DRIVE AXLE AND DIFFERENTIAL ASSEMBLY REPAIR (WET BRAKE) Hyster [PDF]
DRIVE AXLE AND DIFFERENTIAL ASSEMBLY REPAIR (WET BRAKE) S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; S80, 100FTBCS; S120F
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DRIVE AXLE AND DIFFERENTIAL ASSEMBLY REPAIR (WET BRAKE) S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; S80, 100FTBCS; S120FTS; S120FTPRS) [G004, H004, J004]; H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) [N005, P005, R005, S005, U005]
PART NO. 1624740
1400 SRM 1246
SAFETY PRECAUTIONS MAINTENANCE AND REPAIR •
• • • • • • • • • • • • • •
The Service Manuals are updated on a regular basis, but may not reflect recent design changes to the product. Updated technical service information may be available from your local authorized Hyster® dealer. Service Manuals provide general guidelines for maintenance and service and are intended for use by trained and experienced technicians. Failure to properly maintain equipment or to follow instructions contained in the Service Manual could result in damage to the products, personal injury, property damage or death. When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and that the load being lifted is balanced. Make sure the crane, cables, and chains have the capacity to 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 electric lift 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 LIFT TRUCK 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 meet or exceed the specifications of the original equipment manufacturer. Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to remove parts. Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the unit 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 are flammable. Be sure to follow the necessary safety precautions when handling these fuels and when working on these fuel systems. Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the area. Make sure the area is well ventilated. NOTE: The following symbols and words indicate safety information in this manual:
WARNING Indicates a hazardous situation which, if not avoided, could result in death or serious injury.
CAUTION Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury and property damage. On the lift truck, the WARNING symbol and word are on orange background. The CAUTION symbol and word are on yellow background.
Table of Contents
TABLE OF CONTENTS General .....................................................................................................................................................................1 Identification Plate ............................................................................................................................................. 1 Drive Axle Removal .................................................................................................................................................1 Hub Seal Replacement ............................................................................................................................................8 Remove ................................................................................................................................................................ 9 Install .................................................................................................................................................................12 Planetary Reduction Repair ................................................................................................................................. 17 Remove .............................................................................................................................................................. 18 Disassemble .......................................................................................................................................................20 Clean and Inspect ............................................................................................................................................. 26 Assemble ............................................................................................................................................................26 Install .................................................................................................................................................................36 Brake Repair ..........................................................................................................................................................40 Remove and Disassemble ................................................................................................................................. 42 Clean and Inspect ............................................................................................................................................. 51 Assemble and Install ........................................................................................................................................ 52 Bevel Pinion ...........................................................................................................................................................62 Remove .............................................................................................................................................................. 63 Disassemble .......................................................................................................................................................65 Clean and Inspect ............................................................................................................................................. 68 Assemble ............................................................................................................................................................68 Calculation of Measurement Y .................................................................................................................... 70 Calculation of Measurement X .................................................................................................................... 71 Calculation of Measurement S1 ...................................................................................................................72 Calculation of Measurement S2 ...................................................................................................................72 Bevel Pinion Housing ................................................................................................................................... 74 Install .................................................................................................................................................................78 Differential Unit ....................................................................................................................................................80 Remove .............................................................................................................................................................. 81 Disassemble .......................................................................................................................................................90 Differential Assembly ...................................................................................................................................90 Ring Nuts ...................................................................................................................................................... 96 Clean and Inspect ............................................................................................................................................. 97 Assemble ............................................................................................................................................................97 Ring Nuts ...................................................................................................................................................... 97 Differential Assembly .................................................................................................................................100 Install ...............................................................................................................................................................107 Drive Axle Installation ........................................................................................................................................120 Special Tools ........................................................................................................................................................ 128 Torque Specifications .......................................................................................................................................... 129 This section is for the following models: S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; S80, 100FTBCS; S120FTS; S120FTPRS) [G004, H004, J004]; H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) [N005, P005, R005, S005, U005]
©2015 HYSTER COMPANY
i
"THE QUALITY KEEPERS" HYSTER APPROVED PARTS
1400 SRM 1246
General
General This manual covers the repair of the drive axle, differential, and the wet disc brakes.
IDENTIFICATION PLATE See Figure 1.
1. 2. 3. 4.
DANA PART NUMBER DANA SERIAL NUMBER HYSTER PART NUMBER AXLE OVERALL RATIO Figure 1. Identification Plate
Drive Axle Removal 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, onepiece units. 1. Put blocks on each side (front and back) of the steering tires to prevent movement of the lift truck. 2. Raise the lift truck and put blocks under the frame so that the drive wheels do not touch the floor. Put blocks under the counterweight for stability. 3. Remove the mast assembly as described in the section Mast Repairs (S/N A513, A514, A613, A614, A702, A703, A704, A705, A706, A707, A751, A752, B513, B514, B586, B587, B588, B589, B590, B591, B749, B750, B751, B752, B753, B754) 4000SRM1250.
or death. Never loosen nuts that hold together inner and outer wheel halves when there is air pressure in tire. 4. Remove the wheels. 5. Remove the planetary carrier housing fill/level plugs on both sides of the drive axle. See Figure 2 for lift truck models •
See Figure 3 for lift truck models •
On lift trucks with pneumatic tires, completely remove air from tires before removing them from lift truck. Air pressure in tires can cause tire and rim parts to explode, which can cause serious injury
H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005, P005, R005, S005, U005)
6. Remove the center section fill/level plug. See Figure 2 for lift truck models •
WARNING
S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; S80, 100FTBCS; S120FTS; S120FTPRS) (G004, H004, J004)
S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; S80, 100FTBCS; S120FTS; S120FTPRS) (G004, H004, J004)
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Drive Axle Removal
1400 SRM 1246
See Figure 3 for lift truck models •
H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005, P005, R005, S005,U005)
7. Remove the planetary carrier housing drain plugs on both sides of the drive axle to drain the oil from the planetary carrier housings into a suitable container. See Figure 2 for lift truck models •
S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; S80, 100FTBCS; S120FTS; S120FTPRS) (G004, H004, J004)
See Figure 3 for lift truck models •
H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005, P005, R005, S005, U005)
8. Remove the center section drain plug to drain the oil from the center section into a suitable container. See Figure 2 for lift truck models •
S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; S80, 100FTBCS; S120FTS; S120FTPRS) (G004, H004, J004)
See Figure 3 for lift truck models •
2
H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005, P005, R005, S005, U005)
A. REAR VIEW SHOWN B. FRONT VIEW SHOWN 1. PLANETARY CARRIER HOUSING FILL/LEVEL PLUGS 2. PLANETARY CARRIER HOUSING DRAIN PLUGS 3. CENTER SECTION DRAIN PLUG 4. CENTER SECTION FILL/LEVEL PLUG 5. PLANETARY CARRIER HOUSING (RH) 6. PLANETARY CARRIER HOUSING (LH) 7. CENTER SECTION Figure 2. Drive Axle Drain and Fill/Level Plugs for Lift Truck Models S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT; S80, 100FTBCS; S120FTS; S120FTPRS) (G004, H004, J004)
1400 SRM 1246
Drive Axle Removal •
H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005, P005, R005, S005)
See Wet Brakes - NMHG 1800SRM1597 for lift truck models •
S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT; S80, 100FTBCS; S120FTS; S120FTPRS) (J004)
•
H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (U005)
10. Remove the capscrews retaining the line guards and remove the line guards on both sides of the drive axle. See Figure 4 for lift truck models •
S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; S80, 100FTBCS; S120FTS; S120FTPRS) (G004, H004, J004)
See Figure 5 for lift truck models •
H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005, P005, R005, S005, U005)
11. Disconnect the brake cooling lines from both sides of the drive axle. A. REAR VIEW SHOWN B. FRONT VIEW SHOWN 1. PLANETARY CARRIER HOUSING FILL/LEVEL PLUGS 2. PLANETARY CARRIER HOUSING DRAIN PLUGS 3. CENTER SECTION FILL/LEVEL PLUG 4. CENTER SECTION DRAIN PLUG 5. PLANETARY CARRIER HOUSING (RH) 6. PLANETARY CARRIER HOUSING (LH) 7. CENTER SECTION Figure 3. Drive Axle Drain and Fill/Level Plugs for Lift Truck Models H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005, P005, R005, S005, U005) 9. Remove the parking brake cables. Refer to the following section for removal procedures: See Brake System 1800SRM1247 for lift truck models •
S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT; S80, 100FTBCS; S120FTS; S120FTPRS) (G004, H004)
See Figure 4 for lift truck models •
S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; S80, 100FTBCS; S120FTS; S120FTPRS) (G004, H004, J004)
See Figure 5 for lift truck models •
H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005, P005, R005, S005, U005)
12. Disconnect the brake lines from both sides of the drive axle. See Figure 4 for lift truck models •
S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; S80, 100FTBCS; S120FTS; S120FTPRS) (G004, H004, J004)
See Figure 5 for lift truck models •
H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005, P005, R005, S005, U005)
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Drive Axle Removal
1. 2. 3. 4. 5. 6.
BRAKE COOLING LINE (LEFT SIDE) HOSE CLAMP HOSE CLAMP BRAKE COOLING LINE (RIGHT SIDE) BRAKE LINE (RIGHT SIDE) LINE GUARD (RIGHT SIDE)
1400 SRM 1246
7. 8. 9. 10. 11.
CAPSCREW COOLING RETURN HOSES CAPSCREW LINE GUARD (LEFT SIDE) BRAKE LINE (LEFT SIDE)
Figure 4. Brake Cooling Lines and Brake Lines, Lift Truck Model S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; S80, 100FTBCS; S120FTS; S120FTPRS) (G004, H004, J004)
4
1400 SRM 1246
1. 2. 3. 4.
BRAKE COOLING LINE (LEFT SIDE) HOSE CLAMP BRAKE COOLING LINE (RIGHT SIDE) BRAKE LINE (RIGHT SIDE)
Drive Axle Removal
5. BRAKE LINE (LEFT SIDE) 6. COOLING RETURN HOSES 7. BRAKE LINE SUPPLY LINE
Figure 5. Brake Cooling Lines and Brake Lines, Lift Truck Model H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005, P005, R005, S005, U005)
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Drive Axle Removal
1400 SRM 1246
13. Disconnect the cooling return hoses from the drive axle. See Figure 6.
15. Place blocks under the transmission to support the transmission while removing the drive axle.
14. Place blocks under the axle assembly and connect slings and lifting device.
16. Remove the capscrews holding the drive shaft and remove the drive shaft.
A. DRIVE AXLE COOLING HOSE RETURN TO TRANSMISSION SUMP 1. HOSE CLAMP 2. COOLING RETURN HOSE, RIGHT SIDE
3. COOLING RETURN HOSE, LEFT SIDE
Figure 6. Drive Axle Cooling Return Hoses
6
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Drive Axle Removal
17. Remove the transmission isolator mounting bolt located on top of the assembly. See Figure 7.
Legend for Figure 7 1. ISOLATORS 2. WASHER 3. WASHER
4. CAPSCREW 5. TRANSMISSION 6. DRIVE AXLE
18. Remove the four mounting capscrews and washers from the drive axle. See Figure 8. 19. Remove blocks and lower the drive axle assembly. Pull axle forward and away from frame. 20. Place blocks under the differential assembly.
Figure 7. Transmission to Differential Mounting Bolt
1. CAPSCREW 2. WASHER
3. DRIVE AXLE Figure 8. Drive Axle Mounting Capscrews
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Drive Axle Removal
1400 SRM 1246
Hub Seal Replacement
1. 2. 3. 4.
SEAL EXTERNAL BEARING HUB WASHER
5. 6. 7. 8.
RING NUT SAFETY FLANGE SOCKET HEAD SCREW COVER
Figure 9. Hub Seal Replacement
8
1400 SRM 1246
Hub Seal Replacement
REMOVE Refer to Figure 9. STEP 1. Remove the cover from the hub.
1. COVER STEP 2. Mark the position of the ring nut. Remove the socket head screw and the safety flange from the ring nut.
1. SOCKET HEAD SCREW 2. SAFETY FLANGE
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Hub Seal Replacement
1400 SRM 1246
STEP 3. Using special tool T1, loosen the ring nut.
1. SPECIAL TOOL T1 STEP 4. Remove the ring nut and washer.
1. RING NUT 2. WASHER STEP 5. Using a puller, loosen the hub assembly.
1. HUB ASSEMBLY
10
1400 SRM 1246
Hub Seal Replacement
STEP 6. By hand, finish removing the hub assembly.
1. HUB ASSEMBLY NOTE: It may be necessary to use a puller to remove the external bearing. STEP 7. Remove the external bearing.
1. EXTERNAL BEARING STEP 8. Remove the seal from the hub.
1. SEAL
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Hub Seal Replacement
1400 SRM 1246
INSTALL Refer to Figure 9.
CAUTION Make sure the seal is positioned correctly in the hub or damage may occur. STEP 1. Position the seal in the hub.
1. SEAL 2. HUB
CAUTION When installing the sealing ring, make sure to maintain the predefined distance of 21.4 to 21.8 mm (0.842 to 0.858 in.) for pneumatic lift trucks, and 8.9 to 9.1 mm (0.350 to 0.358 in.) for cushion lift trucks. Refer to STEP 3. STEP 2. Position the special tool T2 for cushion lift trucks or special tool T3 for pneumatic lift trucks on the seal and press the seal into the hub.
NOTE: SPECIAL TOOL T2 SHOWN. SPECIAL TOOL T3 IS SIMILAR. 1. SPECIAL TOOL T2
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Hub Seal Replacement
STEP 3. Verify the depth of the seal is correct. 8.9 to 9.1 mm (0.350 to 0.358 in.) for cushion lift trucks, and 21.4 to 21.8 mm (0.842 to 0.858 in.) for pneumatic lift trucks. Check the flatness of the seal.
NOTE: CUSHION LIFT TRUCK SHOWN.
NOTE: PNEUMATIC LIFT TRUCK SHOWN.
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Hub Seal Replacement
1400 SRM 1246
WARNING Hot parts. Wear protective clothing and gloves to prevent burns. STEP 4. Install the external bearing. If necessary, use a suitable drift pin to prevent damage. Alternatively, heat the bearing to 100°C (212°F).
1. EXTERNAL BEARING STEP 5. Install the hub assembly.
1. HUB ASSEMBLY STEP 6. Install the washer. Apply Loctite® 242 to the arm thread and manually thread the ring nut onto the arm thread.
1. APPLY LOCTITE® 242 2. WASHER 3. RING NUT
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Hub Seal Replacement
STEP 7. Lock the wheel hub in position with a lever. Tighten the ring nut as follows: a. Using special tool T1, tighten ring nut to 237 N•m (175 lbf ft). b. Rotate hub 2 to 3 revolutions in both directions. c. Using special tool T1, tighten ring nut to 406 N•m (300 lbf ft). d. Rotate hub 2 to 3 revolutions in both directions.
1. SPECIAL TOOL T1
STEP 8. Tighten the ring nut to 500 to 600 N•m (369 to 443 lbf ft).
NOTE: It may be necessary to move ring nut in the tightening direction to allow alignment of the safety flange to socket head screw hole. STEP 9. Apply Loctite® 242 to the threads of the socket head screw. Place the safety flange in position and install the socket head screw into one of the three holes.
1. SOCKET HEAD SCREW 2. SAFETY FLANGE
15
Hub Seal Replacement STEP 10. Tighten the socket head 10.5 N•m (84 to 93 lbf in).
1400 SRM 1246
screw
to
9.5
to
CAUTION Do not damage the contact surfaces of the cover when installing. STEP 11. Apply Loctite® 510 to the cover and install the cover into the hub.
16
1400 SRM 1246
Planetary Reduction Repair
Planetary Reduction Repair
NOTE: THE S4.5, 5.5FT, S5.5FTS, (S100, 120FT; 100FTBCS; S120FTS; S120FTPRS) (G004, H004, J004); H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005, P005, R005, S005, U005) SERIES LIFT TRUCK DRIVE AXLE WILL HAVE TWO BRAKE DISCS AND TWO FRICTION PLATES. THE S4.0FT, (S80FT; S80FTBCS) (G004, H004, J004) SERIES LIFT TRUCK DRIVE AXLE WILL ONLY HAVE ONE BRAKE DISC AND ONE FRICTION PLATE. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.
COVER SOCKET HEAD SCREW SAFETY FLANGE RING NUT WASHER HUB EXTERNAL BEARING INTERNAL BEARING SEAL CAPSCREW PLANETARY COVER MAGNETIC PLUG PLUG
14. O-RING 15. PLANETARY CARRIER 16. NEEDLE BEARINGS 17. PLANETARY GEAR 18. RETAINING RING 19. DOWEL PIN 20. RING GEAR 21. THRUST WASHER 22. O-RING 23. PINION 24. AXLE SHAFT 25. FRICTION PLATE 26. BRAKE DISC Figure 10. Planetary Reduction Assembly 17
Planetary Reduction Repair
1400 SRM 1246
REMOVE Refer to Figure 10. STEP 1. Remove the cover from the hub.
1. COVER STEP 2. Mark the position of the ring nut. Remove the socket head screw and the safety flange from the ring nut.
1. SOCKET HEAD SCREW 2. SAFETY FLANGE STEP 3. Using a special tool T1, loosen the ring nut.
1. SPECIAL TOOL T1
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Planetary Reduction Repair
WARNING The hub and planetary carrier assembly are heavy. Use caution when removing. STEP 4. Place a sling around the hub and planetary carrier assembly and connect the sling to an overhead lift. Place the sling under light tension. Remove the capscrews from the planetary cover.
1. HUB AND PLANETARY CARRIER ASSEMBLY 2. CAPSCREW STEP 5. Remove the hub and planetary carrier assembly.
1. HUB AND PLANETARY CARRIER ASSEMBLY
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Planetary Reduction Repair
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DISASSEMBLE Refer to Figure 10. STEP 1. Remove the O-ring.
STEP 2. Remove the pinion.
1. PINION NOTE: The S4.5, 5.5FT, S5.5FTS, (S100, 120FT; 100FTBCS; S120FTS; S120FTPRS) (G004, H004, J004); H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005, P005, R005, S005, U005) series lift truck drive axle will have two brake discs and two friction plates. The S4.0FT, (S80FT; S80FTBCS) (G004, H004, J004) series lift truck drive axle will only have one brake disc and one friction plate. NOTE: Note the order of position of the brake discs and friction plates before removing them. If the brake discs and friction plates are not being replaced, do not switch their positions. NOTE: Replace discs when the groove depth thickness is less than 0.1 mm (0.0039 in.).
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Planetary Reduction Repair
STEP 3. Remove the friction plate.
1. FRICTION PLATE NOTE: Replace discs when the groove depth thickness is less than 0.1 mm (0.0039 in.). STEP 4. Remove the brake disc.
1. BRAKE DISC 2. FRICTION PLATE NOTE: STEP 5 and STEP 6 are for S4.5, 5.5FT, S5.5FTS, (S100, 120FT; 100FTBCS; S120FTS; S120FTPRS) (G004, H004, J004); H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005, P005, R005, S005, U005) series lift trucks only. STEP 5. Remove the second friction plate.
1. FRICTION PLATE
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Planetary Reduction Repair
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NOTE: Replace discs when the groove depth thickness is less than 0.1 mm (0.0039 in.). STEP 6. Remove the second brake disc.
STEP 7. Remove the ring gear.
1. RING GEAR STEP 8. Remove the ring nut and washer.
1. RING NUT
22
2. WASHER
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Planetary Reduction Repair
STEP 9. Remove the snap rings.
1. SNAP RING NOTE: Note the assembly side of the planetary gears. STEP 10. Remove the planetary gears.
1. PLANETARY GEAR STEP 11. Remove the planetary carrier from the planetary cover.
1. PLANETARY CARRIER
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Planetary Reduction Repair
1400 SRM 1246
STEP 12. Using a puller, loosen the planetary cover from the hub.
1. PLANETARY COVER STEP 13. Remove the internal bearing.
1. INTERNAL BEARING STEP 14. Remove the planetary cover from the hub.
1. PLANETARY COVER
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Planetary Reduction Repair
STEP 15. Remove the internal and external bearing cones from the planetary cover.
1. INTERNAL BEARING CONE 2. EXTERNAL BEARING CONE NOTE: It may be necessary to use a puller to remove the external bearing. STEP 16. Remove the external bearing.
1. EXTERNAL BEARING STEP 17. Remove the seal from the hub.
1. SEAL
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Planetary Reduction Repair
CLEAN AND INSPECT WARNING Cleaning solvents can be flammable and toxic and can cause skin irritation. When using cleaning solvents, always follow the solvent manufacturer's recommended safety precautions. 1. Clean all the parts with solvent.
1400 SRM 1246 2. Inspect the bearings and bearing cups for damage. If either bearing or bearing cup is damaged, replace both bearings and bearing cups. Also replace the inner hub seal. 3. Inspect the all parts for wear and damage. Replace parts as needed. 4. Inspect the brake disc(s). Replace discs when the groove depth thickness is less than 0.1 mm (0.0039 in.).
ASSEMBLE Refer to Figure 10.
CAUTION Make sure the seal is positioned correctly in the hub or damage may occur. STEP 1. Position the seal in the hub.
1. SEAL
2. HUB
CAUTION When installing the sealing ring, make sure to maintain the predefined distance of 8.9 to 9.1 mm (0.350 to 0.358 in.) for pneumatic lift trucks, and 21.4 to 21.8 mm (0.842 to 0.858 in.) for cushion lift trucks. Refer to STEP 3. STEP 2. Position the special tool T2 for cushion lift trucks or special tool T3 for pneumatic lift trucks on the seal and press the seal into the hub.
NOTE: SPECIAL TOOL T2 SHOWN. SPECIAL TOOL T3 IS SIMILAR. 1. SPECIAL TOOL T2
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Planetary Reduction Repair
STEP 3. Verify the depth of the seal is correct. 8.9 to 9.1 mm (0.350 to 0.358 in.) for pneumatic lift trucks, and 21.4 to 21.8 mm (0.842 to 0.858 in.) for cushion lift trucks. Check the flatness of the seal.
NOTE: PNEUMATIC LIFT TRUCK SHOWN.
NOTE: CUSHION LIFT TRUCK SHOWN.
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Planetary Reduction Repair
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WARNING Hot parts. Wear protective clothing and gloves to prevent burns. STEP 4. Install the external bearing. If necessary, use a suitable drift pin to prevent damage. Alternatively, heat the bearing to 100°C (212°F).
1. EXTERNAL BEARING STEP 5. Using a press, install the internal and external bearing cones.
NOTE: INTERNAL BEARING CONE SHOWN BEING PRESSED INTO THE PLANETARY COVER.
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Planetary Reduction Repair
STEP 6. Place the planetary cover in position on the hub.
1. PLANETARY COVER STEP 7. Using a plastic hammer, drive the planetary cover to the limit stop by lightly hammering around the edge.
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Planetary Reduction Repair
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STEP 8. Place the internal bearing in position. With a plastic hammer and metal punch fixture, tap the bearing in position until it is set in the bearing cone.
STEP 9. Check the position/stop of the internal bearing.
1. INTERNAL BEARING
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Planetary Reduction Repair
STEP 10. Replace the O-ring on the planetary carrier. Lubricate the new O-ring with a lithium based grease before installing.
1. O-RING STEP 11. Install the planetary carrier into the planetary cover.
1. PLANETARY CARRIER
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Planetary Reduction Repair
1400 SRM 1246
STEP 12. Install the planetary gears onto the planetary carrier with the assembly side of the gears as noted in STEP 10 of Disassemble.
1. PLANETARY GEAR STEP 13. Install the snap rings to retain the planetary gears to the planetary carrier.
1. SNAP RING STEP 14. Install the washer. Manually thread the ring nut onto the arm thread but do not tighten.
1. RING NUT
32
2. WASHER
1400 SRM 1246
Planetary Reduction Repair
STEP 15. Install the ring gear onto the planetary gears.
1. RING GEAR STEP 16. Lubricate the internal spline of the pinion with John Deere JDM J20C and install the pinion.
1. PINION NOTE: The S4.5, 5.5FT, S5.5FTS, (S100, 120FT; 100FTBCS; S120FTS; S120FTPRS) (G004, H004, J004); H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005, P005, R005, S005, U005) series lift truck drive axle will have two brake discs and two friction plates. The S4.0FT, (S80FT; S80FTBCS) (G004, H004, J004) series lift truck drive axle will only have one brake disc and one friction plate. NOTE: If installing the brake discs and friction plates for a S4.5, 5.5FT, S5.5FTS, (S100, 120FT; 100FTBCS; S120FTS; S120FTPRS) (G004, H004, J004); H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005, P005, R005, S005, U005) series lift trucks, install the brake discs and friction plates in the same position as removed.
33
Planetary Reduction Repair
1400 SRM 1246
STEP 17. Lightly lubricate the friction plate with John Deere JDM J20C and place it in position on the arm.
1. FRICTION DISC STEP 18. Lightly lubricate the brake disc with John Deere JDM J20C and place it in position on the arm.
1. BRAKE DISC NOTE: STEP 19 through STEP 21 are for S4.5, 5.5FT, S5.5FTS, (S100, 120FT; 100FTBCS; S120FTS; S120FTPRS) (G004, H004, J004); H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005, P005, R005, S005, U005) series lift trucks only. STEP 19. When installing the brake discs, make sure that the circulation holes and the marks "B" are perfectly lined up. When installing the friction disc, the slot corresponding to the oil level cap should always be kept free.
34
1400 SRM 1246
Planetary Reduction Repair
STEP 20. Lightly lubricate the second friction plate with John Deere JDM J20C and place it in position on the arm.
1. FRICTION DISC STEP 21. Lightly lubricate the second brake disc with John Deere JDM J20C and place it in position on the arm.
1. BRAKE DISC
35
Planetary Reduction Repair
1400 SRM 1246
INSTALL Refer to Figure 10.
CAUTION The oil outlet must be on the bottom side. STEP 1. Lubricate a new O-ring with a lithium based grease and install the O-ring on the planetary cover. Place the hub and planetary carrier assembly in position on the drive axle.
1. PLANETARY COVER 2. O-RING STEP 2. Apply Loctite® 242 to the capscrews. Install the capscrews to retain the hub and planetary carrier assembly to the drive axle.
1. HUB AND PLANETARY CARRIER ASSEMBLY 2. CAPSCREW
36
1400 SRM 1246
Planetary Reduction Repair
STEP 3. Tighten the capscrews to 199 to 243 N•m (147 to 179 lbf ft).
STEP 4. Lock the wheel hub in position with a lever. Using a special tool T1, tighten the ring nut as follows: a. Remove ring nut and apply Loctite® 242 to the arm thread. Reinstall ring nut. b. Using a special tool T1, tighten ring nut to 237 N•m (175 lbf ft). c. Rotate hub 2 to 3 revolutions in both directions. d. Using a special tool T1, tighten ring nut to 406 N•m (300 lbf ft).
1. SPECIAL TOOL T1
e. Rotate hub 2 to 3 revolutions in both directions.
37
Planetary Reduction Repair
1400 SRM 1246
STEP 5. Tighten the ring nut to 500 to 600 N•m (369 to 443 lbf ft).
NOTE: It may be necessary to move ring nut in the tightening direction to allow alignment of the safety flange to socket head screw hole. STEP 6. Apply Loctite® 242 to the threads of the socket head screw. Place the safety flange in position and install the socket head screw into one of the three holes.
1. SOCKET HEAD SCREW 2. SAFETY FLANGE
38
1400 SRM 1246 STEP 7. Tighten the socket head 10.5 N•m (84 to 93 lbf in).
Planetary Reduction Repair
screw
to
9.5
to
CAUTION Do not damage the contact surfaces of the cover when installing. STEP 8. Apply Loctite® 510 to the cover and install the cover into the hub.
39
Brake Repair
1400 SRM 1246
Brake Repair
Figure 11. Brake Assembly
40
1400 SRM 1246
Brake Repair Legend for Figure 11
NOTE: THE S4.5, 5.5FT, S5.5FTS, (S100, 120FT; 100FTBCS; S120FTS; S120FTPRS) (G004, H004, J004); H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005, P005, R005, S005, U005) SERIES LIFT TRUCK DRIVE AXLE WILL HAVE TWO BRAKE DISCS AND TWO FRICTION PLATES. THE S4.0FT, (S80FT; S80FTBCS) (G004, H004, J004) SERIES LIFT TRUCK DRIVE AXLE WILL ONLY HAVE ONE BRAKE DISC AND ONE FRICTION PLATE. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.
SOCKET HEAD SCREW PARKING BRAKE LEVER O-RING SOCKET HEAD SCREW O-RING BEARING THRUST LEVER (PARKING BRAKE) CAP BLEEDER SCREW DOWEL PIN DISC TUBE (PART OF PISTON ASSEMBLY) O-RING
14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25.
O-RING PISTON SPRING SOCKET HEAD/PIN SCREW SPRING CAPSCREW SPACER ADJUSTER/STOP SCREW NUT THRUST BUSHING FRICTION PLATE* BRAKE DISC*
*SEE NOTE ABOVE.
41
Brake Repair
1400 SRM 1246
REMOVE AND DISASSEMBLE Refer to Figure 11.
WARNING The hub and planetary carrier assembly are heavy. Use caution when removing. STEP 1. Place a sling around the hub and planetary carrier assembly and connect the sling to an overhead lift. Place the sling under light tension. Remove the capscrews from the planetary cover.
1. HUB AND PLANETARY CARRIER ASSEMBLY 2. CAPSCREW STEP 2. Remove the hub and planetary carrier assembly.
1. HUB AND PLANETARY CARRIER ASSEMBLY
42
1400 SRM 1246
Brake Repair
STEP 3. Remove the O-ring.
STEP 4. Remove the pinion.
1. PINION NOTE: STEP 5 and STEP 6 are for S4.5, 5.5FT, S5.5FTS, (S100, 120FT; 100FTBCS; S120FTS; S120FTPRS) (G004, H004, J004); H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005, P005, R005, S005, U005) series lift trucks only. The S4.5, 5.5FT, S5.5FTS, (S100, 120FT; 100FTBCS; S120FTS; S120FTPRS) (G004, H004, J004); H4.0FT5/ FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005, P005, R005, S005, U005) series lift truck drive axle will have two brake discs and two friction plates. The S4.0FT, (S80FT; S80FTBCS) (G004, H004, J004) series lift truck drive axle will only have one brake disc and one friction plate. NOTE: Note the order of position of the brake discs and friction plates before removing them. If the discs and plates are not being replaced, do not switch their positions. NOTE: Replace discs when the groove depth thickness is less than 0.1 mm (0.0039 in.).
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Brake Repair
1400 SRM 1246
STEP 5. Remove the friction plate.
1. FRICTION PLATE STEP 6. Remove the brake disc.
1. BRAKE DISC 2. FRICTION PLATE STEP 7. Remove the second friction plate.
1. FRICTION PLATE NOTE: Replace discs when the groove depth thickness is less than 0.1 mm (0.0039 in.).
44
1400 SRM 1246
Brake Repair
STEP 8. Remove the second brake disc.
STEP 9. Remove the ring gear.
1. RING GEAR
CAUTION If the socket head/pin screws are being replaced, note down the positions and the different colors for the different brake gaps. STEP 10. Remove the socket head/pin screws guiding the piston.
1. SOCKET HEAD/PIN SCREW
45
Brake Repair
1400 SRM 1246
1. SOCKET HEAD/PIN SCREW STEP 11. Remove the capscrews and return springs from the piston.
1. CAPSCREW 2. RETURN SPRING
46
1400 SRM 1246
Brake Repair
WARNING Compressed air can move particles so that they cause injury to the user or to other personnel. Make sure that the path of the compressed air is away from all personnel. Wear protective goggles or a face shield to prevent injury to the eyes.
CAUTION Hold onto the piston as it may be suddenly ejected and damaged. STEP 12. Mark the position of the piston. Slowly apply compressed air through the brake fluid port to extract the entire piston.
1. PISTON STEP 13. Remove the axle shaft.
NOTE: The O-rings must be replaced each time the unit is disassembled.
47
Brake Repair
1400 SRM 1246
STEP 14. Remove and discard the O-rings from the piston.
1. PISTON 2. O-RING
3. O-RING
STEP 15. Remove the socket head screw retaining the parking brake lever.
1. SOCKET HEAD SCREW 2. PARKING BRAKE LEVER NOTE: Mark the parking brake lever in relation to the thrust lever. STEP 16. Remove the spacer and the parking brake lever.
1. SPACER 2. SOCKET HEAD SCREW
48
1400 SRM 1246
Brake Repair
STEP 17. Remove the socket head screws retaining the thrust bushing.
1. SOCKET HEAD SCREW 2. THRUST BUSHING 3. THRUST LEVER STEP 18. Remove the thrust bushing.
1. THRUST BUSHING STEP 19. Remove and discard the O-ring.
1. O-RING
49
Brake Repair
1400 SRM 1246
STEP 20. Remove and discard the O-ring.
1. O-RING STEP 21. Mark the position of the thrust lever. Remove the thrust lever with bearings.
50
1400 SRM 1246
Brake Repair
STEP 22. Using a press, remove the bearings from the thrust lever.
CLEAN AND INSPECT WARNING Cleaning solvents can be flammable and toxic and can cause skin irritation. When using cleaning solvents, always follow the solvent manufacturer's recommended safety precautions.
3. Inspect the all parts for wear, damage, and rust. Replace parts as needed. 4. Inspect the brake disc(s). Replace discs when the groove depth thickness is less than 0.1 mm (0.0039 in.). The groove depth thickness for a new disc is 0.3 to 0.5 mm (0.0118 to 0.0197 in.).
1. Clean all the parts with solvent. 2. Inspect the bearings for wear or damage. Replace as needed.
51
Brake Repair
1400 SRM 1246
ASSEMBLE AND INSTALL Refer to Figure 11.
WARNING Hot parts. Wear protective clothing and gloves to prevent burns. STEP 1. Heat the bearings to approximately 100°C (212°F) and install the bearings on the thrust lever.
1. BEARING STEP 2. Lubricate the thrust lever and bearings with John Deere JDM J20C and install the thrust lever in position previously marked during removal.
1. THRUST LEVER STEP 3. Lubricate new O-rings with a lithium based grease and install the O-rings on the thrust bushing. Pack the area above the O-ring with multipurpose grease with 2% to 4% molybdenum disulfide prior to installing thrust bushing onto thrust lever.
1. O-RING 2. O-RING 3. APPLY MULTIPURPOSE GREASE HERE
52
1400 SRM 1246
Brake Repair
STEP 4. Install the thrust bushing. Apply Loctite® 242 to the socket head screws and install the socket head screws and tighten to 21 to 30 N•m (15 to 22 lbf ft).
1. SOCKET HEAD SCREW 2. THRUST BUSHING STEP 5. Install the parking brake lever in the position marked previously in disassembly.
1. PARKING BRAKE LEVER STEP 6. Install the spacer and socket head screw.
1. PARKING BRAKE LEVER 2. SPACER 3. SOCKET HEAD SCREW
53
Brake Repair STEP 7. Tighten the socket head 30 N•m (15 to 22 lbf ft).
1400 SRM 1246
screw
to
21
to
1. SOCKET HEAD SCREW 2. PARKING BRAKE LEVER STEP 8. Install the axle shaft.
NOTE: The piston relief must face downwards when installed. STEP 9. Lubricate new O-rings with a lithium based grease and install new O-rings onto the piston.
1. PISTON 2. O-RING
54
3. O-RING
1400 SRM 1246
Brake Repair
STEP 10. Install the stroke automatic regulation springs flush in the piston.
1. STROKE AUTOMATIC REGULATION SPRING 2. PISTON STEP 11. Lubricate the O-rings and the piston and install the piston into the arm. Lightly tap around the edge of the piston with a plastic hammer until the piston is seated.
1. PISTON NOTE: The thread holes must be free of oil. STEP 12. Apply Loctite® 270 to the threads of the capscrews and install the capscrews and return springs. Tighten the capscrews to 10 to 15 N•m (88.5 to 132.8 lbf in).
55
Brake Repair
1400 SRM 1246
CAUTION Be sure to install the socket head/pin screws in the positions previously noted down during disassembly. The different colors of the socket head/pin screws are for the different brake gaps. STEP 13. Apply Loctite® 270 to the threads of the socket head/pin screws.
1. SOCKET HEAD/PIN SCREWS STEP 14. Install the socket head/pin screws and tighten to 5 to 7 N•m (44 to 62 lbf in).
STEP 15. If necessary, replace the alignment dowel pins. Install the new dowel pins with only 5 mm (0.20 in.) of the length into the housing.
1. DOWEL PIN
56
1400 SRM 1246
Brake Repair
STEP 16. Lubricate the internal spline of the pinion with John Deere JDM J20C and install the pinion.
1. PINION NOTE: The S4.5, 5.5FT, S5.5FTS, (S100, 120FT; 100FTBCS; S120FTS; S120FTPRS) (G004, H004, J004); H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005, P005, R005, S005, U005) series lift truck drive axle will have two brake discs and two friction plates. The S4.0FT, (S80FT; S80FTBCS) (G004, H004, J004) series lift truck drive axle will only have one brake disc and one friction plate. NOTE: If installing the brake discs for a lift trucks with two brake discs and two friction plates, install the brake discs and friction plates in the same position as removed. STEP 17. Lightly lubricate the friction plate with John Deere JDM J20C and place it in position on the arm.
1. FRICTION DISC
57
Brake Repair
1400 SRM 1246
STEP 18. Lightly lubricate the brake disc with John Deere JDM J20C and place it in position on the arm.
1. BRAKE DISC NOTE: STEP 19 through STEP 21 are for S4.5, 5.5FT, S5.5FTS, (S100, 120FT; 100FTBCS; S120FTS; S120FTPRS) (G004, H004, J004); H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005, P005, R005, S005, U005) series lift trucks only. STEP 19. When installing the brake discs, make sure that the circulation holes (not fully round holes) and the marks B are perfectly lined up. When installing the friction disc, the slot corresponding to the oil level cap should always be kept free.
B. CIRCULATION HOLES (NOT FULLY ROUND HOLES) STEP 20. Lightly lubricate the second friction plate with John Deere JDM J20C and place it in position on the arm.
1. FRICTION DISC
58
1400 SRM 1246
Brake Repair
STEP 21. Lightly lubricate the second brake disc with John Deere JDM J20C and place it in position on the arm.
1. BRAKE DISC
CAUTION The oil outlet/drain plug must be on the bottom side. STEP 22. Lubricate a new O-ring with a lithium based grease and install the O-ring on the planetary cover. Place the hub and planetary carrier assembly in position on the drive axle.
1. PLANETARY COVER 2. O-RING
59
Brake Repair
1400 SRM 1246
1. OIL LEVEL/FILL PLUG 2. OIL OUTLET/DRAIN PLUG STEP 23. Apply Loctite® 242 to the capscrews. Install the capscrews to retain the hub and planetary carrier assembly to the drive axle.
1. HUB AND PLANETARY CARRIER ASSEMBLY 2. CAPSCREW
60
1400 SRM 1246
Brake Repair
STEP 24. Tighten the capscrews to 199 to 243 N•m (147 to 179 lbf ft).
STEP 25. Apply light pressure to the parking brake lever to bring it to rest with the piston without pre-loading the inside band. Adjust the adjustment screw to draw near to the parking brake lever, leaving a 0.1 to 0.2 mm (0.0039 to 0.0079 in.) gap.
1. PARKING BRAKE LEVER 2. ADJUSTMENT SCREW
CAUTION The idle stroke should be eliminated without preloading the parking brake lever. STEP 26. Lock the adjustment screw in position with the nut. Tighten the nut to 20 to 25 N•m (14.75 to 18.44 lbf ft).
1. PARKING BRAKE LEVER 2. ADJUSTMENT SCREW 3. NUT
61
Bevel Pinion
1400 SRM 1246
Bevel Pinion
1. 2. 3. 4. 5. 6. 7. 8.
PLUG FLANGE (YOKE) RETAINING RING PLATE SEAL RING NUT BEARING SPACER
9. 10. 11. 12. 13. 14. 15. 16.
BEVEL PINION HOUSING SHIM SPACER BEARING O-RING BEVEL PINION PLUG CAPSCREW
Figure 12. Bevel Pinion Assembly
62
1400 SRM 1246
Bevel Pinion
REMOVE Refer to Figure 12. STEP 1. Remove the capscrews retaining the transmission support and remove the support.
STEP 2. Remove the flange (yoke).
1. FLANGE (YOKE) STEP 3. Remove the capscrews retaining the bevel pinion cover.
1. CAPSCREW
63
Bevel Pinion
1400 SRM 1246
NOTE: Mark the position of the bevel pinion housing to the drive axle housing. STEP 4. Using two capscrews, extract the bevel pinion housing assembly.
STEP 5. Remove the bevel pinion housing assembly.
1. BEVEL PINION HOUSING
64
1400 SRM 1246
Bevel Pinion
DISASSEMBLE Refer to Figure 12. STEP 1. Remove the seal.
1. SEAL STEP 2. Place the bevel pinion housing assembly on a workbench. Using special tool T4, lock the pinion in place and loosen the ring nut.
1. SPECIAL TOOL T4 STEP 3. Remove the ring nut.
1. RING NUT
65
Bevel Pinion
1400 SRM 1246
STEP 4. Using a puller, remove the bevel pinion, spacers, and bearings from the housing.
1. BEVEL PINION STEP 5. Bevel pinion, spacers, and bearings removed.
1. SPACER 2. BEVEL PINON
3. BEARING
1. SPACER
2. SPACER
STEP 6. Remove the calibrated spacers.
66
1400 SRM 1246
Bevel Pinion
STEP 7. Using a press, remove the bearing.
1. BEVEL PINION
2. BEARING
STEP 8. Remove the bearing cups from the bevel pinion housing.
STEP 9. Remove the shims from the bevel pinion housing.
1. SHIMS
67
Bevel Pinion
CLEAN AND INSPECT
1400 SRM 1246 Clean and inspect the following parts: •
Bearings - Inspect the cup, cone, rollers, and cage of all tapered roller bearings in the assembly. If bearings show signs of wear, cracks, or damage, replace with new bearing cone and cup.
•
Bevel Pinion - Inspect the bevel pinion for wear or damage. Replace as needed. If the bevel pinion is replaced, the bevel gear must also be replaced.
•
Bevel Pinion Housing - Inspect the housing for wear and damage. Replace as needed.
WARNING Cleaning solvents can be flammable and toxic and can cause skin irritation. When using cleaning solvents, always follow the recommendations of the manufacturer.
WARNING Compressed air can move particles so that they cause injury to the user or to other personnel. Make sure that the path of the compressed air is away from all personnel. Wear protective goggles or a face shield to prevent injury to the eyes.
ASSEMBLE Refer to Figure 12 and Figure 13.
68
1400 SRM 1246
Bevel Pinion
Figure 13. Determining Bevel Pinion Shim Thickness
69
Bevel Pinion
1400 SRM 1246
Calculation of Measurement Y STEP 1. Reset a centesimal digital depth gauge on a 20 mm (0.787 in.) calibrated block.
1. 20 mm (0.787 in.) CALIBRATED BLOCK STEP 2. With the calibrated block on a faceplate, allow the bearing to set by rotating them in both directions and by applying a vertical thrust to position the calibrated block on the external thrust blocks. Check the overall thickness of the bearing (D). Example: D = 35.25 mm
1. D = BEARING THICKNESS STEP 3. Determine the actual bevel pinion mounting distance I. See Figure 13. Example: I = INT ± V •
98 − 0.1 = 97.9 mm
Determine measurement Y. Example: Y=I+D •
70
97.9 + 35.25 = 133.15 mm
1400 SRM 1246
Bevel Pinion
Calculation of Measurement X STEP 1. Measure the case diameter (210 mm). Example: R = central body radius •
210 ÷ 2 = 105 = 105 mm
STEP 2. Measure the thickness of the central body at the pinion bearing contact surface. Example: B = 24.15 mm
STEP 3. Reset a centesimal digital depth gauge. With depth gauge (set to zero at previous point) measure surface between the contact surface and the striking surface of the internal bearing (E). Example: E = pinion support thickness •
E = 5.3 mm
Determine measurement X. Example: X=R+B+E •
105 + 24.15 + 5.3 = 134.45 mm
71
Bevel Pinion
1400 SRM 1246
Calculation of Measurement S1 STEP 1. Determine the thickness of the shims S1. See Figure 13. Example: S1 = X − Y •
134.45 − 133.15 = 1.3 mm
STEP 2. Install the shims.
1. SHIMS
Calculation of Measurement S2 STEP 1. Place the special tool T5 in position under the press. Place the bearing cup and bevel pinion housing in position on the special tool T5.
1. SPECIAL TOOL T5 2. BEVEL PINION HOUSING
72
1400 SRM 1246
Bevel Pinion
STEP 2. Place the opposite bearing cup in position and install the bearing cups using the special tool T5.
1. BEARING CUP 2. SPECIAL TOOL T5 STEP 3. Assemble the special tool T6 with bearings into the bevel pinion housing as shown. Hand tighten until the axial gap is eliminated.
1. 2. 3. 4.
BEARING BEVEL PINION HOUSING SPECIAL TOOL T6 BEARING
STEP 4. Insert the tip of the depth gauge into either side hole of the special tool T6. Reset the depth gauge with a preload of approximately 3 mm.
NOTE: Refer to Figure 12.
73
Bevel Pinion
1400 SRM 1246
STEP 5. Install the spacer (11) and largest calibrated spacer (8) between the bearings, assembled with the special tool T6. Insert the tip of the depth gauge into either side hole and measure the deviation H from the previous reset in STEP 4. Example: H = A − B = 2.93 mm
1. SPECIAL TOOL T6 NOTE: Refer to Figure 12. STEP 6. The deviation H measured must be added to the fixed value X to define the pack S2, installed between the bearings (7, 12) and the spacer (11). The value S2 must be rounded to the upper 5/100. Example: S2 = H + X H=A−B X = 0.10 to 0.11 mm (fixed value)
Bevel Pinion Housing
WARNING Hot parts. Wear protective clothing and gloves to prevent burns. STEP 1. Heat the inner bearing to approximately 100°C (212°F) and install the bearing onto the bevel pinion. Once the bearing has cooled down, lightly lubricate the bearing with John Deere JDM J20C. Install the bevel pinion into the bevel pinion housing.
74
1400 SRM 1246
Bevel Pinion
WARNING Hot parts. Wear protective clothing and gloves to prevent burns. STEP 2. Install the calibrated spacers as shown. Heat the outer bearing to approximately 100°C (212°F) and install the bearing onto the bevel pinion. Once the bearing has cooled down, lightly lubricate the bearing with John Deere JDM J20C. STEP 3. Apply Loctite® 270 to the threads of the ring nut and screw the ring nut onto the pinion.
1. RING NUT STEP 4. Using the special tool T4, tighten the bevel pinion ring nut to a torque setting of 400 to 500 N•m (295 to 369 lbf ft).
1. SPECIAL TOOL T4
75
Bevel Pinion
1400 SRM 1246
CAUTION If the rolling torque exceeds the maximum value, then the size of the calibrated spacer (8) S2 between the bearing (7) and distance spacer (11) needs to be increased. See Figure 12. If the rolling torque does not reach the set value, increase the torque setting of the ring nut in different stages to obtain a maximum value of 500 N•m (369 lbf ft).
CAUTION If the rolling torque does not reach the minimum value, then the size of the calibrated spacer (8) S2 between the bearing (7) and distance spacer (11) needs to be decreased. See Figure 12. STEP 5. Measure the rolling torque of the bevel pinion. The rolling torque should be 1.2 to 1.8 N•m (10.6 to 15.9 lbf in).
NOTE: Only apply oil to the lip of the seal using John Deere JDM J20C.
76
1400 SRM 1246
Bevel Pinion
STEP 6. Using the special tool T7, install the seal.
1. SPECIAL TOOL T7
77
Bevel Pinion
1400 SRM 1246
INSTALL Refer to Figure 12. STEP 1. Lubricate a new O-ring with a lithium based grease and install on the bevel pinion housing.
1. BEVEL PINION HOUSING STEP 2. Apply Loctite® 242 to the threads of the retaining capscrews for the bevel pinion housing. Place the bevel pinion housing in position and install the capscrews. Tighten the capscrews in a cross pattern to 68 to 75 N•m (50 to 55 lbf ft).
1. CAPSCREW
78
1400 SRM 1246
Bevel Pinion
STEP 3. Lubricate the pinion splines with a lithium based grease. Install the flange (yoke).
1. FLANGE (YOKE) STEP 4. Apply Loctite® 242 to the threads of the retaining capscrews for the transmission support. Place the transmission support in position and install the capscrews. Tighten the capscrews to 182 to 202 N•m (134 to 149 lbf ft).
79
Differential Unit
1400 SRM 1246
Differential Unit
1. 2. 3. 4. 5. 6. 7. 8. 9.
SOCKET HEAD SCREW RING NUT SEAL SNAP RING O-RING ROLLER BEARING CENTERING RING/BUSHING CAPSCREW BEVEL GEAR
10. 11. 12. 13. 14. 15. 16. 17. 18.
THRUST WASHER SIDE GEAR DIFFERENTIAL PIN COUPLER PINION GEAR SPHERICAL THRUST WASHER DOWEL PIN PIN DIFFERENTIAL CARRIER
Figure 14. Differential Assembly
80
1400 SRM 1246
Differential Unit
REMOVE Refer to Figure 14.
CAUTION The hub and planetary carrier assembly are heavy. Use caution when removing. STEP 1. Place a sling around the hub and planetary carrier assembly and connect the sling to an overhead lift. Place the sling under light tension. Remove the capscrews from the planetary cover.
1. HUB AND PLANETARY CARRIER ASSEMBLY 2. CAPSCREW STEP 2. Remove the hub and planetary carrier assembly.
1. HUB AND PLANETARY CARRIER ASSEMBLY
81
Differential Unit
1400 SRM 1246
CAUTION If the socket head/pin screws are being replaced, note down the positions and the different colors for the different brake gaps. STEP 3. Remove the socket head/pin screws guiding the piston.
1. SOCKET HEAD/PIN SCREW
1. SOCKET HEAD/PIN SCREW STEP 4. Remove the capscrews and return springs from the piston.
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1400 SRM 1246
Differential Unit
1. CAPSCREW 2. RETURN SPRING
WARNING Compressed air can move particles so that they cause injury to the user or to other personnel. Make sure that the path of the compressed air is away from all personnel. Wear protective goggles or a face shield to prevent injury to the eyes.
WARNING Hold onto the piston as it may be suddenly ejected and damaged. STEP 5. Mark the position of the piston. Slowly apply compressed air through the brake fluid port to extract the entire piston.
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1. PISTON STEP 6. Remove the axle shaft.
NOTE: The O-rings must be replaced each time the unit is disassembled. STEP 7. Remove and discard the O-rings from the piston.
1. PISTON 2. O-RING
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3. O-RING
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Differential Unit
STEP 8. Remove the socket head screw retaining the parking brake lever.
1. SOCKET HEAD SCREW 2. PARKING BRAKE LEVER NOTE: Mark the parking brake lever in relation to the thrust lever. STEP 9. Remove the spacer and the parking brake lever.
1. SPACER 2. SOCKET HEAD SCREW STEP 10. Remove the socket head screws retaining the thrust bushing.
1. SOCKET HEAD SCREW 2. THRUST BUSHING 3. THRUST LEVER
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STEP 11. Remove the thrust bushing.
1. THRUST BUSHING STEP 12. Remove and discard the O-ring.
1. O-RING STEP 13. Remove and discard the O-ring.
1. O-RING
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STEP 14. Mark the position of the thrust lever. Remove the thrust lever with bearings.
STEP 15. Repeat STEP 1 through STEP 14 on the opposite side. STEP 16. Remove the capscrews retaining the transmission support and remove the transmission support.
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CAUTION Check and make note of the static torque before removal/disassembly. STEP 17. Measure the static torque of the bevel pinion and bearings.
STEP 18. Remove the bevel pinion housing assembly. Refer to Bevel PinionRemove.
1. BEVEL PINION HOUSING STEP 19. Mark the position of the ring nuts on both sides of the assembly. Remove the socket head screws from the ring nuts on both sides of the assembly.
1. SOCKET HEAD SCREW 2. RING NUT
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STEP 20. Using the special tool T8, remove the ring nuts on both sides of the assembly.
1. SPECIAL TOOL T8 2. RING NUT STEP 21. Place a sling around the arm to be removed and connect the sling to an overhead hoist. Remove the nuts and slide the arm from the threaded studs.
STEP 22. If the bearings of the differential assembly need replaced, remove the bearing cup from the arm.
1. BEARING CUP
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STEP 23. Remove the differential assembly from the central body.
STEP 24. If the bearings of the differential assembly need replaced, remove the bearing cups from the central body.
1. BEARING CUP
DISASSEMBLE Refer to Figure 14.
Differential Assembly STEP 1. Remove the bearing from the differential carrier.
1. BEARING 2. DIFFERENTIAL CARRIER
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STEP 2. Remove the bearing from the bevel gear side.
1. BEARING 2. BEVEL GEAR STEP 3. If the centering rings/bushings need replaced, use a puller and remove the centering ring/bushing from both sides of the differential carrier.
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STEP 4. Remove the capscrews retaining the bevel gear.
STEP 5. Remove the bevel gear from the differential carrier.
1. BEVEL GEAR 2. DIFFERENTIAL CARRIER STEP 6. Remove the thrust washer and side gear.
1. SIDE GEAR 2. THRUST WASHER
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STEP 7. Remove the pins from the differential pin coupler.
1. PIN STEP 8. With a pin-driver, push the two short differential pins to the outside of the differential carrier.
1. DIFFERENTIAL PIN STEP 9. Remove the long pin with the help of a brass drift.
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STEP 10. Remove the two short pins with the help of a brass drift.
STEP 11. Remove the differential pin coupler.
1. DIFFERENTIAL PIN COUPLER
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STEP 12. Remove the pinion gears and spherical thrust washers.
1. PINION GEAR 2. SPHERICAL THRUST WASHER STEP 13. Remove the remaining side gear and thrust washer.
1. SIDE GEAR 2. THRUST WASHER
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Ring Nuts Perform the following procedures on both ring nuts. STEP 1. Remove the snap ring from the ring nut.
STEP 2. Remove the seal from the ring nut.
STEP 3. Remove and discard the O-ring from the ring nut.
1. O-RING
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CLEAN AND INSPECT
Differential Unit •
Tapered roller bearings - Inspect the cup, cone, rollers, and cage of all tapered roller bearings in the assembly. If bearings show signs of wear, cracks, or damage, replace with new bearing.
•
Bevel Pinion and bevel gear - Inspect the bevel pinion and bevel gear for wear or damage. If the bevel pinion or bevel gear is damaged, they must be replaced as a set.
•
Pinions and side gears - Inspect the pinions and side gears for wear or damage. Pinions and side gears that are worn or damaged must be replaced.
•
Main differential assembly - Inspect all parts of the main differential assembly for wear or damage. Parts that are damaged must be replaced.
WARNING Cleaning solvents can be flammable and toxic and can cause skin irritation. When using cleaning solvents, always follow the recommendations of the manufacturer.
WARNING Compressed air can move particles so that they cause injury to the user or to other personnel. Make sure that the path of the compressed air is away from all personnel. Wear protective goggles or a face shield to prevent injury to the eyes. Clean and inspect the following parts of the differential: •
Drive axle - Clean the parts of the axle with solvent and dry with compressed air. Inspect all machined surfaces and bearings for wear and damage.
ASSEMBLE Refer to Figure 14.
Ring Nuts Perform the following procedures on both ring nuts. STEP 1. Lubricate the outer surface of the new seal with a lithium based grease and install the new seal into the ring nut with special tool T9 to a predetermined depth of 8.35 to 8.65 mm (0.329 to 0.341 in.).
1. SEAL 2. RING NUT
3. SPECIAL TOOL T9
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STEP 2. Install the snap ring. Rotate the snap ring to verify that it is properly set in the groove.
1. SNAP RING STEP 3. Lubricate a new O-ring and install the O-ring onto the ring nut.
1. O-RING
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STEP 4. If the arms are replaced, apply Loctite® 510 to two new setscrews and install the setscrews in the holes on the opposite side of the ring nut socket head screws.
1. SETSCREWS
1. SETSCREW 2. SOCKET HEAD SCREW 3. RING NUT
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Differential Assembly STEP 1. Lubricate a thrust washer and side gear. Install the thrust washer and side gear into the differential carrier.
1. SIDE GEAR 2. THRUST WASHER STEP 2. Lubricate the short pins with John Deere JDM J20C. Insert a pinion gear and spherical thrust washer into the differential carrier and insert a short pin to keep the pinion gear and thrust washer in position. Repeat this step on the opposite side.
1. SHORT PIN 2. SPHERICAL THRUST WASHER 3. PINION GEAR
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STEP 3. Verify that the holes in the short pins are vertically located.
STEP 4. Lubricate the long pin with John Deere JDM J20C. Partially insert the long pin into the differential carrier and install a spherical thrust washer and pinion gear.
1. 2. 3. 4.
SPHERICAL THRUST WASHER PINION GEAR SHORT PIN LONG PIN
STEP 5. Temporarily install a dummy pin in the opposite side and install the remaining spherical thrust washer and pinion gear.
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STEP 6. Place the differential pin coupler in the correct position in the differential carrier.
1. DIFFERENTIAL PIN COUPLER STEP 7. Insert the long pin through the coupler until it pushes the dummy pin out of the opposite side of the differential carrier. Insert the short pins into the coupler.
STEP 8. Verify that the holes in the short and long pins are lined up with the holes in the differential pin coupler. Insert the new spring pins into the differential pin coupler.
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1. SPRING PIN STEP 9. Verify that the spring pins are completely engaged into the journals of the differential pin coupler to prevent damage as the side gear rotates.
STEP 10. Insert the side gear into the differential carrier.
1. SIDE GEAR
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STEP 11. Apply multipurpose grease to the bevel gear thrust washer surface. Place the thrust washer into position on the bevel gear.
1. BEVEL GEAR STEP 12. Place the bevel gear into position on the differential carrier. Apply Loctite® 270 to the retaining capscrews and install the capscrews.
1. BEVEL GEAR 2. CAPSCREW STEP 13. Tighten the capscrews using a cross pattern to 139 to 154 N•m (102.5 to 113.6 lbf ft).
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Differential Unit
STEP 14. Lubricate the outer surface of the centering ring/ bushing with John Deere JDM J20C and place the centering ring/bushing in position on the bevel ring side of the differential carrier.
STEP 15. Install the centering ring/bushing into the differential carrier.
STEP 16. Lubricate the outer surface of the remaining centering ring/bushing with John Deere JDM J20C and place the centering ring/bushing in position on the opposite side of the bevel ring of the differential carrier.
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STEP 17. Install the centering ring/bushing into the differential carrier.
WARNING Hot parts. Wear protective clothing and gloves to prevent burns. STEP 18. Heat the bearing to 100°C (212°F) and install the bearing onto the differential carrier.
1. BEARING STEP 19. Heat the bearing to 100°C (212°F) and install the bearing onto the differential carrier.
1. BEARING
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INSTALL Refer to Figure 14. STEP 1. Place the special tool T8 into the arm to support the differential assembly.
1. SPECIAL TOOL T8 STEP 2. Install the differential assembly into the central body.
STEP 3. If the bearings are being replaced, install new bearing cups into the arm and central body.
1. BEARING CUP
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STEP 4. Lubricate a new O-ring and install the new O-ring onto the arm.
STEP 5. Place the arm in position on the threaded studs to the central body. Apply Loctite® 242 to the threaded studs and install the retaining nuts. Tighten the nuts to 129 to 143 N•m (95 to 105.5 lbf ft).
STEP 6. Lubricate a new O-ring with a lithium based grease and install on the bevel pinion housing.
1. BEVEL PINION HOUSING
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STEP 7. Apply Loctite® 242 to the threads of the retaining capscrews for the bevel pinion housing. Place the bevel pinion housing in position and install the capscrews. Tighten the capscrews in a cross pattern to 68 to 75 N•m (50 to 55 lbf ft).
1. CAPSCREW
STEP 8. Apply Loctite® 242 to the threads of the ring nuts and install the ring nuts on both sides but do not tighten.
1. RING NUT
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STEP 9. Tighten the ring nut on the bevel gear side until the clearance between the bevel pinion and the bevel gear is 0 mm (0 in.). Lock the bevel gear, then loosen the ring nut 1/4 to ½ turn.
CAUTION If the bearings are not new, check the static torque and verify the static torque did not change from the measurement recorded during removal. If the bearings are new, check the continuous torque. STEP 10. Preset the bearings by tightening the ring nut on the opposite side of the bevel gear, so as to increase pinion torque up to 1.6 to 2.2 N•m (14 to 19.5 lbf in). STEP 11. Lubricate the pinion splines with a lithium based grease. Install the flange (yoke).
1. FLANGE (YOKE)
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STEP 12. Block the bevel gear by installing a 30 mm long, 22 × 1.5 mm threaded bolt.
STEP 13. Install a dial gauge as shown and shift the flange to check the tolerance between the bevel gear teeth. Manually move the bevel gear in both directions to check the existing backlash between the bevel pinion and bevel gear.
A. 50 mm (1.9685 in.)
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STEP 14. Adjust the backlash between the bevel pinion and the bevel gear by loosening one of the ring nuts and tightening the opposite ring nut. The backlash must be set between 0.25 to 0.34 mm (0.0098 to 0.01339 in.).
STEP 15. Apply Loctite® 242 to the threads of the socket head screw and install the socket head screw into one of the two holes to lock the ring nut in position. Tighten the socket head screw to 23.8 to 26.2 N•m (17.6 to 19.3 lbf ft). Repeat on opposite side.
STEP 16. Lubricate the thrust lever and bearings with John Deere JDM J20C and install the thrust lever in position previously marked during removal.
1. THRUST LEVER
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Differential Unit
STEP 17. Lubricate new O-rings with a lithium based grease and install the O-rings on the thrust bushing. Pack the area above the O-Ring with multipurpose grease with 2% to 4% molybdenum disulfide prior to installing thrust bushing onto thrust lever.
1. O-RING 2. O-RING 3. APPLY MULTIPURPOSE GREASE HERE STEP 18. Install the thrust bushing. Apply Loctite® 242 to the socket head screws and install the socket head screws and tighten to 21 to 30 N•m (15 to 22 lbf ft).
1. SOCKET HEAD SCREW 2. THRUST BUSHING STEP 19. Install the parking brake lever in the position marked previously in disassembly.
1. PARKING BRAKE LEVER
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STEP 20. Install the spacer and socket head screw.
1. PARKING BRAKE LEVER 2. SPACER 3. SOCKET HEAD SCREW STEP 21. Tighten the socket head 30 N•m (15 to 22 lbf in).
screw
to
21
to
1. SOCKET HEAD SCREW 2. PARKING BRAKE LEVER STEP 22. Install the axle shaft.
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STEP 23. Lubricate new O-rings with a lithium based grease and install new O-rings onto the piston.
1. PISTON 2. O-RING
3. O-RING
STEP 24. Install the stroke automatic regulation springs flush in the piston.
1. STROKE AUTOMATIC REGULATION SPRING 2. PISTON STEP 25. Lubricate the O-rings and the piston and install the piston into the arm. Lightly tap around the edge of the piston with a plastic hammer until the piston is seated.
1. PISTON NOTE: The thread holes must be free of oil.
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STEP 26. Apply Loctite® 270 to the threads of the capscrews and install the capscrews and return springs. Tighten the capscrews to 10 to 15 N•m (88.5 to 132.8 lbf in).
STEP 27. Apply Loctite® 270 to the threads of the socket head/pin screws.
1. SOCKET HEAD/PIN SCREWS STEP 28. Install the socket head/pin screws and tighten to 5 to 7 N•m (44 to 62 lbf in).
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Differential Unit
STEP 29. If necessary, replace the alignment dowel pins. Install the new dowel pins with only 5 mm (0.20 in.) of the length into the housing.
1. DOWEL PIN STEP 30. Lubricate the internal spline of the pinion with John Deere JDM J20C and install the pinion.
1. PINION
CAUTION The oil outlet/drain plug must be on the bottom side. STEP 31. Lubricate a new O-ring with a lithium based grease and install the O-ring on the planetary cover. Place the hub and planetary carrier assembly in position on the drive axle.
1. PLANETARY COVER 2. O-RING
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1. OIL LEVEL/FILL PLUG 2. OIL OUTLET/DRAIN PLUG STEP 32. Apply Loctite® 242 to the capscrews. Install the capscrews to retain the hub and planetary carrier assembly to the drive axle.
1. HUB AND PLANETARY CARRIER ASSEMBLY 2. CAPSCREW
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STEP 33. Tighten the capscrews to 199 to 243 N•m (147 to 179 lbf ft).
STEP 34. Apply light pressure to the parking brake lever to bring it to rest with the piston without pre-loading the inside band. Adjust the adjustment screw to draw near to the parking brake lever, leaving a 0.1 to 0.2 mm (0.0039 to 0.0079 in.) gap.
1. PARKING BRAKE LEVER 2. ADJUSTMENT SCREW
CAUTION The idle stroke should be eliminated without preloading the parking brake lever. STEP 35. Lock the adjustment screw in position with the nut. Tighten the nut to 20 to 25 N•m (14.75 to 18.44 lbf ft). Repeat STEP 16 through STEP 35 on the opposite side.
1. PARKING BRAKE LEVER 2. ADJUSTMENT SCREW 3. NUT
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Drive Axle Installation
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Drive Axle Installation 1. Connect slings and lifting device to drive axle. NOTE: When installing the drive axle, ensure the drive axle is held with the upper surface of the drive axle against the frame. This will prevent any gaps between the frame and the drive axle mount, and will ensure even weight distribution.
NOTE: It is recommended to use a torque multiplier to achieve the torque specification in Step 3. 3. Install the four mounting capscrews and washers. Tighten the capscrews to 820 to 902 N•m (605 to 665 lbf ft). See Figure 15.
2. Position the drive axle in the lift truck.
1. CAPSCREW 2. WASHER
3. DRIVE AXLE Figure 15. Drive Axle Mounting Capscrews
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1400 SRM 1246 4. Place the drive shaft in position and install the retaining capscrews. Tighten the drive shaft capscrews to 50 to 63 N•m (37 to 46.5 lbf ft). 5. Install the transmission isolator mounting bolt located on top of the assembly. Tighten the bolt to 225 to 250 N•m (166 to 184 lbf ft). See Figure 16.
Drive Axle Installation 6. Remove blocks from under the transmission. 7. Connect the cooling return hoses to the drive axle. See Figure 17. 8. Connect the brake lines to the drive axle. See Figure 18 for lift truck models •
S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; S80, 100FTBCS; S120FTS; S120FTPRS) (G004, H004, J004)
See Figure 19 for lift truck models •
H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005, P005, R005, S005, U005)
9. Connect the brake cooling lines to the drive axle. See Figure 18 for lift truck models •
S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; S80, 100FTBCS; S120FTS; S120FTPRS) (G004, H004, J004)
See Figure 19 for lift truck models •
H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-5.5FT (H80, 90, 100, 110, 120FT) (R005, S005, N005, P005, U005)
1. ISOLATORS 4. CAPSCREW 2. WASHER 5. TRANSMISSION 3. WASHER 6. DRIVE AXLE Figure 16. Transmission to Differential Mounting Bolt
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Drive Axle Installation
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A. DRIVE AXLE COOLING HOSE RETURN TO TRANSMISSION SUMP 1. HOSE CLAMP 2. COOLING RETURN HOSE, RIGHT SIDE
3. COOLING RETURN HOSE, LEFT SIDE
Figure 17. Drive Axle Cooling Return Hoses
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1400 SRM 1246
1. 2. 3. 4. 5. 6.
BRAKE COOLING LINE (LEFT SIDE) HOSE CLAMP HOSE CLAMP BRAKE COOLING LINE (RIGHT SIDE) BRAKE LINE (RIGHT SIDE) LINE GUARD (RIGHT SIDE)
Drive Axle Installation
7. 8. 9. 10. 11.
CAPSCREW COOLING RETURN HOSES CAPSCREW LINE GUARD (LEFT SIDE) BRAKE LINE (LEFT SIDE)
Figure 18. Brake Cooling Lines and Brake Lines, Lift Truck Models S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; S80, 100FTBCS; S120FTS; S120FTPRS) (G004, H004, J004)
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Drive Axle Installation
1. 2. 3. 4.
BRAKE COOLING LINE (LEFT SIDE) HOSE CLAMP BRAKE COOLING LINE (RIGHT SIDE) BRAKE LINE (RIGHT SIDE)
1400 SRM 1246
5. BRAKE LINE (LEFT SIDE) 6. COOLING RETURN HOSES 7. BRAKE LINE SUPPLY LINE
Figure 19. Brake Cooling Lines and Brake Lines, Lift Truck Models H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005, P005, R005, S005, U005) 10. Install parking brake cable. Make sure the brake cable is routed properly and has no interference. Verify that the parking brake operates properly. Refer to one of the following sections for procedures:
13. Install the center section drain plug and tighten to 30 to 50 N•m (22 to 37 lbf ft). See Figure 20 for lift truck models •
Brake System 1800SRM1247 for lift truck models •
•
S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; S80, 100FTBCS; S120FTS; S120FTPRS) (G004, H004) H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005, P005, R005, S005)
Wet Brakes - NMHG 1800SRM1597 for lift truck models •
S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; S80, 100FTBCS; S120FTS; S120FTPRS) (J004)
•
H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (U005)
11. Apply multipurpose grease to new O-ring and install O-ring on the drain plug. 12. Install the O-ring and drain plug.
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S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; S80, 100FTBCS; S120FTS; S120FTPRS) (G004, H004, J004)
See Figure 21 for lift truck models •
H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005, P005, R005, S005, U005)
14. Install the planetary carrier housing drain plugs on both sides of the drive axle and tighten to 30 to 50 N•m (22 to 37 lbf ft). See Figure 20 for lift truck models •
S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; S80, 100FTBCS; S120FTS; S120FTPRS) (G004, H004, J004)
See Figure 21 for lift truck models •
H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005, P005, R005, S005, U005)
1400 SRM 1246
Drive Axle Installation
A. REAR VIEW SHOWN B. FRONT VIEW SHOWN 1. PLANETARY CARRIER HOUSING FILL/LEVEL PLUGS 2. PLANETARY CARRIER HOUSING DRAIN PLUGS 3. CENTER SECTION DRAIN PLUG 4. CENTER SECTION FILL/LEVEL PLUG 5. PLANETARY CARRIER HOUSING (RH) 6. PLANETARY CARRIER HOUSING (LH) 7. CENTER SECTION Figure 20. Drive Axle Drain and Fill/Level Plugs for Lift Truck Models S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; S80, 100FTBCS; S120FTS; S120FTPRS) (G004, H004, J004)
A. REAR VIEW SHOWN B. FRONT VIEW SHOWN 1. PLANETARY CARRIER HOUSING FILL/LEVEL PLUGS 2. PLANETARY CARRIER HOUSING DRAIN PLUGS 3. CENTER SECTION FILL/LEVEL PLUG 4. CENTER SECTION DRAIN PLUG 5. PLANETARY CARRIER HOUSING (RH) 6. PLANETARY CARRIER HOUSING (LH) 7. CENTER SECTION Figure 21. Drive Axle Drain and Fill/Level Plugs for Lift Truck Models H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005, P005, R005, S005, U005)
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Drive Axle Installation 15. Fill the planetary gear housings and the drive axle with the proper fluid. Refer to Periodic Maintenance 8000SRM1248 for the correct fluid, quantity, and fill procedure for lift truck models •
H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005, P005)
•
S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; S80, 100FTBCS; S120FTS; S120FTPRS) (G004)
Refer to Periodic Maintenance 8000SRM1558 for the correct fluid, quantity, and fill procedure for lift truck models •
H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-5.5FT (H80, 90, 100, 110, 120FT) (R005)
Refer to Periodic Maintenance 8000SRM1598 for the correct fluid, quantity, and fill procedure for lift truck models •
S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; S80, 100FTBCS; S120FTS; S120FTPRS) (H004)
Refer to Periodic Maintenance 8000SRM1604 for the correct fluid, quantity, and fill procedure for lift truck models •
H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-5.5FT (H80, 90, 100, 110, 120FT) (S005)
Refer to Periodic Maintenance 8000SRM1902 for the correct fluid, quantity, and fill procedure for lift truck models
126
1400 SRM 1246 •
S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; S80, 100FTBCS; S120FTS; S120FTPRS) (J004)
•
H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-5.5FT (H80, 90, 100, 110, 120FT) (U005)
16. Install the center section fill/level plug and tighten to 30 to 50 N•m (22 to 37 lbf ft). See Figure 20 for lift truck models •
S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; S80, 100FTBCS; S120FTS; S120FTPRS) (G004, H004, J004)
See Figure 21 for lift truck models •
H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005, P005, R005, S005, U005)
17. Install the planetary carrier housing fill/level plugs on both sides of the drive axle and tighten to 30 to 50 N•m (22 to 37 lbf ft). See Figure 20 for lift truck models •
S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; S80, 100FTBCS; S120FTS; S120FTPRS) (G004, H004, J004)
See Figure 21 for lift truck models •
H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005, P005, R005, S005, U005)
1400 SRM 1246 18. Remove the air from the brake system. For procedures, refer to one of the following sections: Brake System 1800SRM1247 for lift truck models •
S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; S80, 100FTBCS; S120FTS; S120FTPRS) (G004, H004)
•
H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005, P005, R005, S005)
Drive Axle Installation 19. On pneumatic lift trucks, inflate the tires using a safety cage. Install the wheels and nuts and tighten the nuts to 610 to 680 N•m (450 to 501 lbf ft). NOTE: When tightening the wheel nuts, DO NOT use any lubricant on the studs or nuts. 20. On cushion lift trucks, install the wheel and nuts and tighten the nuts to 610 to 680 N•m (450 to 501 lbf ft).
•
S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; S80, 100FTBCS; S120FTS; S120FTPRS) (J004)
21. Install the mast assembly as described in the section Mast Repairs (S/N A513, A514, A613, A614, A702, A703, A704, A705, A706, A707, A751, A752, B513, B514, B586, B587, B588, B589, B590, B591, B749, B750, B751, B752, B753, B754) 4000SRM1250.
•
H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (U005)
22. Raise the lift truck and remove blocks from under frame and from under the counterweight. Lower the lift truck.
Wet Brakes - NMHG 1800SRM1597 for lift truck models
WARNING Add air to the tires only in a safety cage. Inspect safety cage for damage before use. When adding air, use a clip-on chuck with enough hose to let the operator stand clear of the cage.
23. Remove the blocks on each side (front and back) of the steering tires. 24. Operate the lift truck and check for proper operation and leaks.
NOTE: When tightening the wheel nuts, use lubricant on the studs or nuts.
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Special Tools
1400 SRM 1246
Special Tools Description
Part Number
Description
Part Number
Wet Brake Axle Service Tool T1 Wheel Hub/Planetary Nut
1639261
Wet Brake Axle Service Tool T6
1639265
1639262
Wet Brake Axle Service Tool T7
1639266
Wet Brake Axle Service Tool T2
1672614
Wet Brake Axle Service Tool T8
1639267
Wet Brake Axle Service Tool T3
1639263
Wet Brake Axle Service Tool T9
1639268
Wet Brake Axle Service Tool T4
1660310
1639264
Service Tool - Handle
Wet Brake Axle Service Tool T5
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1400 SRM 1246
Torque Specifications
Torque Specifications Bevel Pinion Housing Capscrews 68 to 75 N•m (50 to 55 lbf ft) Bevel Pinion Ring Nut 400 to 500 N•m (295 to 369 lbf ft)
Parking Brake Lever Socket Head Screw 21 to 30 N•m (15 to 22 lbf ft) Piston Guide Socket Head/Pin Screws 5 to 7 N•m (44 to 62 lbf in)
Bevel Gear Capscrews 139 to 154 N•m (102.5 to 113.6 lbf ft)
Planetary Carrier Cover to Drive Axle Capscrews 199 to 243 N•m (147 to 179 lbf ft)
Differential Adjustment Ring Nut Socket Head Screw 23.8 to 26.2 N•m (17.6 to 19.3 lbf ft)
Planetary Carrier Housing Drain Plug 30 to 50 N•m (22 to 37 lbf ft)
Drive Axle Arm to Drive Axle Central Body Nuts 129 to 143 N•m (95 to 105.5 lbf ft) Drive Axle Center Section Drain Plug 30 to 50 N•m (22 to 37 lbf ft) Drive Axle Center Section Fill/Level Plug 30 to 50 N•m (22 to 37 lbf ft) Drive Axle to Frame Mounting Capscrews 820 to 902 N•m (605 to 665 lbf ft) Drive Shaft Capscrews 50 to 63 N•m (37 to 46.5 lbf ft) Hub Ring Nut 500 to 600 N•m (369 to 443 lbf ft) Parking Brake Lever Adjustment Screw Nut 20 to 25 N•m (14.75 to 18.44 lbf ft)
Planetary Carrier Housing Fill/Level Plug 30 to 50 N•m (22 to 37 lbf ft) Return Spring Capscrews 10 to 15 N•m (88.5 to 132.8 lbf ft) Safety Flange Socket Head Screw 21 to 30 N•m (15 to 22 lbf ft) Thrust Bushing Socket Head Screws 21 to 30 N•m (15 to 22 lbf ft) Transmission Isolator Mounting Bolt 225 to 250 N•m (166 to 184 lbf ft) Transmission Support Capscrews 182 to 202 N•m (134 to 149 lbf ft) Wheel Nuts 610 to 680 N•m (450 to 501 lbf ft)
129
NOTES
130
TECHNICAL PUBLICATIONS 1400 SRM 1246
4/15 (12/13)(3/13)(9/12)(1/12)(5/09)