PLANETARY GEAR AXLE

H40.00-48.00XM-12 (H800-1050HD/HDS) [A917];

H36.00-48.00E (H800-1050E) [D117];
RS45-27CH, RS45-30CH, RS45-27IH, RS46-33CH, RS46-30IH,
RS46-36CH, RS46-33IH [A222]; RS45-27CH, RS45-31CH,
RS46-36CH, RS46-40CH, RS46-41S CH, RS46-41L CH,
RS46-41LS CH, RS45-24IH, RS45-28IH, RS46-33IH, RS46-37IH,
RS46-38S IH, RS46-38L IH, RS46-38LS IH (HR45-27, HR45-31,
HR45-36, HR45-40, HR45-41S, HR45-41L, HR45-41LS) [B222];
HR45-25, HR45-27, HR45-31, HR45-40S, HR45-36L,
HR45-40LS, HR45-45LSX [A227, B227, C227];
H40.00-52.00XM-16CH (H1050HD-CH, 1150HD-CH) [E117,
F117]; RS45-27CH, RS45-31CH, RS46-36CH, RS46-41L
CH, RS46-41S CH, RS46-41LS CH, RS45-24IH, RS45-28IH,
RS46-33IH, RS46-38L IH, RS46-38S IH, RS46-38LS
IH (RS45-27, RS45-31, RS46-36, RS46-41L, RS46-41S,
RS46-41LS) [C222]; H36XMS-12, H40XM-12, H44XM-12, H48XM-12
(H800HD, H1050HD) [B917]; H40XM-16CH,
H44XM-16CH, H48-16CH, H50-16CH, H52XM-16CH
(H1050HD, H1150HD) [G117]

PART NO. 1574068 1400 SRM 1171

 SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• 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 back-
ground. The CAUTION symbol and word are on yellow background.
Planetary Gear Axle Table of Contents

TABLE OF CONTENTS

General ............................................................................................................................................................... 1
Description ......................................................................................................................................................... 2
Operation............................................................................................................................................................ 2
Planetary Gear Axle Repair .............................................................................................................................. 4
Remove ........................................................................................................................................................... 4
Drive Wheels and Tires............................................................................................................................. 4
Disassemble ................................................................................................................................................... 5
Drive Axle .................................................................................................................................................. 5
Planetary Gear Carrier ............................................................................................................................. 6
Ring Gear, Ring Gear Hub, and Wheel Hub ............................................................................................ 8
Hub Oil Seal and Bearings ....................................................................................................................... 9
Axle Shaft .................................................................................................................................................. 9
Spindle ....................................................................................................................................................... 10
Repair ............................................................................................................................................................. 10
Repairing or Replacing Parts.................................................................................................................... 10
Welding ...................................................................................................................................................... 10
Clean .............................................................................................................................................................. 11
Ground or Polished Parts.......................................................................................................................... 11
Parts With Rough Finishes ....................................................................................................................... 11
Axle Assemblies......................................................................................................................................... 11
Drying Cleaned Parts................................................................................................................................ 11
Preventing Corrosion..................................................................................................................................... 11
Parts Inspection ............................................................................................................................................. 12
Assemble ........................................................................................................................................................ 12
Spindle ....................................................................................................................................................... 12
Axle Shaft .................................................................................................................................................. 12
Hub Oil Seal and Bearings ....................................................................................................................... 12
Ring Gear, Ring Gear Hub, and Wheel Hub ............................................................................................ 13
Wheel Bearing Preload ............................................................................................................................. 13
Adjust..................................................................................................................................................... 13
Planetary Gear Carrier ............................................................................................................................. 14
Drive Axle .................................................................................................................................................. 15
Wheel Ends ................................................................................................................................................ 16
Fill.......................................................................................................................................................... 16
Install ............................................................................................................................................................. 16
Drive Wheels and Tires............................................................................................................................. 16
Torque Specifications ......................................................................................................................................... 20
Troubleshooting ................................................................................................................................................. 21

©2012 HYSTER COMPANY i

Table of Contents Planetary Gear Axle

TABLE OF CONTENTS (Continued)

This section is for the following models:

H40.00-48.00XM-12 (H800-1050HD/HDS) [A917];

H36.00-48.00E (H800-1050E) [D117];
RS45-27CH, RS45-30CH, RS45-27IH, RS46-33CH, RS46-30IH,
RS46-36CH, RS46-33IH [A222];
RS45-27CH, RS45-31CH, RS46-36CH, RS46-40CH, RS46-41S CH, RS46-41L
CH, RS46-41LS CH, RS45-24IH, RS45-28IH, RS46-33IH, RS46-37IH,
RS46-38S IH, RS46-38L IH, RS46-38LS IH (HR45-27, HR45-31, HR45-36,
HR45-40, HR45-41S, HR45-41L, HR45-41LS) [B222];
HR45-25, HR45-27, HR45-31, HR45-40S, HR45-36L, HR45-40LS,
HR45-45LSX [A227, B227, C227];
H40.00-52.00XM-16CH (H1050HD-CH, 1150HD-CH) [E117, F117];
RS45-27CH, RS45-31CH, RS46-36CH, RS46-41L CH, RS46-41S
CH, RS46-41LS CH, RS45-24IH, RS45-28IH, RS46-33IH, RS46-38L
IH, RS46-38S IH, RS46-38LS IH (RS45-27, RS45-31, RS46-36,
RS46-41L, RS46-41S, RS46-41LS) [C222];
H36XMS-12, H40XM-12, H44XM-12, H48XM-12 (H800HD, H1050HD) [B917];
H40XM-16CH, H44XM-16CH, H48-16CH, H50-16CH, H52XM-16CH
(H1050HD, H1150HD) [G117]

ii
1400 SRM 1171 General

General
This section has a description and the repair procedures for the planetary gear axle.

Figure 1. Planetary Axle With Oil-Cooled Brakes

1
Operation 1400 SRM 1171

Legend for Figure 1

1. AXLE HOUSING 11. INNER HUB
2. SPINDLE 12. WHEEL BEARING ADJUSTMENT NUT
3. SEAL 13. WHEEL BEARING ADJUSTING LOCK NUT
4. ROTOR 14. AXLE
5. OIL SEAL 15. THRUST BUTTON
6. BEARING CONE 16. PLANETARY GEAR CARRIER
7. BEARING CUP 17. COVER
8. WHEEL HUB 18. PINION SHAFT (3)
9. RING GEAR HUB 19. PINION THRUST WASHER
10. RING GEAR 20. PINION GEAR (3)

Description
The planetary gear axle has an axle housing and two
final drive assemblies. See Figure 1 and Figure 2.
Each final drive assembly is a planetary gear unit.
The planetary gear assembly changes the final drive
ratio, which increases the torque to the drive wheels.
Each unit has a drive axle, sun gear, ring gear hub,
and ring gear. There are also three planetary pin-
ions, a planetary spider, and a housing. The differ-
ential is also installed in the axle housing. The ser-
vice brake is also installed on the drive axle. See the
section Service Brake for your lift truck, for repair
instructions of the brakes.

Operation
The rotation of the differential causes the axle shafts and the sun gears to rotate. The sun gears then cause
the planetary pinions to rotate. Rotation of the pinions causes the planetary spiders to rotate the hubs and the
drive wheels. The ring gear and the ring gear hub do not rotate.

2
1400 SRM 1171 Operation

1. DRAIN/FILL PLUG 15. RETAINER PLATE

2. COVER 16. CAPSCREW
3. AXLE SHAFT THRUST BUTTON 17. CAPSCREW
4. CAPSCREW 18. WHEEL STUD NUT
5. PLANETARY GEAR CARRIER 19. WHEEL STUD NUT WASHER
6. SNAP RING 20. WHEEL RIM CLAMP
7. SUN GEAR 21. WHEEL STUD
8. THRUST WASHER 22. WHEEL STUD WASHER
9. WHEEL BEARING ADJUSTING NUT 23. OIL DRAIN PLUG
10. LOCK NUT LOCK PLATE 24. PINION SHAFT
11. LOCK PLATE CAPSCREW 25. PINION OUTER THRUST WASHER
12. LOCK NUT LOCK PLATE 26. PINION GEAR
13. RING GEAR 27. PINION INNER THRUST WASHER
14. RING GEAR HUB

Figure 2. Planetary Axle Components

3
Planetary Gear Axle Repair 1400 SRM 1171

Planetary Gear Axle Repair

REMOVE
Drive Wheels and Tires
NOTE: The final drive assemblies can be removed
with the drive axle installed in the lift truck. If the
drive axle must be removed, do the following steps.
If the drive axle will not be removed, do only the re-
quired steps.
1. Place lift truck on solid, level surface.
2. Put blocks on each side (front and back) of the
steer tires to prevent movement of the lift truck.
See Figure 3, Figure 4, and Figure 5.
3. Put mast in a vertical position.
4. Put a block under each outer mast channel.
5. Tilt mast fully forward until drive tires are raised
from the surface.
CAUTION
Do not place blocks under fuel and hydraulic
hoses or fuel and hydraulic tank. Damage to
the lift truck may occur.
WARNING
Completely remove air pressure from tire be-
fore it is removed from lift truck. Because dual
wheels are installed, remove air pressure from
both tires. Air pressure in tires can cause tire
and wheel parts to explode, causing serious in-
jury or death.
7. Remove air from tire.
8. Remove valve core to verify that all air is out of
inner tube.
9. Push a wire through valve stem to verify the stem
does not have a restriction.
10. Remove wheel nuts and clamps.
WARNING
The tires and wheels can weigh approximately
875 kg (1929 lb). Verify the lifting device has
the rated capacity to lift the tires and wheels
or personal injury may occur.
11. Remove wheel and tire from lift truck.

6. Put additional blocks under frame behind the

drive tires.

1. STEER AXLE/STEER TIRES 2. DRIVE AXLE/DRIVE TIRES

Figure 3. Put Lift Truck on Blocks (A917)

4
1400 SRM 1171 Planetary Gear Axle Repair

1. STEER AXLE/STEER TIRES 2. DRIVE AXLE/DRIVE TIRES

Figure 4. Put the Lift Truck on Blocks (B222)

4. Remove oil drain plug and drain oil.

5. Drain cooling oil from service brakes.

WARNING
Brake linings can contain dangerous fibers.
Breathing dust from these linings is a cancer
or lung disease hazard. Do not create dust! Do
not clean brake parts with compressed air or
by brushing. Use vacuum equipment approved
for brake dust or follow the cleaning proce-
dure in this section. When the brake drums
are removed, do not create dust.

Do not sand, grind, chisel, hammer, or change

linings in any way that will create dust. Any
changes to linings must be done in a restricted
area with special ventilation. Protective cloth-
ing and a respirator must be used.

NOTE: Under normal conditions, the disc assembly

1. STEER AXLE/STEER TIRES (fixed and rotating discs) of the oil-cooled brakes is
2. DRIVE AXLE/DRIVE TIRES replaced when the drive axle is disassembled.

Figure 5. Put the Lift Truck on Blocks (E117
and F117)
DISASSEMBLE
Drive Axle
1. Apply brakes ten to twenty times until accumu-
lated hydraulic brake pressure is released.
2. Drain oil from the end of axle housing.
3. Rotate hub assembly until oil drain plug in plan-
etary gear carrier is at the bottom.
6. Disconnect service brake lines.
7. Disconnect brake lines for parking brake at the
differential.
8. Disconnect cooling oil lines for oil-cooled brakes.
9. Put caps on all hydraulic lines, ports, and fit-
tings.
10. Disconnect drive shaft at differential.
11. Put forks of another lift truck under the axle for
support.

5
Planetary Gear Axle Repair 1400 SRM 1171

12. Remove bolts and nuts that hold the axle to the 2. Remove cover from planetary gear carrier. See
frame. Figure 7.

WARNING
Verify the lifting device has the rated capacity
of 4500 kg (9921 lb) when moving the drive axle.

13. Remove drive axle from lift truck frame.

WARNING
Cleaning solvents are flammable and toxic and
can cause skin irritation. When using clean-
ing solvents, always follow the solvent manu-
facturer’s recommended safety precautions.

WARNING
Compressed air can move particles so that they
cause injury to the user or to other personnel.
Verify that the path of the compressed air is
away from all personnel. Wear protective gog-
gles or a face shield to prevent injury to the
eyes.
14. Clean all parts in solvent and dry with com-
pressed air.
Planetary Gear Carrier
1. Align marks on planetary gear carrier and wheel
hub for correct alignment when reassembling the
unit. See Figure 6.
1. HUB
2. COVER
3. PLANETARY GEAR CARRIER
Figure 7. Planetary Gear Carrier Cover
3. Remove planetary gear carrier capscrews.
NOTE: Do not remove planetary gear carrier at this
time.
4. Insert a pry bar into assembly notches and sep-
arate planetary gear carrier from wheel hub as-
sembly. See Figure 8.

A. RIM MOUNTED Figure 8. Planetary Gear Carrier Separation

1. ALIGNMENT MARKS

Figure 6. Alignment Marks

6
1400 SRM 1171 Planetary Gear Axle Repair

NOTE: If a press is not available, use a brass drift

WARNING
Use caution when using lifting devices. When
using a lifting strap, inspect strap for damage
before using. Do not use a lifting strap to shock
load or drop load a component. Serious per-
sonal injury and damage to components may
occur.
Verify the lifting device has the rated capacity
of 150 kg (331 lb) when moving the planetary
gear carrier.
5. Use a lifting device to remove planetary gear car-
rier from wheel hub assembly. See Figure 9.
and mallet to remove pinion shafts.
6. Place the planetary gear carrier assembly in a
press with flange side DOWN. Support the spi-
der assembly as required.
NOTE: Use a soft material in bottom of the catch con-
tainer to prevent damage to the pinion shafts.
7. Place a container under the press to catch the
planetary pinion shafts as they are pressed out of
the planetary gear carrier and planetary pinion
gears.
8. Press each pinion shaft out of planetary gear car-
rier and planetary gear. See Figure 10.

9. Remove planetary gears and thrust washers

from planetary gear carrier.

1. SPIDER
Figure 9. Planetary Gear Carrier Removal 2. PINION SHAFT
3. OUTER THRUST WASHER
4. PLANETARY GEAR
WARNING 5. SMALL BORE INNER THRUST WASHER
Observe all WARNINGS and CAUTIONS pro- Figure 10. Pinion Shaft
vided by press manufacturer concerning press
operation to avoid serious injury and possible
damage to components during assembly and
installation procedures.

7
Planetary Gear Axle Repair 1400 SRM 1171

Ring Gear, Ring Gear Hub, and Wheel Hub
1. Remove snap ring from end of axle shaft. See
Figure 11.
2. Remove sun gear. See Figure 11
4. Remove capscrews from wheel bearing adjusting
lock nut. See Figure 2 and Figure 12.
5. Remove wheel bearing adjusting lock nut and
wheel bearing adjusting nut. See Figure 2 and
Figure 12.

WARNING
Support the wheel hub before you remove
ring gear and ring gear hub assembly. Do not
remove ring gear and ring gear hub assembly
without supporting the wheel hub. Serious
injury and damage to components may occur.
See Figure 13.

NOTE: To avoid dropping and possibly damaging

the outer wheel bearing cone, verify the outer wheel
bearing cone remains in place as you remove the
ring gear hub.

NOTE: If the ring gear hub cannot be removed by

hand, install capscrews into the puller screw holes
1. SUN GEAR 3. AXLE SHAFT in the ring hub flange. Tighten each capscrew the
2. SNAP RING 4. RING GEAR same amount to separate ring gear hub from spindle
and wheel hub.
Figure 11. Sun Gear
6. Remove ring gear hub by pulling it straight out
3. Remove sun gear thrust washer assembly. See of wheel hub and off of spindle.
Figure 12.

1. WHEEL BEARING ADJUSTING NUT

2. WHEEL BEARING ADJUSTING LOCK NUT
3. CAPSCREW
4. AXLE SHAFT Figure 13. Ring Gear Hub
5. THRUST WASHER

Figure 12. Thrust Washer Assembly

8
1400 SRM 1171 Planetary Gear Axle Repair

7. Remove retainer plate capscrews to remove ring 3. Remove the rotor.

gear from ring gear hub. See Figure 14.
CAUTION
Do not scratch hub seal bore surface.

4. Remove bearing cups with a suitable puller.

5. Remove bearing cone with a suitable puller.

6. Remove wheel hub oil seal.

Axle Shaft
1. Remove axle shaft from spindle bore and hous-
ing.

2. Disassemble oil-cooled brakes as described in the

section Service Brake for your lift truck.

1. RING GEAR HUB

2. OUTER WHEEL BEARING
3. RETAINER PLATE
4. RING GEAR

Figure 14. Retainer Plate

8. Remove outer wheel bearing from ring gear hub.

NOTE: The ring gear hub assembly includes the hub

and ring sleeve insert. You cannot service these com-
ponents separately.

9. Use a hoist or similar device to lift the wheel hub

and drum slightly to relieve the hub weight and
drum-to-brake shoe drag. See Figure 15.

10. Remove wheel hub assembly from wheel hub

spindle.

Hub Oil Seal and Bearings

1. Position wheel hub with brake end UP to remove
Figure 15. Wheel Hub and Drum
hub oil seal and bearings.

2. Remove rotor mounting capscrews and washers.

9
Planetary Gear Axle Repair
Spindle
NOTE: The spindle and brake cover are assembled to
the axle housing with the same capscrews.
1. Remove two of the capscrews (opposite each
other) that fasten the spindle to the axle hous-
ing. Replace with two studs, which are long
enough to support the spindle. See Figure 16.
1. STUD
Figure 16. Brake Housing Studs
2. Remove the remaining capscrews.
3. Hold the spindle against the axle housing.
WARNING
Verify the lifting device has the rated capacity
to lift the spindle.
4. Use a lifting device to remove the spindle. See
Figure 17.
REPAIR
Repairing or Replacing Parts
WARNING
Do not repair axle housings by bending or
straightening. Repair of axle housings by
bending or straightening can cause poor
10
1400 SRM 1171
performance and possible unsafe operation
of the axle. This can cause serious personal
injury.
NOTE: Threads must be without damage and clean,
so accurate adjustment and correct torque values can
be applied to fasteners and parts.
Replace worn or damaged parts of an axle assembly.
The following are some examples for possible repair
and replacement:
• Replace any fastener if corners of wrench flats are
worn.
• Replace washers if damaged.
• Replace gaskets, oil seals, and grease seals.
• Clean parts and apply silicon gasket material,
where required.
• Remove nicks, marks, and burrs from parts having
machined or ground surfaces. Use a fine file, India
stone, emery cloth, or crocus cloth.
• Clean and repair threads of fasteners and holes.
Use a die or tap of correct size or a fine file.
Welding
Do not repair the drive axle assemblies by welding.
Welding can detract from the structural integrity of a
component, particularly to heat-treated parts where
the benefit of heat treatment can be nullified by weld-
ing.
1. LIFTING DEVICE 2. SPINDLE
Figure 17. Spindle
1400 SRM 1171
CLEAN
Ground or Polished Parts
WARNING
To prevent serious eye injury, always wear safe
eye protection when performing vehicle main-
tenance or service.
WARNING
Solvent cleaners are flammable, poisonous,
and can cause burns. Examples of solvent
cleaners are carbon tetrachloride, emul-
sion-type cleaners, and petroleum-based
cleaners. To avoid serious personal injury
when using solvent cleaners, carefully follow
the manufacturer’s product instructions and
these procedures.
• Wear safe eye protection.
• Wear clothing that protects your skin.
• Work in a well-ventilated area.
• Do not use gasoline or solvents that contain
gasoline. Gasoline can explode.
• Use hot solution tanks or alkaline solutions
correctly. Follow the manufacturer’s instruc-
tions carefully.
CAUTION
• Use only solvent cleaners to clean ground
or polished metal parts. Hot solution tanks
or water and alkaline solutions will damage
these parts. Isopropyl alcohol, kerosene, or
diesel fuel can be used for this purpose.
• If required, use a sharp knife to remove gas-
ket material from parts. Be careful not to
damage the ground or polished surfaces.
1. Use a cleaning solvent, kerosene, or diesel fuel
to clean ground or polished parts or surfaces.
NEVER USE GASOLINE.
2. Remove gasket material from parts. Use caution
not to damage ground surfaces. Apply grease to
prevent corrosion.
3. DO NOT clean ground or polished parts in a hot
solution tank, water, steam, or alkaline solution.
Planetary Gear Axle Repair
Parts With Rough Finishes
1. Use a cleaning solvent or a hot solution tank with
a weak alkaline solution to clean parts with a
rough finish.
2. Leave parts in the hot solution tank until they
are completely cleaned and heated. When the
parts are clean, remove them from the tank.
3. Wash the parts with water until alkaline solution
is completely removed.
Axle Assemblies
NOTE: A complete axle assembly can be steam
cleaned on the outside to remove dirt.
NOTE: Before the axle is steam cleaned, close or put
a cover over all the openings in the axle assembly.
Examples of openings are the breathers or vents in
air chambers.
Drying Cleaned Parts
CAUTION
Dry bearings with clean paper or rags. Do not
use compressed air, which can cause abrasive
particles to contaminate the bearings. Damage
to components and reduced lining life can re-
sult.
Immediately after cleaning, use clean paper, rags, or
compressed air to dry parts.
PREVENTING CORROSION
NOTE: Parts must be clean and dry before lubricating
them.
1. If assembling the parts immediately after clean-
ing them, lubricate the clean, dry parts with
grease to prevent corrosion.
2. If storing the parts after cleaning them, apply
a corrosion-preventive material to all machined
surfaces. Store the parts in a special paper or
other material that prevents corrosion.
11
Planetary Gear Axle Repair
PARTS INSPECTION
It is very important to inspect all parts carefully and
completely before axle or carrier is assembled. Check
all parts for wear and replace damaged parts. Re-
placement of damaged or worn parts will prevent
breakdown of assembly later.
ASSEMBLE
Spindle
1. Install two studs opposite each other on the axle
housing flange. Verify the studs are long enough
to support the spindle.
2. Apply a bead of silicone gasket material on the
mounting surface of the axle housing flange. The
bead must go around each capscrew hole. See
Figure 18.
1. AXLE FLANGE
2. SILICONE BEAD
Figure 18. Axle Flange
WARNING
Verify the lifting device has the rated capacity
to lift the spindle.
3. Use a lifting device to install the spindle on the
guide studs. Verify the spindle cannot fall before
removing the lifting device. See Figure 18.
4. Tighten the capscrews to the torque specified.
See Table 2.
Axle Shaft
1. Replace oil-cooled brake as described in the sec-
tion Service Brake for your lift truck.
12
1400 SRM 1171
2. Install axle shaft through the spindle bore and
housing until it engages the differential side
gear. The shaft end with the snap ring groove
must extend beyond the outer end of the spindle.
Hub Oil Seal and Bearings
1. Position wheel hub with brake end UP to install
hub oil seal and bearings.
2. Position new wheel hub oil seal so that the spring
lip of the seal faces the wheel bearing. Use a suit-
able seal driver to drive seal into same location as
original wheel hub oil seal.
CAUTION
Use caution not to nick the seal oil wear sleeve
end when installing the oil seal wear sleeve. A
nicked oil seal wear sleeve end can damage the
seal lip when installing the wheel hub. Lubri-
cant loss and damage to components may oc-
cur.
3. Carefully install a new oil seal wear sleeve on the
spindle.
4. Lubricate new seals as follows:
• Lubricate the oil seal lips of conventional seals.
• Lubricate the inside diameter of unitized seals.
• Lubricate contact surfaces of the metal rings on
face seals. Do not apply lubricant to any other
part of the face seal.
5. Apply a thin coat of lubricant to the oil seal jour-
nal surface of the spindle.
6. Apply lubricant to the inner bearing cone rollers.
7. Install the inner bearing cone into wheel hub.
NOTE: If the hub bearing cups need to be replaced,
install the new cups with a suitable driver.
8. Install bearing cups into wheel hub.
NOTE: If slinger fits loosely between wheel hub and
drum, apply a bead of liquid gasket material to pre-
vent rattling.
9. Install brake rotor or drum and oil slinger.
10. Install drum or rotor mounting capscrews and
washers.
1400 SRM 1171
Ring Gear, Ring Gear Hub, and Wheel Hub
WARNING
Use caution when using lifting devices. When
using a lifting strap, inspect strap for damage
before using. Do not use a lifting strap to shock
load or drop load a component. Serious per-
sonal injury and damage to components may
occur.
1. Using a hoist or similar device, carefully lift
the wheel hub assembly over wheel hub spin-
dle. Keep the wheel hub assembly aligned with
wheel hub spindle to avoid oil seal damage. See
Figure 15.
2. Install outer wheel bearing cone on the ring gear
hub journal squarely against hub shoulder. Ap-
ply the same lubricant used in the wheel ends to
the rollers. Slip fit outer wheel bearing cone over
ring gear hub journal. See Figure 14.
3. Install retainer plate with bolts.
4. Install ring gear assembly, which includes outer
bearing cone, on wheel hub spindle.
5. Install wheel bearing adjusting lock nut and
wheel bearing nut on spindle. See Figure 2 and
Figure 12.
Wheel Bearing Preload
Adjust
1. Tighten the wheel bearing adjusting nut to the
initial seating torque listed in Table 1.
2. Rotate the wheel hub, a minimum of two full rev-
olutions in both directions.
3. Using a suitable bar and not to exceed 5 kg (10 lb)
of force, tap the ring gear hub to assist in seating
the wheel hub. For location of tapping of suitable
bar, see Figure 19.
Table 1. Wheel Bearing Adjustment Torque
Axle Models
Initial Seating
PRC-5324 to 7314 813 N•m (600 lbf ft)
PRC-7534 949 N•m (700 lbf ft)
Planetary Gear Axle Repair
4. Repeat tightening the wheel bearing adjusting
nut to the initial seating torque listed in Table 1.
5. Rotate the wheel hub, a minimum of two full rev-
olutions in both directions.
6. Tap the ring gear hub to assist in seating the
wheel hub.
7. Loosen the adjusting nut 1/8 to ¼ turn.
8. Tighten the adjusting nut to the final adjustment
nut torque listed in Table 1.
9. Rotate the wheel hub, a minimum of two full rev-
olutions in both directions.
10. Tap the ring gear hub to assist in seating the
wheel hub.
11. Tighten the adjusting nut to the final adjustment
nut torque listed in Table 1.
12. Repeat Step 9 thru Step 11 until the adjusting
nut can no longer be turned.
13. Install the lock plate. If the lock plate cannot be
assembled, tighten the adjusting nut further to
the next position so that the locking plate can be
installed.
Figure 19. Location of tapping the ring gear
hub
Adjusting Nut Torque
Final Adjustment
678 N•m (500 lbf ft)
746 N•m (550 lbf ft)
13
Planetary Gear Axle Repair 1400 SRM 1171

Planetary Gear Carrier

NOTE: The chambers must be smooth to prevent
damage to nylon coating on planetary pinion shaft
during installation. If large bore chambers are not
smooth, use an emery cloth to clean chamber surface.

1. Inspect large bore chambers.

NOTE: Do not use planetary gears with rough bore

surfaces.

2. Inspect planetary gear bores.

WARNING
Observe all WARNINGS and CAUTIONS pro-
vided by press manufacturer concerning press
operation to avoid serious injury and possible
damage to components during assembly and 1. PINION SHAFT
installation procedures. 2. PLANETARY GEAR CARRIER/SPIDER
ASSEMBLY
3. Place planetary gear carrier in press with flange 3. INNER THRUST WASHER (SMALL BORE)
side UP. Support planetary gear carrier as re- 4. PINION GEAR
quired. 5. OUTER THRUST WASHER

4. Install inner thrust washer (small bore). Place
washer tab in spider indent and align washer
bore with planetary gear carrier bore.
5. Apply thin coat of same gear lubricant used in
the wheel end to the planetary gear bore.
6. Slide planetary gear and outer thrust washer
into planetary gear carrier. Align the bores of
the parts and place outer thrust washer tab in
planetary gear carrier indent.
7. Apply thin coat of gear lube to nylon coating on
pinion shaft.
NOTE: The pinion shaft must be aligned so flat sur-
face on large end faces toward outside of wheel hub
circle. This alignment provides clearance for plane-
tary gear carrier cover and prevents shaft from rotat-
ing when planetary gear carrier cover is installed.
8. Install planetary pinion shaft in planetary gear
carrier and through planetary gear and thrust
washer. Allow large end of shaft to extend from
the spider assembly. See Figure 20.
Figure 20. Planetary Pinion Shaft
9. Repeat Step 1 through Step 8 to install second
and third set of planetary pinion shafts, gears,
and washers.
NOTE: When necessary, rotate shafts so the plane-
tary gear carrier cover fits over the flats. After you
align shafts, remove cover.
10. Check alignment of pinion shafts by placing plan-
etary gear carrier cover over shaft ends.
NOTE: If you cannot install pinion shaft into plane-
tary gear carrier assembly by hand, use a press to
install pinion shaft into planetary gear carrier as-
sembly until shoulder bottoms against inner (bottom)
thrust washer. When a press is not available, use a
brass drift and a mallet to install pinion shafts.
11. Install each pinion shaft into planetary gear car-
rier assembly by hand.

14
1400 SRM 1171
WARNING
Small amounts of acid vapor are present when
applying some silicone gasket materials. To
prevent personal injury, verify there is good
ventilation in work area. If silicone gasket
material gets in eyes, flush eyes with water for
15 minutes. Have eyes checked by a doctor.
CAUTION
Use only correct gasket material. Do not use
non-approved gasket material. Lubricant loss
and damage to components may occur.
12. Apply silicone gasket material to planetary gear
carrier flange at wheel hub mounting face.
13. Install planetary gear carrier and pinion assem-
bly in wheel hub.
14. Align planetary gear teeth with the sun gear and
ring gear teeth.
15. Align planetary gear carrier flange and wheel
hub alignment marks previously marked at dis-
assembly. See Figure 6.
16. Correctly align planetary gear carrier mounting
holes with wheel hub holes or studs.
17. Push planetary gear carrier assembly against
wheel hub.
18. Install nuts and washers.
19. Tighten wheel studs and nuts according to torque
specifications as shown in Table 2.
Table 2. Planetary Gear Carrier Capscrew
and Stud Torque Specifications
Size Torque
1/2"-13 115 to 156 N•m
(85 to 115 lbf ft)
9/16"-12 176 to 224 N•m
(130 to 165 lbf ft)
3/4"-10 420 to 542 N•m
(310 to 400 lbf ft)
7/8"-14 780 to 1017 N•m
(575 to 750 lbf ft)
Planetary Gear Axle Repair
20. Apply silicone gasket material to cover flange at
planetary gear carrier mounting face.
21. Align drain arrow on planetary gear carrier cover
with drain plug.
22. Install planetary gear carrier cover and cap-
screws.
23. Tighten cover capscrews to 115 to 156 N•m (85
to 115 lbf ft).
Drive Axle
WARNING
Verify lifting device has the rated capacity of
4500 kg (9921 lb) when installing the drive axle.
1. Carefully move drive axle assembly into position
under lift truck using another lift truck.
2. Align axle assembly to the frame.
3. Install nuts and bolts that hold axle to the
frame and tighten to 1650 to 2050 N•m (1217 to
1512 lbf ft).
4. Connect drive shaft at differential.
WARNING
Brake linings can contain dangerous fibers.
Breathing dust from these linings is a cancer
or lung disease hazard. Do not create dust! Do
not clean brake parts with compressed air or
by brushing. Use vacuum equipment approved
for brake dust or follow the cleaning proce-
dure in this section. When the brake drums
are removed, do not create dust.
Do not sand, grind, chisel, hammer, or change
linings in any way that will create dust. Any
changes to linings must be done in a restricted
area with special ventilation. Protective cloth-
ing and a respirator must be used.
5. Connect service brake lines.
6. Connect brake lines for parking brake at differ-
ential.
7. Connect cooling oil lines for oil-cooled brakes.
15
Planetary Gear Axle Repair 1400 SRM 1171

Wheel Ends 3. Tap lock ring lightly to verify it is in the seat.

Fill
1. Rotate wheel end until oil fill line and oil level
line are parallel to ground.
NOTE: Clean all magnetic plugs and install oil drain
plug in spider prior to filling wheel end with lubri-
cant.
2. Remove oil fill plug from cover.
NOTE: The rigid axle wheel end and housing bowl
share the same oil and oil level.
Do not fill through axle housing bowl only. For axles
with a common level, fill axle at each wheel end and
axle housing bowl to the bottom of the fill plug hole
with specific oil. Wait to allow the oil to flow through
the axle. Check oil level again and fill to specified
level if necessary.
3. Add oil to each wheel end and then to the bowl.
See the section Periodic Maintenance for your
lift truck.
4. Replace and securely tighten all plugs.
INSTALL
Drive Wheels and Tires
WARNING
The tires and wheels can weigh approximately
750 kg (1653 lb). Verify the lifting device has
the rated capacity to lift the tires and wheels
or personal injury may occur.
4. Install wheels on lift truck.
CAUTION
Check all wheel nuts after 2 to 5 hours of op-
eration, when new lift trucks begin operation
and on all lift trucks when the wheels have
been removed and installed. Tighten the nuts
as shown in Figure 23, Figure 24, Figure 25,
Figure 26, and Figure 27. When the nuts stay
tight for eight hours, the interval for checking
the torque can be extended to 500 hours.
5. Tighten the wheel nuts as shown in Figure 23,
Figure 24, Figure 25, Figure 26, and Figure 27.
First, tighten the nuts to 35 N•m (26 lbf ft), then
tighten to 100 N•m (74 lbf ft). Check for cor-
rect alignment of wheel parts and inside wheel-
to-hub alignment after tightening nuts 1 through
4. Finally, tighten the nuts to the torque value
shown in Figure 23, Figure 24, Figure 25, Fig-
ure 26, and Figure 27.

WARNING
Add air pressure to the tires only in a safety
cage. Inspect safety cage for damage before
use. When air pressure is added to the tire, use
a chuck that fastens onto valve stem of inner
tube. Verify there is enough air hose to permit
the operator to stand away from the safety cage
when air pressure is added to the tire.

1. Put tire in a safety cage. See Figure 21.

NOTE: If installation is not correct, remove all air

pressure from the tire. Remove valve core to verify
all air pressure has been removed and make adjust-
ments. Clearance at ends of lock ring should be 13
to 25 mm (0.5 to 1 in.) when tire has the correct air
Figure 21. Add Air to the Tires
pressure.

2. Verify all wheel parts are correctly installed. See

Figure 22.

16
1400 SRM 1171 Planetary Gear Axle Repair

1. SIDE FLANGE 7. RIM CLAMP

2. WHEEL RIM 8. HUB
3. FLANGE SEAT 9. WEDGE BAND
4. VALVE STEM 10. SPACER
5. LOCK RING 11. DRIVER
6. O-RING

Figure 22. Wheel Arrangement

17
Planetary Gear Axle Repair 1400 SRM 1171

Figure 24. Wheel Nut Tightening Sequence

(A227 and B227)

A. STEER WHEEL
B. DRIVE WHEEL

Figure 23. Wheel Nut Tightening Sequence

(A222)
NOTE: REFER TO THE SECTION PERIODIC MAIN-
TENANCE FOR THE FINAL TORQUE VALUES.

Figure 25. Wheel Nut Tightening Sequence

(C227)

18
1400 SRM 1171 Planetary Gear Axle Repair

A. STEER WHEEL
B. DRIVE WHEEL

Figure 26. Wheel Nut Tightening Sequence

(D117)

A. STEER WHEEL
B. DRIVE WHEEL

Figure 27. Wheel Nut Tightening Sequence

(A917, B222, E117, and F117)

19
Torque Specifications 1400 SRM 1171

Torque Specifications
Table 3. Standard Torque Values for Axle Fasteners

Lock Nuts Capscrews, Studs, and Nuts

Size
N•m lbf ft N•m lbf ft
1/4-20 UNC 12 to 15 9 to 11 13 to 18 10 to 13
1/4-28 UNF 13 to 18 10 to 13 13 to 18 10 to 13
5/16-18 UNC 24 to 33 18 to 24 27 to 40 20 to 30
5/16-24 UNF 27 to 40 20 to 30 27 to 40 20 to 30
3/8-16 UNC 40 to 54 30 to 40 48 to 68 35 to 50
3/8-24 UNF 48 to 68 35 to 50 48 to 68 35 to 50
7/16-14 UNC 68 to 88 50 to 65 81 to 102 60 to 75
7/16-20 UNF 81 to 102 60 to 75 88 to 115 65 to 85
9/16-12 UNC 102 to 135 75 to 100 115 to 155 85 to 114
9/16-18 UNF 115 to 155 85 to 114 135 to 175 100 to 130
5/8-11 UNC 150 to 195 110 to 144 175 to 225 130 to 166
5/8-18 UNF 175 to 225 130 to 166 200 to 260 148 to 192
5/8-11 UNC 200 to 260 148 to 192 245 to 310 181 to 229
5/8-18 UNF 245 to 310 181 to 229 285 to 365 210 to 269
3/4-10 UNC 265 to 475 195 to 350 420 to 540 310 to 398
3/4-16 UNF 420 to 540 310 to 398 490 to 640 361 to 472
7/8-9 UNC 595 to 785 439 to 579 680 to 860 502 to 634
7/8-14 UNF 680 to 880 502 to 649 780 to 1015 575 to 749
1.0-8 UNC 880 to 1185 649 to 874 1050 to 1355 774 to 999
1.0-12 UNF 985 to 1290 726 to 951 1150 to 1490 848 to 1099
1.0-14 UN 985 to 1290 726 to 951 1150 to 1490 848 to 1099
1-1/4-12 UNC N/A N/A 2305 to 2983 1700 to 2200
NOTE: Torque values are for parts lubricated with a lightweight oil.

20
1400 SRM 1171 Troubleshooting

Troubleshooting

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

The lift truck will not move. The axle shaft is broken. Replace axle shaft.

The gears in the final drive are dam- Replace gears.

aged.

The final drive makes noise. The gears or shafts in the final drive Replace gears.
are damaged.

There is no oil in the axle. Fill axle with oil.

The final drive has leaks. There is no sealant between the Replace sealant.
joints of the planetary assembly.

There are capscrews missing from Replace missing capscrews.

the cover of the planetary assembly.

There are plugs missing from the Replace missing plugs.

cover or housing of the planetary
axle.

Oil seals are worn or damaged. Replace oil seals.

Fittings or oil lines are loose or dam- Tighten fittings or oil lines.
aged (units with oil-cooled brakes
only).

21
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 TECHNICAL PUBLICATIONS

1400 SRM 1171 1/12 (7/11)(2/08)(7/07)(1/07)(7/06)(5/06)(8/05)(3/05)(8/04)(7/04) Printed in United Kingdom