PART NO. 897656

1300 SRM 568

SAFETY PRECAUTIONS

MAINTENANCE AND REPAIR

•

When lifting parts or assemblies, make sure that all slings, chains or cables
are correctly fastened and that the load being lifted is balanced. Make sure
that 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 and working area clean and in order.

•

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 that all nuts, bolts, snap rings and other fastening devices are
removed before using force to remove parts.

•

Always fasten a DO NOT OPERATE sign to the controls of the unit when
making repairs or if the unit needs repairs.

•

Make sure you follow the DANGER, WARNING and CAUTION notes in
the instructions.

•

Gasoline, Liquid Petroleum Gas (LPG), and Diesel are flammable fuels.
Make sure that you 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 has ventilation.

INTRODUCTION

This section describes disassembly and assembly proce-
dures for the repair of transaxle assemblies used in
J30XMT, J35XMT and J40XMT or J1.60XMT,
J1.80XMT and J2.00 XMT lift trucks. This series of lift
trucks can be equipped with either solid tires, pneumatic
shaped solid tires or pneumatic tires. A description of
the wheels and tires is included in the section PERIOD-
IC MAINTENANCE, 8000 SRM 528 or 8000 SRM
584.

The transmission/drive axle assembly is called a trans-
axle. There are two different transaxle assemblies used

on the J30XMT, J35XMT and J40XMT or J1.60XMT,
J1.80XMT and J2.00 XMT lift trucks. The S1 series was
used from product introduction until mid 1996. Trucks
manufactured after mid 1996 are equipped with the S2
series transaxle.

When servicing the transaxle it is important to deter-
mine if it is a S1 series or S2 series assembly. Compo-
nents and assemblies are not interchangeable. Different
traction motors are used for the different transaxle as-
semblies. Left and right transaxles must always be of the
same series.

S1 Series Transaxle

S2 Series Transaxle

Brake rotor retained with nut.

Brake rotor retained with bolt.

No grease fittings.

Grease fitting at top of case for pinion bearing lubrication.

Pinion gear is mounted on traction motor armature shaft.

Pinion gear is part of the transaxle assembly (integral).

Traction motor has upper and lower bearings.

Traction motor has upper (brush end) bearing only.

TABLE 1 – TRANSAXLE IDENTIFICATION

GENERAL

The J30XMT, J35XMT and J40XMT or J1.60XMT,
J1.80XMT and J2.00 XMT lift truck has a left and a
right drive unit. Each of the two drive units consists of a
transaxle and a traction motor. Each transaxle assembly
is attached to the truck frame. The traction motor is
mounted directly on the transaxle. The torque of the
traction motor is transmitted independently to each
drive wheel by dual reduction gearing in each transaxle
assembly. The pinion gear engages the matched ring
gear in the transaxle assembly. The traction motors nor-
mally turn in opposite directions to enable the drive
wheels to turn in the same direction. When the steering
angle of the steer tire reaches 60 degrees, power to the
inside traction motor is removed. When the angle of the
steer tire reaches 85 degrees, the inside traction motor is
reversed. This arrangement permits this series of lift
trucks to turn in a smaller than normal space

The transaxle features a dual reduction design utilizing
both spiral bevel and helical gears. Left and right trans-
axle assemblies of each series are the same except for
the housing, housing cover, service brake bracket and
park brake bracket. There are left and right assemblies
for these components.

S1 Series

Transaxle

S2 Series

Transaxle

Weight

80 kg (177 lb)

Gear Ratio

15.87:1

15.61:1

Gear Oil
Capacity

1.3 litres (0.34 gal)

1.18 litres (0.313 gal)

TABLE 2 – TRANSAXLE SPECIFICATIONS

Disc brakes are connected to the intermediate shafts of
the gear reduction system. Both the park and service
brake use the same brake rotor.

LUBRICATION

Both transaxles are lubricated using standard gear oil.
See the section, PERIODIC MAINTENANCE, 8000
SRM 528 or 8000 SRM 584 for additional information.

There are three plugs and a breather on each transaxle
assembly. The breather and the fill plug are located in
the top of the housing. The drain plug and an oil level
plug, to check the oil level, are located in each housing
cover. The gear oil should be changed every 2000 hours.

On S2 series transaxles, grease is used to lubricate the
outer pinion bearing. A grease fitting is located at the top
of each transaxle assembly to allow lubrication at the

required intervals. The grease fittings are accessed by
removing the drive tires. Multi-purpose grease (Hyster
P/N 3020399 or equivalent) must be used. See the sec-
tion, PERIODIC MAINTENANCE, 8000 SRM 528
or 8000 SRM 584 for lubrication instructions, lubrica-
tion intervals and grease specifications.

Care must be taken during greasing of the outer pin-
ion bearing. If grease is allowed to remain on the ex-
terior of the transaxle assembly or traction motor,
the grease may contaminate the disc brake system
and cause brake system malfunction. Personal inju-
ry or property damage can result if the brake system
fails.

REPAIRS

REMOVAL

Each transaxle assembly is fastened to the frame with
five capscrews and lockwashers. The transaxle and trac-
tion motor may be removed from the lift truck as a unit
or the traction motor may be removed separately. The
instructions that follow are for removing one transaxle
assembly (including the traction motor).

The lift truck must be put on blocks for some types of
maintenance and repair. The removal of the battery,
mast, transaxle, or the counterweight, will cause
large changes in the center of gravity. When the lift
truck is put on blocks, put additional blocks in the
following positions:

a. If the battery and transaxle are to be re-
moved. Put blocks under the counterweight so
that the lift truck cannot fall backward.

b. If the battery and counterweight are to be re-
moved. Put blocks under the mast assembly so
that the lift truck cannot fall forward.

1. Remove the mast assembly. See the section,
MASTS, 4000 SRM 522 for removal information. Re-
fer to REPAIRS.

2.. Loosen, but do not remove, the drive wheel lug nuts.

3. Do not remove the battery. Disconnect the battery
and separate the connector. Put the lift truck on blocks.
Make certain the blocks are behind the wheel. See the
section PERIODIC MAINTENANCE, 8000 SRM
528 or 8000 SRM 584. Refer to HOW TO PUT THE
LIFT TRUCK ON BLOCKS.

4. If pneumatic tires are on the lift truck, deflate the
tires. Remove the drive wheel lug nuts. Remove the
drive wheels from the axles. See the section, PERIOD-
IC MAINTENANCE, 8000 SRM 528 or 8000 SRM
584. Refer to WHEELS AND TIRES.

5. Remove the drain plug and drain the oil from the
transaxle housing into a suitable container (minimum
0.5 gallon capacity).

6. Remove the capscrews retaining the disc brake
shield and remove the shield.

7. Remove the cotter pin and clevis pin to disconnect
the park brake linkage.

8. Disconnect the hydraulic brake lines from the ser-
vice brake calipers. Plug both the brake lines and the cal-
iper ports to keep dirt from entering the system and the
brake fluid from leaking out.

9. Remove the floor plates. Mark and disconnect the
power cables from the traction motor.

The transaxle and traction motor assembly is heavy.
Be sure that all lifting devices (hoists, cables, chains,
slings etc.) are suitable and of adequate capacity to
lift the transaxle and traction motor. The transaxle
and traction motor can weigh approximately 111 kg
(245 lbs).

10. The traction motor has a M10

1.5 threaded hole

for attaching a lifting eye. Either use a lifting eye and a
hoist, or position a floor jack under the transaxle assem-
bly. If a floor jack is used make certain that the transaxle
rests firmly on the jack so that it will not fall.

11. Remove the five capscrews and washers retaining
the transaxle to the frame. Use the floor jack or lifting

device to lower the transaxle assembly from the frame.
Make sure the cables and hoses do not cause interfer-
ence when the transaxle assembly is removed from the
lift truck.

INSPECTION

Cleaning solvents can be flammable and toxic, and
can cause skin irritation. Wear protection when han-
dling solvents and always follow the recommenda-
tions of the manufacturer.

1. Before assembling the transaxle, wash and thor-
oughly clean all parts in a suitable solvent and dry. Make
certain that all gasket material or sealing compound has
been removed from the housing and covers, and that all
mating surfaces are smooth.

2. Check housing for cracks. Check all threaded holes
and wheel studs for damage. Check to see that the trans-
axle breather is not plugged.

3. Check all bearings for excessive wear or flat spots.
Dip clean bearings in new, clean gear oil and wrap in a
clean, lint free cloth until ready for assembly.

4. Check all gears and shafts for excessive wear or
damaged teeth.

On the S1 series transaxle only, check for damaged
keyways. Check keys for rounded edges or cracks.
Check the keys for proper fit in the keyways of the shafts
where they belong. If the keys do not fit properly, re-
place the key and/or shaft.

5. Replace all worn or damaged parts. When assem-
bling the transaxle use all new stake nuts, O-rings and
seals. The pinion gear and ring gear must be replaced as
a matched set.

INSTALLATION

1. Position the transaxle assembly under the lift truck.
Using a floor jack or hoist, raise the transaxle assembly
high enough to install the capscrews and washers. Apply
Loctite 271 (Hyster P/N 226414) or equivalent to the
threads of the capscrews before installation. Tighten the
capscrews to 256 N

m (189 lbf ft).

2. Connect the power cables to the traction motor.

3. Remove the plugs from the hydraulic brake lines
and the service brake caliper. Attach the brake lines to
the calipers.

4. Install the clevis pin and attach the park brake link-
age. Install a new cotter pin.

5. Install the disc brake shield between the transaxle.
Install the drive wheels. Tighten the wheel nuts to 170
N

m (125 lbf ft).

6. Remove the lift truck from the blocks.

7. Remove the fill and level plugs from the transaxle
and fill the transaxle with the recommended gear oil. Fill
until oil starts to come out of the level plug opening.
Install the plugs.

8. Install the floor plates.

9. Check, adjust and bleed the brakes if necessary. See
the section, BRAKES, 1800 SRM 570.

10. Install the mast assembly and connect the battery.
See the section, MASTS, 4000 SRM 522 for installa-
tion information.

S2 SERIES TRANSAXLE

DISASSEMBLY

NOTE:

There are several groups of shims used to set

clearances in the transaxle assembly. During disassem-
bly, use a piece of mechanics wire and a tag to separate
and identify each shim group for use in assembly.

1. Remove the four capscrews and washers retaining
the traction motor to the transaxle. Remove the traction
motor. The traction motor has a M10

1.5 threaded hole

in the top of the motor to enable a lifting eye to be
installed.

CAUTION

Failure to completely straighten the staked portion
of the nut prior to removal can cause damage to the
shaft threads.

2. Straighten the staked portion of the pinion shaft nut.

3. Manually apply the park brake. Loosen, but do not
remove, the pinion shaft stake nut and the bolt retaining
the brake rotor.

4. Remove the service brake and the mounting bracket
from the transaxle housing. See the section, BRAKES,
1800 SRM 570.

5. Remove the park brake and park brake bracket from
the transaxle housing. See the section, BRAKES, 1800
SRM 570.

6. Remove the bolt and plain washer from the brake
rotor side of the shaft. Remove the brake rotor.

7. Remove the bolts retaining the outer bearing cap to
the transaxle housing. Remove the cap and O-ring.

8. Remove the outer shims. Use a piece of mechanics
wire and a tag to group and identify the shims for use in
assembly.

9. Remove the bolts retaining the inner bearing cap to
the transaxle cover. Remove the cap and O-ring.

10. Remove the seal from the inner bearing cap.

11. Remove the inner shims. Use a piece of mechanics
wire and a tag to group and identify the shims for use in
assembly.

12. Remove the transaxle cover.

13. Remove the inner bearing race from the transaxle
cover.

14. Remove the intermediate shaft assembly.

15. If necessary, press the inner bearing and outer bear-
ing from the intermediate shaft.

16. Remove the outer bearing race from the transmis-
sion housing.

CAUTION

Failure to completely straighten the staked portion
of the nut prior to removal can cause damage to the
shaft threads.

17. Straighten the staked portion of the axle shaft nut.

18. Remove the nut and washer from the axle shaft. Dis-
card the stake nut.

19. Remove the helical gear from the axle shaft.

20. Remove the axle shaft from the housing.

21. Remove the outer oil seal from the housing.

22. Remove the inner and outer bearings and races.

23. Remove the pinion shaft stake nut, washer, upper
spacer, grease seal and upper bearing. Discard the stake
nut.

24. Remove the pinion shaft.

25. Remove the outer shims. Use a piece of mechanics
wire and a tag to group and identify the shims for use in
assembly.

26. Remove the oil seal and intermediate spacer.

27. Remove the inner bearing from the pinion shaft.

28. Remove the inner shims. Use a piece of mechanics
wire and a tag to group and identify the shims for use in
assembly.

29. Remove the inner and outer bearing races from the
housing.

ASSEMBLY

General

NOTE:

The ring and pinion gears must be replaced as

a matched set.

The numbers in the ( ), in the following procedures re-
fer to item numbers in FIGURE 1.

Ring Gear Installation

1. Inspect the housing, cover and internal components
for wear or damage. Refer to TRANSAXLE, INSPEC-
TION.

2. Mount the ring gear (30) to the intermediate shaft
(29) by uniformly heating the ring gear to 82-105

(180-221

F). This will allow the ring gear to slip over

the shaft without interference.

CAUTION

Do not use a press or hammer to install the ring gear.
Damage to the ring gear and/or intermediate shaft
could result.

Immerse the ring gear in a non-flammable solu-

tion such as water and heat the solution to the proper
temperature. If the immersion method is not practi-
cal, the ring gear may be dry heated to the proper
temperature in an oven.

b. While the ring gear is hot, bolt the ring gear to
the intermediate shaft using bolts (32) and washers
(31). Lubricate the bolt threads and tighten it to 50
N

m (37 lbf ft).

NOTE:

The ring gear must be bolted to the intermedi-

ate shaft while the ring gear is hot. The bolts must be
torqued while the ring gear is hot.

Allow the assembly to cool and torque the ring

gear retaining bolts again. Torque the bolts to 50
N

m (37 lbf ft).

Intermediate Shaft Installation

1. Press the inner bearing (33), and outer bearing (27)
on the intermediate shaft.

2. Install the outer bearing race (28) into the housing
(1). Install the inner bearing (34) race into the housing
cover (65).

3. Install the ring gear and intermediate shaft assembly
into the housing. Lubricate the bearings with gear oil
prior to installation.

NOTE:

Do not install sealant on the transaxle or

transaxle housing at this time.

4. Install the housing cover (65) on the housing using
bolts (5) and lockwashers (69). Tighten the bolts to 52
N

m (38 lbf ft).

NOTE:

Do not install the inner oil seal (40) in the

bearing cap at this time. Do not install outer O-ring (22)
or inner O-ring (39) at this time.

5. Install the the outer shims.

If using the ring and pinion gears removed at

disassembly reuse the original shims in the original
locations.

b. If the ring and pinion gears are replaced or if the
tooth contact pattern is not correct, install shims
(35, 36, 37, 38) as required to obtain a total shim
thickness of 1.6 mm (0.063 in). Refer to the ap-
propriate Parts Manual for a listing of available
shims and shim thickness.

6. Install the outer bearing cap (20) using bolts (21).
Tighten the bolts to 26.1 N

m (232 lbf in).

7. Install the inner shims.

If using the ring and pinion gears removed at

disassembly reuse the original shims in the original
locations.

b. If the ring and pinion gears are replaced or if the
tooth contact pattern is not correct, install shims
(23, 24, 25, 26) as required to obtain a total shim
thickness of 1.6 mm (0.063 in). Refer to the ap-
propriate Parts Manual for a listing of available
shims and shim thickness.

8. Install the inner bearing cap (41).

9. Temporarily install the brake rotor (43). Use washer
(44) and bolt (45) to retain the brake rotor to the inter-
mediate shaft assembly.

10. Check the rotating torque of the assembly at bolt
(45).

Adjust the rotating torque of the intermediate shaft as-
sembly to 0.7-1.7 N

m (6.0-15.0 lbf in) by adding or re-

moving shims.

If the rotating torque is too low, add a shim(s). If

the dimension on the pinion is a

), add shims under

the outer bearing cap. If the dimension on the pinion
is a

*, add shims under the inner bearing cap.

b. If the rotating torque is too high, remove a
shim(s). If the dimension on the pinion is a

), re-

move shims from under the inner bearing cap. If the
dimension on the pinion is a

*, remove shims from

under the outer bearing cap.

Axle Shaft Installation

1. Remove the brake rotor.

2. Remove the transaxle housing cover from transaxle
housing. Do not remove the bearing end caps.

3. Remove the intermediate shaft assembly complete
with bearings.

4. Using the proper installation tools, install the axle
shaft inner bearing race (16) and outer bearing race (14)
into the housing.

5. Install the outer bearing (13) and oil seal (12) into
the housing. Lubricate the outer bearing and the lip of
the oil seal with gear oil prior to installation.

6. Install the axle shaft (11) into the housing.

7. Install the inner bearing (15) on the axle shaft. Lu-
bricate the bearing with gear oil prior to installation.

8. Install the helical gear (17) on the axle shaft. Install
the washer (18) and a new stake nut (19) on the axle
shaft. Tighten the stake nut to 200 N

m (148 lbf ft) lubri-

cated, while rotating the axle shaft to seat the bearings.
Loosen the stake nut until the axle shaft rotates freely
with no end play. Tighten the stake nut to 40 N

m (30 lbf

ft).

9. Stake the nut (19) using a 8 mm (0.31 in) spherical
end punch. The stake must reach the bottom of the slot in
the pinion shaft.

10. If the axle shaft wheel studs (73) were removed,
coat the threads of the studs with Loctite 271 (Hyster
P/N 226414) or equivalent. Tighten the studs to 30 N

(22 lbf ft).

Pinion Gear Installation

1. Install the pinion gear oil seal (54). The oil seal is
installed from the outside of the housing with the lip fac-
ing in. Lubricate the lip of the oil seal with gear oil.

2. Install the outer bearing race (53) into the housing.

3. Install the inner bearing race (53) into the housing.

4. Install the inner shims on the pinion gear.

If using the ring and pinion gears removed at

disassembly reuse the original shims in the original
locations.

b. If the ring and pinion gears are replaced or if the
tooth contact pattern is not correct the inner shim
pack thickness must be calibrated.

Nominal inner shim pack thickness is 1.6 mm
(0.063 in). Add the dimension on the end of the pin-
ion to the nominal thickness to determine the correct
inner shim thickness

"0.05 mm ("0.002 in). If the

difference is

), the nominal inner shim pack thick-

ness must be increased by that amount. If the differ-
ence is

*, the nominal inner shim pack thickness

must be decreased by that amount.

Stack items (46, 47, 48, 49, 50, 51) as required to ob-
tain the dimension calculated. Refer to the appropri-
ate Parts Manual for a listing of available shims and
shim thickness.

NOTE:

The number etched on the pinion is metric

(mm).

5. Install the inner bearing (52) on the pinion gear.
Install the pinion gear assembly through the housing (1).
Lubricate the bearing with gear oil prior to installation.

NOTE:

Do not install the outer grease seal or grease

the bearings at this time.

6. Install the intermediate spacer (55) on the pinion
gear.

7. Install the intermediate shims.

If using the ring and pinion gears removed at

disassembly reuse the original shims in the original
locations.

b. If the ring and pinion gears are replaced or if the
tooth contact pattern is not correct, install inter-
mediate shims (57, 58, 59, 60) as required to obtain
a total shim thickness of 1.6 mm (0.063 in). Refer to

46
47

50
51

30 P/O

23
24
25
26

57
58
59
60

FIGURE 1 – TRANSAXLE–S2 SERIES (R.H. SHOWN)

1. HOUSING
2. SERVICE BRAKE BRACKET
3. PARK BRAKE BRACKET
4. FOAM RUBBER TAPE (0.38 X 0.50)
5. CAPSCREW M10 X 1.5 X 40
6. DUST COVER
7. BRAKE ROTOR
8. WASHER
9. STAKE NUT

10. O-RING

11. AXLE SHAFT

12. OIL SEAL
13. BEARING
14. BEARING RACE
15. BEARING
16. BEARING RACE
17. HELICAL GEAR
18. WASHER
19. STAKE NUT
20. OUTER BEARING CAP
21. CAPSCREW M8 X 1.25 X 25
22. O-RING
23. SHIM 0.127

MM (0.005 IN.)

24. SHIM 0.178 MM (0.007 IN.)
25. SHIM 0.279 MM (0.011 IN.)
26. SHIM 0.508 MM (0.020 IN.)
27. OUTER BEARING
28. OUTER BEARING RACE
29. INTERMEDIATE SHAFT
30. RING PINION GEAR SET
31. WASHER
32. BOLT
33. INNER BEARING
34. INNER BEARING RACE
35. SHIM 0.127

MM (0.005 IN.)

36. SHIM 0.178 MM (0.007 IN.)
37. SHIM 0.279 MM (0.011 IN.)
38. SHIM 0.508 MM (0.020 IN.)

39. O-RING
40. OIL SEAL
41. INNER BEARING CAP
42. WEAR SLEEVE
43. BRAKE ROTOR
44. WASHER
45. CAPSCREW M12 X 1.75 X 60
46. SHIM 0.432 MM (0.017 IN.)
47. SHIM 0.457 MM (0.018 IN.)
48. SHIM 0.508 MM (0.020 IN.)
49. SHIM 0.559 MM (0.022 IN.)
50. SHIM 0.610 MM (0.024 IN.)
51. SHIM 0.635 MM (0.025 IN.)
52. BEARING
53. BEARING RACE
54. OIL SEAL
55. SPACER
56. DOWEL PIN
57. SHIM 0.127 MM (0.005 IN.)
58. SHIM 0.178 MM (0.007 IN.)
59. SHIM 0.279 MM (0.011 IN.)
60. SHIM 0.508 MM (0.020 IN.)
61. GREASE SEAL
62. SPACER
63. KEYED WASHER
64. STAKE NUT
65. COVER, HOUSING
66. CAPSCREW M10 X 1.5 X 25
67. CAPSCREW M10 X 1.5 X 50
68. WASHER
69. WASHER
70. PLUG
71. PLUG
72. BREATHER ASSEMBLY
73. BOLT STUD
74. CALIPER, SERVICE BRAKE
75. CALIPER, PARK BRAKE
76. FITTING, LUBE

FIGURE 1 – TRANSAXLE–S2 SERIES (CONTINUED)

23. Adjust the ring and pinion gear backlash if neces-
sary. Backlash is adjusted by removing the brake rotor
and bearing caps retaining the intermediate shaft and ad-
justing shims.

NOTE:

The inner and outer shims are different part

numbers and cannot be interchanged.

If backlash is too great, move the ring gear to-

wards the pinion by removing a shim from beneath
the outer bearing cap and installing a shim of the
same thickness beneath the inner bearing cap.

b. If the backlash is too little, move the ring gear
away from the pinion by removing a shim from be-
neath the inner bearing cap and installing a shim of
the same thickness beneath the outer bearing cap.

NOTE:

The thickness of total number of shims (in-

ner+outer) on the intermediate shaft must remain
constant. If a shim is removed from one side of the inter-
mediate shaft, a shim of the same thickness must be
installed on the opposite side of the intermediate shaft.
Changing the thickness of total number of shims on the
intermediate shaft will change the intermediate shaft ro-
tating torque. Refer to the appropriate Parts Manual for
a listing of available shims and shim thickness.

24. Install the brake rotor and the inner and outer bear-
ing caps.

25. Repeat this procedure from Step 22.

26. Check the ring and pinion gear tooth contact. Fol-
low the procedure in FIGURE 3. Manually apply the
park brake to provide resistance to the ring gear while
rotating the pinion to create a clear tooth contact pattern
on the gears.

NOTE:

It will be necessary to remove the transaxle

housing cover and intermediate shaft assembly to check
or adjust the ring and pinion gear tooth contact.

If the tooth contact is correct proceed to FINAL AS-
SEMBLY, Step 1.

If the tooth contact is not correct, adjust the ring and pin-
ion as shown in FIGURE 3.

HIGH NARROW CONTACT
Move the pinion in.
Add a pinion inner shim (46, 47, 48, 49, 50 or 51)

and

Move the ring gear out.

Remove a shim (23, 24, 25 or 26) from behind the
inner bearing cap and add the same thickness shim
(35, 36, 37 or 38) behind the outer bearing cap.

LOW NARROW CONTACT
Move the pinion out.
Remove a pinion inner shim (46, 47, 48, 49, 50 or
51)

and

Move the ring gear in.
Remove a shim (35, 36, 37 or 38) from behind the
outer bearing cap add the same thickness shim (23,
24, 25 or 26) behind the inner bearing cap and.

NOTE:

As the pinion gear is moved in or out, the ring

gear must be moved in the opposite direction approxi-
mately 1/4 of the distance the pinion gear has moved.
This adjustment factor is necessary due to the angle be-
tween the ring and pinion gears.

27. Repeat this procedure from Step 21.

Final Assembly

1. Clean the surface of the housing and the housing
cover. Apply Loctite 515 (Hyster P/N 313022) or equiv-
alent on the housing. Install the housing cover.

2. Remove the inner bearing cap (41) and install O-
ring (39) in the housing. Install the oil seal (40) in the in-
ner bearing cap. Install the inner bearing cap.

3. Clean the inner bearing cap bolts. Install the bolts
using Loctite 290 (Hyster P/N 251099) or equivalent on
the threads. Torque the bolts to 26 N

m (19 lbf ft).

4. Remove the outer bearing cap (20) and install O-
ring (22) in the housing Install the outer bearing cap.

5. Clean the outer bearing cap bolts. Install the bolts
using Loctite 290 (Hyster P/N 251099) or equivalent on
the threads. Torque the bolts to 26 N

m (19 lbf ft).

6. Install a new wear sleeve (42) on the brake rotor if
necessary. Use Loctite 290 (Hyster P/N 251099) or
equivalent between the sleeve and brake rotor.

7. Install the brake rotor (43). Use washer (44) and bolt
(45) to retain the brake rotor to the intermediate shaft as-
sembly. It is only necessary to hand tighten the bolt at
this time.

8. Install the park brake assembly. See the section,
BRAKES, 1800 SRM 570.

9. Install the service brake assembly. See the section,
BRAKES, 1800 SRM 570.

10. Manually activate the park brake assembly to hold
the brake rotor from turning. Torque the brake rotor bolt
(45) to 90 N

m (66 lbf ft).

11. Lubricate the outer bearing assembly (52, 53) with
multi-purpose grease (Hyster P/N 3020399 or equiva-
lent). Install the grease through the grease fitting (76)
while rotating the pinion. Be sure to fill the entire cavity
with grease. Use a high pressure grease gun to install the
grease.

12. Manually activate the park brake assembly to hold
the pinion from rotating. Remove the pinion nut (64)
and install the upper grease seal (61).

13. Install the pinion nut and tighten it to 340 N

m (250

lbf ft). Manually activate the park brake assembly to
hold the pinion from rotating.

14. Stake the pinion nut using a 8 mm (0.31 in) spherical
end punch. The stake must reach the bottom of the slot in
the pinion shaft.

Care must be taken during greasing of the outer pin-
ion bearing. If grease is allowed to remain on the ex-
terior of the transaxle assembly or traction motor
the grease may contaminate the disc brake system
and cause brake system malfunction. Personal inju-
ry or property damage can result if the brake system
fails.

15. Lubricate the outer bearing through the grease fit-
ting (76) while rotating the pinion until grease exits

from the cavity vent. Use a high pressure grease gun to
install the multi-purpose grease (Hyster P/N 3020399 or
equivalent). Wipe all excess grease from the housing.

16. Verify that the foam rubber tape (4) is intact and in
place as shown in FIGURE 1. It is in place to deflect any
grease exiting the relief port away from the brake sys-
tem.

The foam rubber tape is installed on the top of the trans-
mission case parallel to the brake rotor. It is located
8mm (0.3 in) from the outside of the inner edge of the
transmission case.

17. Install a new O-ring on the transaxle end of the trac-
tion motor armature shaft. Lubricate the O-ring with
gear oil prior to installation.

18. Install the traction motor on the transaxle and install
the capscrews and washers. Tighten the capscrews to
30-36 lbf ft (41-50 N

m).

19. Install the traction motor and transaxle assembly in
the frame. Refer to TRANSAXLE, INSTALLATION.

S1 SERIES TRANSAXLE

DISASSEMBLY

1. Remove the four capscrews and washers retaining
the traction motor to the transaxle. Remove the traction
motor. The traction motor has a M10

1.5 threaded hole

in the top of the motor to enable a lifting eye to be
installed.

2. Remove the service brake and the mounting bracket
from the transaxle housing. See the section, BRAKES,
1800 SRM 570.

3. Remove the park brake and park brake bracket from
the transaxle housing. See the section, BRAKES, 1800
SRM 570.

4. Remove the three capscrews and lockwashers re-
taining the cap to the housing. Remove the cap.

5. Remove the eight capscrews and lockwashers re-
taining the cover to the housing.

6. Straighten the staked portion of both nuts on the in-
termediate shaft. Remove the nut and plain washer from
the brake rotor side of the shaft.

7. Remove the cover, service brake and park brake as-
semblies and the brake rotor as one item from the hous-
ing. The spacer, oil seal and bearing for the intermediate
shaft will come off with the housing.

8. Remove the remaining nut and spacer from the in-
termediate shaft. Remove the intermediate shaft assem-
bly from the housing.

9. Remove the ring gear and key from the shaft. Wire
the shims together for use at assembly. Remove the ta-
pered roller bearings, shims and spacers from the inter-
mediate shaft.

10. Straighten the staked portion of the nut retaining the
helical gear to the axle shaft. Remove the nut, washer

and the helical gear. Use a drift to remove the axle shaft
from the housing. Remove the bearings from the hous-
ing.

11. Remove the tapered roller bearings and oil seal from
the housing.

12. Remove the O-ring from the intermediate shaft.

13. If necessary, remove the pinion gear from the trac-
tion motor shaft by removing the nut. Remove the pin-
ion gear and the shims. Wire the shims together for reuse
at assembly.

14. Remove the O-ring from the traction motor.

ASSEMBLY

1. Inspect the housing, cover and internal components
for wear or damage. Refer to TRANSAXLE, INSPEC-
TION.

2. If the axle shaft wheel studs were removed, coat the
threads of the studs with Loctite 271 (Hyster P/N
226414) or equivalent. Install the studs in the axle shaft
until the studs are 32mm (1.25 in) above the face of the
axle shaft.

3. Install the bearings in the transaxle housing for the
axle shaft. Apply Loctite 515 (Hyster P/N 313022) or
equivalent to oil seal and install oil seal into the housing.
Carefully install the axle shaft into the housing. Install
the helical gear on the axle shaft. Install the washer and
nut on the axle shaft. Tighten the stake nut to 200 N

(148 lbf ft) lubricated, while rotating the axle shaft to
seat the bearings. Back off on the stake nut until the axle
shaft rotates freely with no end play. Tighten the stake
nut to 30 lbf ft (40 N

m). Stake the nut, using a 8 mm

(0.31 in) spherical end punch, until reaching the bottom
of the slot in the axle shaft.

4. Install the inner bearing for the intermediate shaft
into the housing. Install the intermediate shaft through
the inner bearing. Install the spacer and the shims re-
moved at disassembly on the shaft. Install the outer
bearing, washer and nut onto the shaft. Tighten the nut to
160 N

m (118 lbf ft) torque. Check the rotating torque of

the shaft using the nut to turn the shaft. The rotating
torque should be 3.7 to 4.3 N

m (2.73 to 3.17 lbf ft). If

necessary, remove the nut and add or remove shims to
obtain the correct rotating torque. NOTE: Tapping on

the housing with a soft mallet will seat the bearings and
may lower the actual rotating torque measured. After
the proper rotating torque has been achieved, stake the
nut using a 8 mm (0.31 in) spherical end punch, until
reaching the bottom of the slot in the intermediate shaft.

5. When using the ring and pinion gear removed at dis-
assembly, install the shims removed at disassembly on
the intermediate shaft (between the helical gear and the
ring gear). Install the key in the keyway and install the
ring gear on the shaft. Lubricate and install a new O-ring
on the intermediate shaft.

NOTE:

The ring and pinion gears must be replaced as

a matched set. If the set is being replaced, note and re-
cord the dimension on the end of the old pinion gear.
Note and record the dimension on the end of the new
pinion gear. Calculate the difference between the two. If
the difference is

, the shim pack behind the pinion

gear must be increased by that amount. If the difference
is

, the shim pack must be decreased by that amount.

6. Install the roller bearing in the housing cover. Apply
Loctite 515 (Hyster P/N 313022) or equivalent to oil
seal and install oil seal into the housing. Apply sealant
Loctite 515 or equivalent to the housing. Install the cov-
er on the housing. Install the capscrews and washers.
Tighten the capscrews to 41 N

m (30 lbf ft). Install the

spacer, brake rotor, washer and nut onto the intermedi-
ate shaft. Tighten the nut to 160 N

m (118 lbf ft) torque.

7. Install the park brake and park brake mounting
bracket on the transaxle. See the section, BRAKES,
1800 SRM 570.

8. Apply gear marking compound to eight or nine
teeth of the ring gear. Lubricate and install a new O-ring
on the traction motor. Install the shims removed at disas-
sembly, the pinion gear and the nut on the traction motor
shaft. Tighten the nut to 48 N

m (65 lbf ft).

9. Install the traction motor on the transaxle and install
the capscrews and washers. Tighten the capscrews to 30
to 36 lbf ft (41 to 50 N

m). Rotate the transaxle axle

shaft at least one revolution. Remove the traction motor
and check the tooth contact pattern.

10. After the correct tooth contact pattern has been es-
tablished, check the backlash between the ring and pin-
ion gears. Install Special Tool 5051462-01 on the top of
the traction motor using a M12

1.75 capscrew and

washer. (NOTE: The thread in the armature is 127 mm
(0.50 in) deep.) Mount a dial indicator on the motor
housing. Adjust the indicator so it just touches the out-
side edge of the special tool. Apply pressure to the park
brake lever and check the backlash while turning the
axle shaft. Check the backlash in two or three places.
The backlash should be 0.28 to 0.41 mm (0.011 to 0.016
in). If the proper backlash is not achieved, disassemble
the motor and add or remove shims from under the pin-
ion gear gear to obtain the proper backlash.

11. After the correct tooth contact pattern and backlash
has been established, install the service brake and ser-
vice brake mounting bracket on the transaxle. See the
section, BRAKES, 1800 SRM 570. Stake the nut re-
taining the brake rotor using a 8 mm (0.31 in) spherical
end punch, until reaching the bottom of the slot in the in-
termediate shaft.

17 18

1. COVER
2. SERVICE BRAKE BRACKET
3. PARK BRAKE BRACKET
4. PARK BRAKE ASSEMBLY
5. SPACER
6. OIL SEAL
7. BRAKE ROTOR
8. WASHER
9. STAKE NUT

10. O-RING

11. BALL BEARING

12. SERVICE BRAKE

ASSEMBLY

13. CAPSCREW
14. WASHER

15. PLUG
16. CAPSCREW
17. WASHER
18. CAP
19. RADIAL ROLLER BEARING
20. SHIMS
21. SPACER
22. BREATHER
23. RING AND PINION GEAR SET
24. INTERMEDIATE SHAFT
25. SHIMS
26. STAKE NUT
27. WASHER
28. KEY
29. HELICAL GEAR
30. DOWEL PIN
31. STUD
32. RADIAL ROLLER BEARING

33. AXLE HOUSING
34. RADIAL ROLLER BEARING
35. WASHER
36. AXLE SHAFT

FIGURE 2 – TRANSAXLE–S1 SERIES (R.H. SHOWN)

STEP 1.

STEP 2.

STEP 3.

Apply gear marking compound to
about 12 teeth of the ring gear.

Check the tooth contact pattern on the
ring gear. Check the pattern on the side
of the tooth where the pinion teeth ap-
ply the force.

CORRECT CONTACT PATTERN

WRONG CONTACT PATTERN

LOW NARROW CONTACT

SHORT HEEL CONTACT

SHORT TOE CONTACT

If the pattern shows the pinion gear is too far
from the center of the ring gear, an adjustment
in the direction of the arrows is necessary.
Adjust the shim sets at the spiral ring gear as
described in the assembly procedure.

If the pattern shows the pinion gear is too close
to the center of the ring gear, an adjustment in
the direction of the arrows is necessary. Adjust
the shim sets at the ring gear as described in the
assembly procedure.

If the pattern shows the pinion gear is too close
to the center of the ring gear, an adjustment in
the direction of the arrows is necessary. Adjust
the thickness of the shim sets as described in
the assembly procedure.

ADJUSTMENT OF CORRECT CONTACT PATTERN OF

GEAR TEETH

HIGH NARROW CONTACT

If the pattern shows the pinion gear is too far
from the center of the ring gear, an adjustment
in the direction of the arrows is necessary.
Adjust the thickness of the shim sets as
described in the assembly procedure.

Apply a small amount of resistance to
the drive wheel and rotate the pinion
gear using a wrench. Rotate the pinion
gear so the ring gear makes one revo-
lution.

FIGURE 3 – GEAR TOOTH CONTACT PATTERN

TROUBLESHOOTING

PROBLEM

POSSIBLE CAUSE

One drive wheel will not move

Check the operation of the traction motor. If the operation of
the traction motor is correct, Check the gear reduction
system in the transaxle for damage.

Noise during operation that is not normal

Low oil level. Add oil to the correct level.

Check for wear and damage in the gear reduction system if
the noise continues.

Ring and pinion backlash is not properly adjusted. Check the
backlash.

Check that the ring and pinion is a matched gear set.

Oil leaks

Replace the O-rings and oil seals as necessary. Use new
O-rings and oil seals if the transaxle is disassembled for
repairs.

Drain or fill plug loose.

9/96 (1/96) ( 6/95) (5/95)(5/94) Litho in U.S.A.

TECHNICAL PUBLICATIONS

1300 SRM 568

TECHNICAL PUBLICATIONS

Document Outline

INTRODUCTION
- GENERAL
- LUBRICATION
REPAIRS
S2 SERIES TRANSAXLE
- DISASSEMBLY
- ASSEMBLY
S1 SERIES TRANSAXLE
- DISASSEMBLY
- ASSEMBLY
TROUBLESHOOTING

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