Professional Documents
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• 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.
• 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.
• 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 back-
ground. The CAUTION symbol and word are on yellow background.
Differential Table of Contents
TABLE OF CONTENTS
General ............................................................................................................................................................... 1
Description ......................................................................................................................................................... 1
Differential Repair ............................................................................................................................................. 1
Remove ........................................................................................................................................................... 1
Differential Carrier From Axle Housing, Remove................................................................................... 1
Differential and Ring Gear From Differential Carrier, Remove............................................................. 5
Drive Pinion and Pinion Carrier From Differential Carrier, Remove .................................................... 7
Disassemble ................................................................................................................................................... 8
Differential and Ring Gear Assembly, Disassemble................................................................................ 8
Drive Pinion and Pinion Carrier, Disassemble........................................................................................ 9
Clean and Inspect .......................................................................................................................................... 12
Assemble ........................................................................................................................................................ 13
Pinion, Bearings, and Pinion Carrier, Assemble ..................................................................................... 13
Pinion Bearings, Adjust Preload .............................................................................................................. 13
Press Method......................................................................................................................................... 13
Yoke or Flange Method ......................................................................................................................... 14
Triple-Lip Seal, Install.............................................................................................................................. 15
Pinion Carrier Shim Set, Adjust Thickness (Depth of Pinion) ............................................................... 16
Differential and Ring Gear, Assemble...................................................................................................... 18
Differential Gears Rotating Torque, Check ............................................................................................. 21
Differential and Ring Gear Assembly, Install.......................................................................................... 21
Differential Bearings, Preload Adjust ...................................................................................................... 23
Ring Gear, Runout Check ......................................................................................................................... 24
Ring Gear Backlash, Adjust...................................................................................................................... 24
Gear Set, Tooth Contact Pattern Check................................................................................................... 27
Thrust Screw, Install and Adjust.............................................................................................................. 30
Install ............................................................................................................................................................. 30
Differential Assembly Into Axle Housing, Install ................................................................................... 30
Specifications...................................................................................................................................................... 32
Troubleshooting ................................................................................................................................................. 36
General
This section contains description and repair procedures for the differential. There is a Specifications section
and a Troubleshooting section at the end of this section.
Description
This differential is fastened to the drive axle hous- transfers power from the pinion through the differen-
ing of the lift truck. The differential provides a sin- tial assembly to the axles. The differential assembly
gle-speed reduction for an increase in torque to the permits the drive wheels to rotate at different speeds
drive wheels. There is a housing, a ring and pinion during a turn. See Figure 1.
gear set, and the differential assembly. The ring gear
Differential Repair
REMOVE necessary, see the Drive Axle service manual for
your lift truck model.
NOTE: The repair procedures cover all units unless
otherwise indicated. 1. Remove the mast. See the Mast service manual
for your lift truck model for the removal proce-
Differential Carrier From Axle Housing, dures.
Remove
2. Raise the end of the vehicle where the axle is
NOTE: The differential assembly can normally be mounted. Use a jack or other lifting tool, and
removed without removing the drive axle. On some place safety stands under each side of the axle.
trucks, including the H7.00-12.50H (H150-275H), See Figure 2.
the drive axle must be removed to remove the dif-
ferential assembly. If removal of the drive axle is
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Differential Repair 1400 SRM 46
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1400 SRM 46 Differential Repair
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Differential Repair 1400 SRM 46
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1400 SRM 46 Differential Repair
1. DIFFERENTIAL CARRIER
2. REPAIR STAND
5
Differential Repair 1400 SRM 46
1. BEARING CAP
2. BEARING ADJUSTING RING
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1400 SRM 46 Differential Repair
CAUTION
Do not use a hammer or mallet to loosen and
remove the yoke or flange. A hammer or mal-
let can damage the parts and cause driveline
runout or driveline imbalance problems after
carrier to driveline assembly.
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Differential Repair 1400 SRM 46
CAUTION
Do not use a pry bar to remove the pinion car-
rier from the carrier. A pry bar can damage the
bearing case, shims, and differential carrier.
8
1400 SRM 46 Differential Repair
c. Press the rivets through holes in the ring 6. If the differential bearings need to be replaced,
gear and flange case half. Press from the remove the bearing cones from the case halves.
drilled rivet head. Use a bearing puller or press. See Figure 17.
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Differential Repair 1400 SRM 46
1. PRESS 5. SUPPORT
2. DRIVE PINION 6. SPIGOT BEARING
3. OIL SEAL 7. FLANGE SUPPORT
4. PINION CARRIER
WARNING
Use a brass or leather mallet for assembly and 1. DRIVE PINION
2. OIL SEAL
disassembly procedures. Do not hit steel parts 3. OUTER BEARING (CUP AND CONE)
with a steel hammer. Pieces of a part can break 4. INNER BEARING (CUP AND CONE)
off and cause serious personal injury. 5. SPIGOT BEARING
6. SNAP RING
NOTE: The inner bearing cone and bearing spacer 7. BEARING SPACER
will remain on the pinion shaft. See Figure 19.
Figure 19. Drive Pinion
3. If a press is not available, use a leather, plastic
or rubber mallet to drive the pinion through the 5. Inspect the pinion bearings and replace if neces-
pinion carrier. sary. If the pinion bearings need to be replaced,
perform the following:
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1400 SRM 46 Differential Repair
CAUTION
The puller must fit under the inner race of
the cone to remove the cone correctly without
damage.
1. PRESS 4. SUPPORTS
2. DRIVE PINION 5. INNER BEARING
3. BEARING PULLER CONE
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Differential Repair 1400 SRM 46
WARNING
Cleaning solvents can be flammable and toxic
and can cause skin irritation. When using
cleaning solvents, always follow the recom-
mendations 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 differen- Figure 25. Main Differential Assembly
tial: Inspection
• Yoke- Clean the surface of the yoke journal with a
cleaning solvent and inspect the original yoke seal
surface for any grooves.
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1400 SRM 46 Differential Repair
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Differential Repair 1400 SRM 46
7. Use the following procedure to calculate the bear- 6. Attach a torque wrench on the drive pinion nut.
ing preload (torque): Rotate the drive pinion and read the value indi-
• Pounds pulled × radius (inches) = lb-in preload. cated on the wrench. See Figure 27.
- Preload × 0.113 = N•m preload.
• Kilograms pulled × radius (cm) = kg-cm lb-in
preload
- Preload × 0.098 = N•m preload.
OR
EXAMPLES:
• Reading from spring scale = 3.4 kg (7.5 lb).
• Diameter of pinion carrier = 16.8 cm (6.62 in.).
• Radius of pinion carrier = 8.4 cm (3.31 in.).
7.5 lb × 3.31 in = 24.8 in-lb preload.
Preload × 0.113 = 2.8 N•m preload.
OR
3.4 kg × 8.4 cm = 28.6 kg-cm preload.
Preload × 0.098 = 2.8 N•m preload.
WARNING
Observe all warnings and cautions provided
by the press manufacturer to avoid damage to
components and serious personal injury.
Figure 27. Torque Value Reading
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1400 SRM 46 Differential Repair
Triple-Lip Seal, Install NOTE: If a press is not available, use a mallet and a
sleeve or driver to install the oil seal.
Once the preload has been adjusted, remove the drive
pinion and pinion carrier from the differential carrier 2. Place the drive pinion and carrier assembly in a
as outlined in the first five steps in the section Drive press, with seal bore toward the top.
Pinion and Pinion Carrier From Differential Carrier,
Remove. 3. Press the seal into pinion carrier until flange of
seal is flat against the top of pinion carrier. Use
a sleeve or seal driver of the correct size that fits
CAUTION against the metal flange of oil seal. The diameter
Make sure that the seal lips are clean and free of the sleeve must be larger than the diameter of
from dirt and particles that will cause a leak the flange. See Figure 29.
between the yoke and the seal.
1. APPLY GREASE
2. TRIPLE-LIP OIL SEAL
3. APPLY LUBRICANT TO SEAL BORE 1. PRESS 4. OIL SEAL
4. PINION CARRIER 2. SLEEVE 5. PINION CARRIER
5. DRIVE PINION 3. SUPPORTS 6. DRIVE PINION
Figure 28. Triple-Lip Oil Seal Lubrication Figure 29. Triple-Lip Oil Seal Installation
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Differential Repair 1400 SRM 46
WARNING CAUTION
Use a brass or leather mallet for assembly and Always use a minimum of three shims for the
disassembly procedures. Do not hit steel parts shim set. Use the thinnest shims on the outside
with a steel hammer. Pieces of a part can break of the set for a better seal.
off and cause serious personal injury.
1. The correct shim set thickness can be found by
4. Once the triple-lip oil seal has been installed, using the old and new parts. Use the old shim set
check the gap between the flange and pinion car- thickness and the numbers on the old and new
rier with a feeler gauge, at several points around pinion and ring gear sets. For the location and
the seal. See Figure 30. The gap must be within identification of the numbers, see Figure 32.
0.38 to 0.76 mm (0.015 to 0.030 in.). The differ-
ence between the largest and smallest gap mea-
surement must not exceed 0.0254 mm (0.010 in.).
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1400 SRM 46 Differential Repair
NOTE: Always check the gear set for the correct NOTE: The pinion cone number is not used when the
marks to make sure the gears are a matched set. gear set number is being checked. The pinion cone
number is used when you adjust the depth of the pin-
2. The location of the pinion and ring gear marks ion in the carrier.
are shown in Figure 32. A description of the
marks is as follows: Example: PC+3, PC 3, +3, or 3 equals 0.003
inch (variation). PC+0.03, PC 0.03, +0.03, or
Part Number. The part numbers are the part 0.03 equals 0.03 mm (variation).
number of the manufacturer. The part num-
ber for the ring gear is always an even number. Find the correct thickness of the shim set as fol-
The part number for the pinion is the next odd lows:
number. Check to make sure the pinion and
3. Use a micrometer to measure the total thickness
ring gear are in a sequence. Examples of gear
of the old shim set that was removed from under
set part numbers: ring gear, 36786; drive pin-
the pinion carrier. Make a note of the measure-
ion, 36787. If a gear set number has a letter
ment for later use.
that follows the number, the letters must be
the same for both the ring gear and pinion. 4. Check the pinion cone number for the old pinion.
See Figure 33. If this number is a plus (+) value,
Gear Teeth Number. The gear teeth num- subtract the value from the value in Step 3. If
bers are the numbers of the teeth on the pinion the pinion cone number is a minus ( ) value, add
and ring gear. The number of pinion teeth is the number to the value in Step 3. The number
the first number. An example of this number shown is in 0.00 × inch (+2 = +0.002 inch). The
is 5-37. In the example, the drive pinion has 5 result is the standard thickness for a shim set.
teeth and the ring gear has 37 teeth.
NOTE: The value calculated in Step 4 is the thickness
Gear Set Number. The gear set number is a of the standard shim set, without a variation.
letter and number. Make sure the letter and
number are the same on the drive pinion and 5. Check the pinion cone number for the new pin-
ring gear. An example of a gear set number is ion. Add or subtract this number to the standard
M29. thickness value of Step 4. Add the number if the
value is a plus (+) value. Subtract the number if
Pinion Cone Number. The pinion cone num- the value is a minus ( ) value. The result is the
ber is the variation from the design center. correct thickness for the new shim set. See the
The design center is the exact design distance examples.
from the end of the pinion cone to the ring gear
NOTE: The value calculated in Step 5 is the thickness
centerline. See Figure 33.
of the new shim set that will be installed. See the
examples shown in Specifications, Table 5.
CAUTION
Always use a minimum of three shims for the
shim set. Use the thinnest shims on the outside
of the set for a better seal.
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Differential Repair 1400 SRM 46
b. If there is a speed reducer or drop box, install Make sure the ring gear is part of the set of the pinion
it on the pinion carrier assembly. Use John and ring gear. See Figure 32.
Crane No. 2® as a sealant. Tighten the nuts
to the correct value shown in Specifications,
CAUTION
Table 7.
Do not install a cold ring gear on the flange
case half. A cold ring gear will damage the
case half because of the close tolerance. Metal
particles between the parts will cause gear
runout that will exceed the specification of
0.2 mm (0.008 in.).
WARNING
Wear protective clothing to prevent injury
1. PINION AND PINION CARRIER when handling the hot ring gear.
2. SHIMS
3. DIFFERENTIAL HOUSING
CAUTION
Figure 34. Pinion Carrier Assembly
Never use a press or hammer to install the ring
Installation
gear.
CAUTION 2. Lift the ring gear from the water using a lifting
On H7.00-12.50H (H150-275H) trucks, DO NOT tool.
use the washer that is on the new pinion.
3. Install the ring gear on the flange case half im-
Use the thicker spacer (Hyster Part Number
mediately after the gear is heated. If the ring
125277). The threads can be damaged or the
gear does not fit easily on the case half, heat the
nut can loosen if the washer is used.
gear again.
7. Install the universal joint yoke, flange for the
4. Align fastener holes of the ring gear and flange
brake rotor or brake drum, or the gear for the
case half. Rotate the ring gear as needed.
speed reducer. See Figure 35.
5. If special capscrews are used to fasten the ring
8. Install the spacer and pinion nut. Tighten the
gear to the flange case half, install the capscrews,
pinion nut to the correct torque as shown in Spec-
washers, and nuts as shown in Figure 36. The
ifications, Table 7.
capscrew heads must be against the ring gear.
Use pairs of capscrews opposite each other to
Differential and Ring Gear, Assemble
tighten the case and ring gear together. For cap-
screw torque specifications, see Specifications,
CAUTION Table 7.
Assembly of ring gear on the differential case
must be correct for correct gear adjustment
and maximum wear.
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1400 SRM 46 Differential Repair
NOTE: On S/H6.00-7.00XL (S/H135-155XL, S/H135- the distance between the flange outer diameter
155XL 2) (B024, C024, F006, G006) lift truck models, and the pilot diameter for the gear. If the gauge
if rivets were use to hold the ring gear and flange goes more than half the distance, the ring gear
case half together, replace them with bolts, nuts, and must be removed and installed again. See Fig-
washers ure 38.
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Differential Repair 1400 SRM 46
10. Put the flange case half on a bench with the ring
gear teeth toward the top.
11. Install one thrust washer and side gear into the
flange case half. 1. THRUST WASHER 4. CASE HALF
2. SIDE GEAR 5. ALIGNMENT
3. SPIDER GEARS MARKS
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1400 SRM 46 Differential Repair
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Differential Repair 1400 SRM 46
WARNING
Wear eye protection. Do not hit steel parts with
a steel hammer. Parts can break and cause in-
jury.
CAUTION
If bearing caps are not installed in the correct
1. BEARING CUP 3. BEARING BORE original locations, the bores and threads in
2. CARRIER 4. PUT ADHESIVE caps will not match the carrier. Assembling
HERE mismatched caps into the carrier can result in
carrier damage after reassembly to axle and
Figure 44. Differential Assembly Installation during vehicle operation. Do not force the
bearing caps into unmatched bore locations in
5. Use a lifting device that has the capacity to lift
the carrier.
the weight of the differential assembly and in-
stall the assembly into the differential carrier. 8. Use a light leather, plastic, or rubber hammer
The bearing cups must be flat against the bores and seat each bearing cap to move it into posi-
between the differential carrier legs. See Fig- tion. The caps must fit easily against the bear-
ure 44. Make sure that the ring gear does not ings, adjustment rings, and carrier. Do not force
touch the pinion. the bearing caps into position.
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1400 SRM 46 Differential Repair
1. DIAL INDICATOR
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Differential Repair 1400 SRM 46
b. Use two pry bars between the differential 4. Rotate the ring gear and check the dial indicator
case or ring gear and the carrier at locations for the maximum needle movement. The maxi-
other than described in Step a. The pry bars mum movement permitted is 0.20 mm (0.008 in.).
must not touch the differential bearings. See
Figure 48. 5. If the movement exceeds the maximum limit,
remove the differential and ring gear assembly
from the differential carrier and find the reason
for the movement. See Step 5 and Step 6 in
the section Differential and Ring Gear From
Differential Carrier, Remove for the removal
procedures.
6. Continue assembly and check the runout of the 1. MEASURE OUTER DIAMETER FOR
ring gear. APPROXIMATE PITCH DIAMETER
1. Attach a dial indicator to the mounting flange of If the old gear set is installed, adjust the backlash to
the differential carrier as shown in Figure 46. the setting that was measured before the differential
carrier was disassembled.
2. Adjust the dial indicator so that the plunger or
pointer is against the back surface of the ring If a new gear set will be installed, adjust the backlash
gear. to the correct specifications for new gear sets. See
Table 1.
3. Set the indicator to zero.
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1400 SRM 46 Differential Repair
Check the tooth contact pattern first. See Gear Set, NOTE: When adjusting backlash, move the ring gear
Tooth Contact Pattern Check. Once the gear contact only. Do not move the drive pinion.
pattern has been checked, backlash can be adjusted
within specifications, if needed. 8. Loosen one bearing adjusting ring one notch,
then tighten the opposite ring the same amount.
To change the location of the pattern, follow the steps See Figure 51 and Figure 52.
outlined below:
6. If the backlash reading is within specifications, 1. LOOSEN ADJUSTING RING THIS SIDE
(see Table 1), continue checking tooth contact 2. DECREASE BACKLASH
patterns. 3. TIGHTEN ADJUSTING RING THIS SIDE
7. If the backlash reading is not within specifica- Figure 52. Backlash Decrease
tions, (see Table 1), adjust backlash as needed.
Continue onto Step 8 and Step 9.
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Differential Repair 1400 SRM 46
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1400 SRM 46 Differential Repair
Gear Set, Tooth Contact Pattern Check NOTE: If the original gear set is installed, adjust the
clearance to the original value recorded in Differen-
NOTE: The gear clearance can be changed within the tial and Ring Gear Assembly, Disassemble. If a new
limits of 0.13 to 0.38 mm (0.005 to 0.015 in.) for better gear set is installed, adjust the adjustment rings for
tooth contact. 0.25 mm (0.010 in.). Refer to Ring and Pinion Tooth
Contact Adjustment.
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Differential Repair 1400 SRM 46
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1400 SRM 46 Differential Repair
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Differential Repair 1400 SRM 46
Thrust Screw, Install and Adjust 0.889 mm (0.025 to 0.035 in.). For later model
H6.00-7.00XL (H135-155XL, H135-155XL 2)
NOTE: Not all differential carrier models will have a (F006, G006) units, the correct clearance be-
thrust screw. Some may have a thrust block instead. tween the thrust screw and the ring gear is 0.65
Before installing and adjusting either the thrust to 1.14 mm (0.025 to 0.045 in.).
screw or thrust block, install the adjusting ring
locking device as described in Step 1.
CAUTION
If the differential carrier has cotter pins, lock
the adjusting rings only with cotter pins. If the
differential carrier has dowel pins, reuse the
dowel pins or lock the adjusting rings with cot-
ter pins. Do not force a dowel pin into a cotter
pin hole.
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1400 SRM 46 Differential Repair
31
Specifications 1400 SRM 46
Specifications
Table 3. General Specifications Table 5. Pinion Adjustment (Continued)
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1400 SRM 46 Specifications
33
Specifications 1400 SRM 46
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1400 SRM 46 Specifications
35
Troubleshooting 1400 SRM 46
Troubleshooting
The lift truck will not move. Ring and pinion gears are damaged. Repair the damaged gears.
The differential makes noise. The gears or shafts in the differential Repair the damaged gears.
are damaged.
There is no oil in the axle housing. Fill the axle with the correct oil.
Parts of the brake assembly are dam- Repair the parts of the brakes.
aged.
The ring and pinion are not adjusted Check and adjust the gears.
correctly.
The nut for the input yoke is loose. Tighten the nut.
The thrust screw is not adjusted cor- Adjust and tighten the screw and jam
rectly. nut.
The differential has leaks. There is no sealant between the dif- Assemble the parts with the correct
ferential and drive axle housing. sealant.
There are plug(s) missing from the Install the missing plug(s).
differential housing.
36
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