip yoke from the splined stub by sliding them apart. 3. Inspect the inner and outer splines of the slip yoke and splined stub for damage. 4. Inspect for backlash when pushing back and forth at the slip yoke. If there is any backlash the drive shaft must be replaced. 5. Inspect the seal of the yoke for damage and tears. 1. 2. DRIVE SHAFT ASSEMBLY DRIVE SHAFT ALIGNMENT MARKS Figure 8. Alignment Marks 8

  19. 1400 SRM 1931 Remove and Replace Assemble CAUTION drive 30 kg (66 lb). Dents or damage to the drive shaft can cause premature failure. 1. Apply a thin coat of grease at the sealing area of the slip yoke. See Figure 7. The shaft weighs approximately CAUTION DO NOT force the splines into each other as dam- age can occur. 1. Place the drive shaft in position at the under- side of the lift truck. 2. Attach a sling to each end of the drive shaft. Use a lifting device to raise the drive shaft into place. NOTE: Incorrect alignment may cause vibrations during operation. 2. Align the splined stub and slip yoke and insert the splined stub into the splines of the slip yoke while aligning the alignment marks. See Fig- ure 8. 3. Apply Loctite 271 to the threads of the cap screws. 4. Install the cap screws at each end of the drive shaft that retain the universal joints to the drive axle flange and transmission flange. Tor- que the cap screws to 120 to 136 N•m (90 to 100 lbf ft). 3. Install the two universal joints with the cap screws. Torque the cap screws to 120-130 N•m (88.5-95.8 lbf ft). 4. Repeat Step 3 for the remaining universal joint. 5. Install the drive shaft catch. 6. Lower the cab until it is in the fully seated and latched into position. Install WARNING Use caution when using lifting devices. When us- ing a lifting strap, inspect the strap for damage before use. DO NOT use a lifting strap to shock load or drop load a component. Serious personal injury and damage to components may occur. PLANETARY GEAR ASSEMBLY NOTE: The parts of the planetary gear assembly can be removed with the drive axle installed on the lift truck. 9

  20. Remove and Replace 1400 SRM 1931 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. WHEEL HUB 11. O-RING 12. OUTER BEARING CUP 13. OUTER BEARING CONE 14. WHEEL STUD 15. RING GEAR 16. RING GEAR HUB 17. LOCK RING SPINDLE FLAT WASHER CAP SCREW WEAR SLEEVE WET DISC BRAKE (NOT SHOWN) TORIC RING FACE SEAL ASSEMBLY OIL SEAL ASSEMBLY INNER BEARING CONE INNER BEARING CUP 18. SPINDLE NUT 19. SET SCREW 20. SUN GEAR THRUST WASHER 21. PLANETARY SUN GEAR 22. SNAP RING 23. PLANETARY GEAR SHAFT 24. NEEDLE ROLLERS 25. SPACER 26. PLANETARY PINION GEAR 27. THRUST PLATE 28. THRUST BUTTON 29. O-RING 30. PLANETARY SPIDER 31. MACHINE SCREW 32. MAGNETIC DRAIN PLUG 33. SPIRAL RETAINING RING Figure 9. Planetary Gear Assembly 10

  21. 1400 SRM 1931 Remove and Replace Planetary Spider 1. 2. 3. 4. 5. 6. MACHINE SCREW PLANETARY SPIDER PLANETARY GEAR MAGNETIC DRAIN PLUG O-RING SPIRAL RETAINING RING 7. 8. 9. 10. NEEDLE ROLLERS 11. SPACER PLANETARY PINION SHAFT AXLE SHAFT THRUST WASHER THRUST PLATE Figure 10. Planetary Spider 11

  22. Remove and Replace 1400 SRM 1931 6. Attach a lifting device to the planetary spider. Remove 7. Remove the 3 slotted head machine screws that attach the planetary spider to the hub. WARNING Use caution when using lifting devices. When us- ing a lifting strap, inspect the strap for damage before use. DO NOT use a lifting strap to shock load or drop load a component. Serious personal injury and damage to components may occur. 8. Remove the planetary spider assembly from the wheel hub and put it on a workbench. Rest the spider with the large flange ending up. Disassemble 1. Put the lift truck on blocks. See Precautions, Putting the Lift Truck on Blocks. 1. If the original pinion shafts are reused, mark the planetary pinion shafts and the planetary spider to aid in reassembly. The slots in the pinion shafts must face the outside of the hous- ing to allow entry of the spiral retaining ring. See Figure 12. 2. Remove the drive wheels. See Periodic Main- tenance 8000SRM1939. 3. Put a drain pan under the planetary housing. 4. Rotate the hub to put the magnetic oil plug in the lowest position. 5. Remove the magnetic oil plug and drain the oil. See Figure 11. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. PINION SHAFT 11. PINION SHAFT SLOT SPIRAL RETAINING RING PLANETARY SPIDER LARGE FLANGE THRUST BUTTON O-RING THRUST WASHER PLANETARY PINION GEAR NEEDLE ROLLERS SPACER 1. 2. OIL DRAIN PLUG SLOTTED MACHINE SCREWS Figure 12. Planetary Spider Assembly Figure 11. Planetary Spider, Remove 12

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  24. 1400 SRM 1931 Remove and Replace 2. Place the planetary spider assembly on blocks with the large flange end facing DOWN. 3. Remove the spiral retaining ring by lifting ex- posed ring end with a screw driver and spira- ling ring out from slot in pins. If removal is not possible, the spiral retaining ring may be cut into sections. WARNING Observe all warnings and cautions provided by the press manufacturer to avoid damage to com- ponents and serious personal injury. A. AXLE SHAFT THRUST BUTTON WEAR Use a brass or leather mallet for assembly and disassembly procedures. Do not hit steel parts with a steel hammer. Pieces of a part can break off and cause serious personal injury. 1. 2. 3. 4. 5. AXLE SHAFT THRUST BUTTON PLANETARY SPIDER SUN GEAR SNAP RING SUN GEAR AXLE SHAFT Figure 13. Axle Shaft Thrust Button Wear CAUTION To avoid damage to the pinion shaft, provide a soft cushioned area to receive pinion shaft when it is removed from spider. Assemble 4. Use a press to remove pinion shafts out of the spider. If a press is not available, use a brass drift and mallet to drive out shaft. Press or drive pinion shaft out toward large flange end of the planetary spider. WARNING When applying silicone gasket materials, small amounts of acid vapor are present. To prevent possible serious injury, the work area must be well ventilated. If the silicone gasket material gets into the eyes, flush with water for 15 minutes. Have eyes checked by a doctor as soon as possi- ble. 5. Remove the planetary pinions and the thrust plate from the planetary spider. Inspect 1. Apply grease to the planetary pinion shafts. Replace the axle shaft thrust button if it protrudes insufficiently from the planetary spider. See Fig- ure 13. 2. Stick 33 needle rollers against the shaft on the pinion flange. 3. Put a spacer on top of the needles. If axle shaft thrust button is removed, apply adhe- sive material to the thrust button before placing it into the spider. 4. Stick another 33 needle rollers against the shaft on top of the spacer. 5. Install a planetary gear over the needle rollers. Check the planetary pinions for wear and damage. Pinions that are worn must be replaced. 13

  25. Remove and Replace 1400 SRM 1931 6. Install an O-ring on each pinion shaft. 2. Install the planetary spider assembly on the wheel hub. 7. Repeat Step 1 through Step 6 for the other three pinion shafts. 3. Install the 3 slotted head machine screws. 8. Position the thrust plate in the planetary spi- der. 4. Make sure the magnetic oil plug is at the fill position. 9. Observe the correct position of the slot in the planetary pinion shaft and insert the shafts into the planetary gear. 5. Remove the magnetic oil plug. 6. Fill the planetary spider with 4.4 liter (1.16 gal) of oil. 10. Press each shaft into the planetary gear until the top of the shafts align with the top of the planetary spider housing. 7. Install the drive wheels. See Periodic Mainte- nance 8000SRM1939. Install 1. Attach a lifting device to the planetary spider. 1. 2. 3. 4. 5. SNAP RING SUN GEAR SUN GEAR THRUST WASHER AXLE SHAFT SET SCREW 6. 7. 8. 9. 10. OUTER BEARING SPINDLE NUT PLANETARY RING GEAR LOCK RING PLANETARY RING GEAR HUB Figure 14. Planetary Sun Gear, Axle Shaft and Ring Gear Hub 14

  26. 1400 SRM 1931 Remove and Replace Planetary Sun Gear, Axle Shaft and Ring Gear Hub Remove and Disassemble 1. Remove axle shaft, planetary sun gear, and snap ring assembly. See Figure 14. NOTE: The sun gear thrust washer may come out with the axle shaft and sun gear assembly. 2. Remove the sun gear thrust washer from the axle shaft or if necessary from the end of the spindle. See Figure 15. 1. 2. 3. 4. 5. 6. SET SCREW SPINDLE NUT LOCK RING RING GEAR HUB RING GEAR OUTER WHEEL BEARING CONE Figure 16. Ring Gear Hub Assembly Inspect Inspect the cup, cone, rollers and cage of the wheel bearing. 1. 2. 3. 4. SNAP RING PLANETARY SUN GEAR THRUST WASHER AXLE SHAFT If any of the following conditions exist, replace the bearing: • The centers of the large diameter end of the rollers are worn level with or below the sur- face. See Figure 17. • The centers of the large diameter end of the rollers are worn to a sharp edge. Figure 15. Axle Shaft Assembly 3. Remove the snap ring to allow removal of sun gear from axle shaft. 4. Remove the lock ring. 5. Remove the set screw from the spindle nut and remove the spindle nut. See Figure 16. 6. Remove the ring gear hub. The outer wheel bearing cone will remain on the ring gear hub. 7. Remove the lock ring from the ring gear and push the ring gear hub out of the ring gear. 8. If damaged, remove the outer wheel bearing cone from the ring gear hub. 1. WORN RADIUS 2. WORN SURFACE Figure 17. Roller Large Diameter End Wear 15

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