REAR AXLE

Structure
Rear Axle

3
5

207066

1 Rear axle 5 Tie rods

2 Steering cylinder 6 Wheel hub
3 Steering knuckles 7 Shims
4 King pins
The lift truck is steered by the rear wheels. The ture, the rear axle can oscillate up to 3° in each
rear axle is connected to the frame by its center direction.
pivot shaft. Because of the center pivoting fea-

7-1
REAR AXLE

Steering Cylinder
12
1.0 to 1.8 ton models * *: Parts contained in seal kit
11
* 14 13
17 * * 6

▲ ▲

▲ ▲ ▲
▲

9
8
16
10 * 7
▲

▲
▲
▲

•▲ •

5 ▲ ▲ •

▲ ▲
2 * 1
3 15 207168
4

2 to 3.5 ton models

11 12 13
* * 17 6 *

10 16

7
5
1 8
2
* 9 207111
3 15 4

1 Cylinder tube 7 Tie-rod 13 O-ring

2 Piston rod 8 Nut 14 O-ring
3 Cylinder head 9 Spring washer 15 Guide ring
4 Cylinder head 10 Stopper ring 16 Piston seal
5 Pivot joint 11 Wiper 17 Bushing
6 Snap ring 12 U-seal
Double-action cylinder is used.

7-2
 REAR AXLE

Removal and Installation

Rear Wheels
Removal
1 Wheel nuts
2 Rear wheel

Start by:
1. Set the parking brake, and block the front 1
wheels.
2 404897
2. Raise the rear end of the lift truck with a jack
or hoist.
(1) Method using a jack
Position the jack under the counterweight at
the jacking point and raise the rear tire.

202790

(2) Method using a crane

Attach lifting slings to the lift holes in the
counterweight, and lift it.
CAUTION
When the vehicle is raised by either method,
place wood blocks under the frame to support
it securely.

204898

Installation
To install, follow the reverse of removal proce- 1
dure.
NOTE 6 3
Tighten the wheel nuts to the specified torque.

157 N·m
Tightening torque for 4 5
(16 kgf·m)
wheel nuts
[116 lbf·ft]
2 101212

7-3
REAR AXLE

Rear Axle
Removal

207112

Sequence
1 Rear wheel, wheel nut 3 Bearing support
2 Steering hose 4 Rear axle assembly [thrust washer]

Start by:
1. Apply the parking brake and block the front
wheel.
2. Raise the rear end of the truck with a jack and
place wood blocks under the side frames (with
the left and right rear wheels slightly clearing
the floor).
3. A hoist can be used instead of the jack to raise
the rear end (counterweight).

WARNING
Be sure the pressure in the hydraulic system is
released before any lines or hoses are discon-
nected. 202790

7-4
 REAR AXLE

Suggestion
1. Removing wheel assembly
Remove the wheel assembly from the rear
axle. Be careful not to cause damage to the oil
seal fitted to the rim. After removing the
assembly, raise the counterweight to a position
400 to 500 mm (16 to 20 in.) from the floor.

2. Removing rear axle assembly

Support the rear axle at its center with a garage
jack and remove the bolts that hold the bearing
supports.

Weight of rear axle

1.0 to 1.8 ton models 182 kg (402 lb)
2 to 3.5 ton models 220 kg (486 lb)

204900

Installation
To install, follow the reverse of removal sequence
and do the following steps:
1. Adjusting bearing support clearances
Adjust clearance between bearing support to
be 0.8 mm (0.031 in.) or less in total by using
thrust washers.
NOTE
Insert thrust washers evenly. 0.8 mm (0.03 in.)
or less

0.8 mm (0.031 in.)

Thrust washer type
2.0 mm (0.078 in.)
206651

7-5
REAR AXLE

2. Removing support bushing

Do not remove the bushing in the support if
not necessary. When replace the blushing,
place the mating line at the bottom (align with
the grease nipple).

Bushing mating line

205431

3. Tightening bearing support

Tighten the bolts holding the bearing support
to the specified torque.
145 N·m
Tightening torque for
(14.8 kgf·m)
bearing support bolts
[107 lbf·ft]

7-6
 REAR AXLE

Rear Axle Assembly

Disassembly

16

14 17
15
4
17 2

15
19

13
11

10

9 3
8

6
18

5 10 1

12

207108

Disassembly sequence
1 Taper roller bearing (inner), Retainer 10 Oil seal
2 Tie-rod pin, Bolt, Spring washer, Plain 11 Cover, Retainer
washer, Collar, Grease nipple 12 Boot
3 Spherical bushing, Ring, Retainer, Dust 13 Cover
seal 14 Clamp, Bolt, Spring washer
4 Tie-rod 15 Pipe (L.H., R.H.)
5 Kingpin plate, Shim 16 Steering cylinder, Bolt, Spring washer,
6 Kingpin, O-ring Nut
Remove parts 7 through 12 as assembly. 17 Elbow, O-ring
7 Knuckle 18 Stopper bolt, Lock nut
8 O-ring 19 Rear axle housing
9 Taper roller bearing

7-7
REAR AXLE

Suggestions
Removing retainer and bearing
Use a puller to remove the retainer and inner
bearing 1 from the knuckle.

207031

Inspection after Disassembly

1. Tie-rods and pins
(1) Make sure that the pins are free of any sur-
face flaws such as grooving or stepped wear.
Examine the tie-rod pin weld for cracking.
(2) Examine the bearings for wear or damage.
(3) Examine the tie-rods for damage and align-
ment. Inspect the welds for signs of cracks.
NOTE
If a pin must be replaced, replace its bearing
as well.

2. Kingpins
Check the kingpins for any surface flaws such
as grooving or stepped wear. Inspect the pins
for cracks at the bearing shoulder.
3. Kingpin bearings
Examine the rollers and bearing races for
grooving, abrasive wear, pitting, bruising, or
corrosion. Replace both the cup and cone of
damaged bearings.
4. Knuckles
Inspect the inside of each knuckle for wear or
damage. Be sure to examine for casting
cracks. Check the tie rod pin hole. Examine
the wheel nut threads for damage.
5. Seals and O-rings
Examine all seals and O-rings for damage
such as cuts and tears. Replace seals which
show signs of aging.
6. Hydraulic pipes
Inspect the hydraulic pipes for cracks, espe-
cially at the joints with the end fittings. Check
for leaks.
7. Cylinder rod
Examine the rod for surface or plating dam-
age. Inspect the rod for straightness. Examine
the piston for damage check the tie rod pin
hole for damage or wear.
7-8
 REAR AXLE

Reassembly

5 3
4
16
3 17
4
1

15
11

10

9 7
8

13
18

14 10 19

12

207108

Assembly sequence
1 Rear axle 11 Cover, Retainer
2 Steering cylinder, Bolt, Spring washer, 12 Boot
Nut 13 Kingpin, O-ring, Bolt, Spring washer
3 Elbow, O-ring 14 Kingpin plate, Shim, Bolt, Spring washer
4 Pipe (L.H., R.H.) 15 Cover
5 Clamp, Bolt, Spring washer 16 Tie-rod
6 Knuckle 17 Tie-rod pin, Bolt, Spring washer, Plain
7 Spherical bushing, Ring, Retainer, Dust washer, Collar, Grease nipple
seal 18 Stopper bolt, Lock nut
8 O-ring 19 Retainer, Taper roller bearing
9 Taper roller bearing
10 Oil seal

7-9
REAR AXLE

Suggestions
1. Reassembling steering cylinder
Use an alternating tightening pattern to tighten
the mounting bolts when attaching the cylin-
der assembly to the rear axle.
262 N·m
Tightening torque
(26.7 kgf·m)
for bolts
[193 lbf·ft]

2. Reassembling knuckles
(1) Insert bearing cups into knuckles. Adequately
fill bearing cages with “AUTOLEX A”
grease. Apply a coat of grease to the oil seal
grooves. Insert the bearing cages in the knuck-
les and apply additional grease as required to
meet the recommended amount.
Unit: cc (cu.in.)
1.0 to 1.8 ton 2 to 3.5 ton
models models
Quantity of grease 40 (2.44) 80 (4.88)

(2) Reassemble remaining components (seals, O-

rings, covers, and boots).
(3) Assemble parts, knuckle 6 through boot 12,
and insert this sub-assembly into the rear axle
housing.

3. Reassembling kingpins
(1) Install the kingpins and measure the distances
“A” on both the left and right kingpins.

A 207037

7-10
 REAR AXLE

(2) Add shims to each side to within 0.1 mm

(0.004 in.) of the measured distance “A” and
tighten kingpin bolt “B”.
Unit: mm (in.)
1.0 (0.039)
0.3 (0.012)
Shim thickness 0.2 (0.008)
0.1 (0.004)

Shims

▲
Kingpin bolt B

▲
▲
Keeper plate bolts 207038

(3) Measure the tangential force at point “C”.

When the tangential force is larger than the
values shown in the table below, add shims.
When the tangential force is smaller than the ▲
values shown in the table below, remove
shims. Repeat this procedure until the values
in the table attainted. C

Tangential force 30.4 to 79.4 N

for kingpin (3.1 to 8.1 kgf)
bearings [6.8 to 17.8 lbf] 207039

(4) Tighten kingpin keeper plate bolts.

Unit: N·m (kgf·m) [lbf·ft]
Kingpin bolt Keeper plate bolts
16.7 33.4
Tightening torque
(1.7) (3.4)
for bolts
[12.3] [24.6]

207040

7-11
REAR AXLE

4. Reassembling tie-rods
Replace dust seals. Tighten tie-rod pin bolts to
Bolt
the specified torque. Grease the joints using
the grease gun.
Collar
6.9 N·m
Tightening torque for bolts (0.7 kgf·m) Tie-rod pin
[5 lbf·ft]

Grease nipple

Dust
seals

207107

5. Reassembling rear axle hub

(1) The inner race of the inner bearing must be
driven onto the shaft by using a special tool, as
shown:

Special tool needed

1.0 to 1.8 ton 2 to 3.5 ton
models models
Bearing
91268-01500 64309-40400 207032
installer

(2) There is a space between two tapered roller

bearings inside the rear axle hub. Be sure to Fill up with grease
fill up this space with grease. Grease the oil
seal lip groove and roller retainers, too. Do not
overfill the oil seal lip groove as this can cause
leakage.

Oil seal

207110

7-12
 REAR AXLE

(3) Bearing preload is specified. Tighten the

inside nut first to secure the prescribed pre-
load; after this tightening, tighten the outside
nut (lock nut) to the specified torque value;
and then re-check the preload. If the hub bear-
ings (taper roller bearings) have long been in
service, it is advisable to aim at a value of pre-
load in the lower half of the specified range.
1 ton-model 2, 3 ton-model
207169
0.5 to 4.9 N·m
Preload for hub bearing (5 to 50 kgf·cm)
[0.4 to 3.6 lbf·ft]
Tangential force for hub 6.8 to 68 5.4 to 54 Inside nut
bearing at hub bolt (0.7 to 6.7) (0.55 to 5.5)
N (kgf) [lbf] [1.5 to 15] [1.2 to 12]
Outside nut
157 N·m •• (lock nut)
Tightening torque for
(16 kgf·m)
lock nut
[116 lbf·ft]

207110

(4) Use a new lockwasher and bend it to both

Wrong
sides (inward and outward).

(5) Fill the cap with grease, and install the cap.
Right

205436

Raise the rear end of the truck and remove the

blocking from the side frames. Lower the truck
until the rear wheels just touch the floor.

7-13
REAR AXLE

Steering Cylinder
Disassembly

*: Parts contained in repair kit 10

*

11
9

A
11
3
*
4
5
2
* 1
6 *
7 7
A * 6
*
2
5
4

*
1 3

8
1
207036

Disassembly sequence
1 Nut, Spring washer, Stud 6 Wiper
Remove parts 2 through 7 as assembly. 7 U-seal
2 Cylinder head 8 Cylinder tube
3 O-ring 9 Piston rod
4 Snap ring 10 Guide ring, Piston seal
5 Bushing 11 Stopper ring, Pivot joint

NOTE
(1) Do not remove bushing 5 from the cylin-
der head 2 if not necessary.
(2) Do not remove bearing 11 from piston
rod 9 if not necessary.

7-14
 REAR AXLE

Suggestions
Mark cylinder end caps
Mark the cylinder end caps for proper alignment
before they are disassembled from the cylinder. Mark

▲
Mark

207035

Inspection and Repair

(1) Cylinder tube 8
Check for wear, damage or rust inside the
cylinder.
(2) Piston rod 9
Check for rust, damage, scratches or impact
marks on the rod surface.
(3) Rings and gaskets
Replace the entire seal kit with new one.

A: Standard value
Unit: mm (in.)
205439
1.0 to 1.8 ton 2 to 3.5 ton
models models
Internal diameter
A 63 (2.480) 75 (2.953)
of cylinder tube 1
External diameter
A 40 (1.575) 50 (1.968)
of piston rod 2

2 1

207034

7-15
REAR AXLE

Reassembly

10 11

13
9 8 6 7 14
16 2

12

15

1 3 4
5 5
207168

Assembly sequence
1 Piston rod 7 Snap ring 13 Spring washer
2 Piston seal 8 U-seal 14 Nut
3 Guide ring 9 Wiper 15 Pivot joint
4 Cylinder tube 10 O-ring 16 Stopper ring
5 Cylinder head 11 O-ring
6 Bushing 12 Tie rod

Suggestions
1. Replace all seals and O-rings whenever
reassembling cylinder. Smear hydraulic fluid
on seals and O-rings.
2. Assemble Wiper and U-seal as shown.

Wiper U-seal
207042

7-16
 REAR AXLE

3. Align marks on the end caps to marks on the

cylinder body. Tighten nuts. Mark
Unit: N·m (kgf·m) [lbf·ft]
Tightening torque for 19 to 23
cylinder nuts (1.9 to 2.3)
N·m (kgf·m) [lbf·ft] [14 to 17]

Mark

207035

4. Pressure test cylinder reassembly for leaks.

Unit: kPa (kgf/cm2) [psi]
1.0 to 1.8 ton 2 to 3.5 ton
models models
10500 15690
Minimum
(107) (160)
test pressure
[1522] [2275]

7-17
REAR AXLE

Inspection and Adjustment

Minimum Turning Radius Adjustment
1. Use a turning radius gauge, and measure the
angular swing of rear wheels.
2. Setting the turning angle of each rear wheel to R
the specification is not enough. The lift truck
must be driven to make the sharpest possible
turn to either side, and the radius of the track
left behind by the outer wheel must be mea-
sured for confirmation. The standard mini-
mum turning radius is indicated below. 202800
1.0 to 1.8 ton 2 to 3.5 ton
models models
Steering angle
Inside 82° 83°
Outside 55° 56°
Tightening
67 N·m
torque for
(6.8 kgf·m)
knuckle stopper
[49 lbf·ft]
bolt lock nut

3. Drive the lift truck at low speeds in such a

manner as to make the sharpest possible turn
to either side, and measure the radius of track
left by the outer rear wheel.
4. The minimum turning radius R is the distance
from the turning center to the center of tire
contact with the surface of the wheel describ-
ing the largest circle, while the truck is exe-
cuting its sharpest practicable turn, plus the
rear overhang (the distance from the center of
rear tire to the outermost end of counter-
weight).
Unit: mm (in.)
Minimum turning radius
GP/DP15K 1990 (78.3)
GP/DP18K 2020 (79.5)
GP/DP20K 2185 (86.0)
GP/DP25K 2245 (88.4)
GP/DP30K 2445 (96.2)
GP/DP35K 2485 (97.8)

7-18
 REAR AXLE

Troubleshooting
Complaints Possible Causes Remedies
Heavy steering a) Overloaded steer axle Reduce load.
b) Damaged mechanical linkage Replace.
c) Dry mechanical linkage joints Lubricate.
d) Mechanical joints too tight Readjust.
e) Kingpin bearings improperly preloaded Readjust.
Truck wandering a) Damaged or worn mechanical linkage Replace.
b) Loose cylinder piston Replace cylinder rod.
Truck drifting a) Damaged or worn mechanical linkage Replace.
b) Tire diameter differs between right and left Replace tire.
Erratic steering Loose cylinder piston Replace cylinder rod.
Excessive free play at Damaged or worn linkage between cylinder Replace.
steered wheels and steered wheels
Axle shimmy a) Excessive clearance between the kingpin Repair or replace.
and its bearings
b) Worn or damaged hub bearing Replace.
Rear tires wear Tire on one side differs in kind or brand from Replace tires.
prematurely or unevenly that on the other side.

7-19
REAR AXLE

Service Data
A= Assembly standard B= Repair or service limit
Unit: mm (in.)
Truck Models
GP/DP15K, 18K GP/DP20K thru 35K
Items
Oscillating angle A 3°
Toe-in A 0°
Caster A 0°
Camber A 1°
A 0.8 (0.031)
Total fore-aft play of axle at center pin 1
B 1.2 (0.047)
Inside 2 A 82° 83°
Turning angle
Outside 3 A 55° 56°
Tightening torque Support bolts 4 A 145 (14.8) [107]
N·m (kgf·m) [lbf·ft] Stopper bolt nuts 5 A 67 (6.8) [49]
Cylinder minimum test pressure,
A 10500 (107) [1522] 15690 (160) [2275]
kPa (kgf/cm2) [psi]
Rear axle

2
4 5

3
1

207043

7-20
 REAR AXLE

A= Assembly standard
Unit: mm (in.)
Truck Models
GP/DP15K, 18K GP/DP20K thru 35K
Items
Outer locknut 6 A 157 (16) [116]
Cylinder nuts 7 A 19 to 23 (1.9 to 2.3) [14 to 17]
Tightening torque
Cylinder bolts 8 A 262 (26.7) [193]
N·m (kgf·m) [lbf·ft]
Kingpin bolts 9 A 16.7 (1.7) [12.3]
Keeper plate bolts 10 A 33.4 (3.4) [24.6]
Tie rod bolts 11 A 6.9 (0.7) [5]
6.8 to 68 5.4 to 54
Tangential force for hub bearing 12
A (0.7 to 6.7) (0.55 to 5.5)
at hub bolt N (kgf) [lbf]
[1.5 to 15] [1.2 to 12]
Preload for hub bearings 12
A 0.5 to 4.9 (5 to 50) [0.4 to 3.6]
N·m (kgf·cm) [lbf·ft]
Tangential force for kingpin bearings 13 30.4 to 79.4 (3.1 to 8.1)
A
N (kgf) [lbf] [6.8 to 17.8]
GP/DP20K GP/DP35K
2.24 to 5.88 thru 30K
Preload for kingpin bearings 13
A (22.9 to 60.0) 2.73 to 7.14 2.43 to 6.35
N·m (kgf·cm) [lbf·ft]
[1.65 to 4.34] (27.9 to 72.9) (24.8 to 64.8)
[2.02 to 5.27] [1.79 to 4.68]
Rear axle

11

13

12
8

13
12

10 9 6
207067
7-21
REAR AXLE

A= Assembly standard
Unit: mm (in.)
Truck Models
GP/DP15K, 18K GP/DP20K thru 35K
Items
Internal diameter of cylinder tube 1 A 63 (2.480) 75 (2.953)
External diameter of piston rod 2 A 40 (1.575) 50 (1.068)
Steering cylinder

2 1

207034

7-22