DRIVE AXLE

H20-30E [B001]; H30-60H [D003]; H40-50J [F003];
H60JS [F003]; H60-80C [C005]; H60-110E [D005];

H110-150F [D006]; H6.00-7.00XL (H135-155XL,

H135-155XL

2

) [F006, G006]; H7.00-

12.50H (H150-275H) [C007]; P40-50A [A119];

P60-80A [A018]; P7.00-9.00B (P150-200B) [C007];
S20-30A [A010]; S5.50-7.00A (S125-150A) [A024];

J40-60AS [A168]; KE [B011]

PART NO. 910073

1400 SRM 49

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 Mainte-
nance 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 condition that can cause immediate death or injury!

CAUTION

Indicates a condition that can cause property damage!

Drive Axle

Table of Contents

TABLE OF CONTENTS

General ...............................................................................................................................................................

1

Description .........................................................................................................................................................

1

Drive Axle Repair...............................................................................................................................................

2

Disassemble (Type 1 Shown).........................................................................................................................

2

Clean ..............................................................................................................................................................

5

Inspect ............................................................................................................................................................

5

Assemble (Type 1 Shown)..............................................................................................................................

6

Torque Specifications .........................................................................................................................................

9

Troubleshooting..................................................................................................................................................

10

This section is for the following models:

H20-30E; [B001];

H30-60H; [D003];

H40-50J; [F003];

H60JS; [F003];

H60-80C; [C005];

H60-110E; [D005];

H110-150F; [D006];

H6.00-7.00XL (H135-155XL, H135-155XL

2

) [F006, G006];

H7.00-12.50H (H150-275H) [C007];

P40-50A; [A119];

P60-80A; [A018];

P7.00-9.00B (P150-200B) [C007];

S20-30A; [A010];

S5.50-7.00A (S125-150A) [A024];

J40-60AS; [A168];

KE [B011]

©2003 HYSTER COMPANY

i

"THE

QUALITY

KEEPERS"

HYSTER

APPROVED

PARTS

1400 SRM 49

Description

General

The size of the drive axles, hubs, and wheels vary with each series of lift trucks. The disassembly, assembly,
and service procedures for this type of axle are similar and are described in this section.

Description

The direct drive axle has a housing, two axle shafts and two hubs. See Figure 1. The rotation of the differential
turns the axle shafts and the hubs. The hubs rotate on tapered roller bearings. The brake drums and wheels
are installed on the hub.

NOTE: TYPE 1 USED ON: H30-60H, H40-60J, H60-80C, H60-110E, P40-50A, J40-60A
TYPE 2 USED ON: H20-30E, S20-30A, S125-150A, H100-150F, H135-155XL AND H135-155XL

2

, H150-275H*,

P60-80A, P150-200B, KE.
*THIS SEAL IS NOT USED ON THE H150-275H OR P150-200B UNITS STARTING WITH THE FOLLOWING SE-
RIAL NUMBERS: C7A-2267B, C7P-4034B, C7S-1632C.

A. TYPE 1

B. TYPE 2

1.

AXLE HOUSING

2.

AXLE SHAFT

3.

HUB

4.

BEARING CUP

5.

BEARING CONE

6.

BRAKE DRUM

7.

SEAL

8.

LOCK NUT

9.

LOCK PLATE

10. ADJUSTMENT NUT
11. WHEEL NUT
12. BRAKE DRUM NUT
13. WEAR SLEEVE
14. AXLE SHAFT NUT
15. TAPERED CAPSCREW
16. TAPERED SLEEVE
17. O-RING

Figure 1. Drive Axle

1

Drive Axle Repair

1400 SRM 49

Drive Axle Repair

WARNING

Completely remove the air from the tire before
removing the tire and wheel from lift truck.
Air pressure in the tires can cause the tire and
wheel parts to explode causing serious injury
or death.

NOTE:

Late model lift trucks use tapered capscrews

(15) instead of tapered sleeves and nuts on the end of
the axle shafts.

It is usually not necessary to remove the axle housing
from the frame for repairs to the drive axle.

The axle can be removed without removing the
wheels and hubs.

The axle housing is normally removed during trans-
mission removal. See the Service Manual section
Transmission for your lift truck model, if the axle
housing needs removing.

DISASSEMBLE (TYPE 1 SHOWN)

STEP 1.

Put blocks under the frame to raise the drive wheels from the floor. Remove the wheels. Remove the brake
drum (Type 1).

1.

BRAKE DRUM

2.

WHEEL

3.

WHEEL STUD

4.

WHEEL NUT

5.

SPACER

6.

OUTER WHEEL NUT (DUAL WHEELS)

7.

INNER WHEEL NUT (DUAL WHEELS)

2

1400 SRM 49

Drive Axle Repair

STEP 2.

Remove the nuts or capscrews holding the axle shaft
to the hub.

Hit the end of the axle shaft with a

hammer until it is loose. If used, remove the tapered
sleeves.

STEP 3.

Pull the axle shaft from the axle housing. If used,
remove the O-ring or the oil seal.

STEP 4.

Remove the wheel bearing lock nut. 1000 to 1500 kg
(2000 to 3000 lb) capacity lift trucks use only a lock
plate and adjustment nut.

3

Drive Axle Repair

1400 SRM 49

STEP 5.

Remove the lock plate and the adjustment nut.

NOTE:

Remove bearing cups only if they are damaged or if the bearings are being replaced.

STEP 6.

Remove the hub and bearings from the housing. Re-
move the brake drum (Type 2).

4

1400 SRM 49

Drive Axle Repair

STEP 7.

Remove the seals and bearings from the hub.

1.

AXLE HOUSING

2.

WHEEL HUB

3.

OUTER SEAL

4.

INNER BEARING

5.

INNER SEAL

6.

WEAR SLEEVE

CLEAN

WARNING

Cleaning solvents can be flammable and toxic
and can cause skin irritation.

When using

cleaning solvents, always follow the recom-
mendations of the manufacturer.

WARNING

Compressed air can move particles so that they
cause injury to the user or to other personnel.

Make sure that the path of the compressed air
is away from all personnel.

Wear protective

goggles or a face shield to prevent injury to the
eyes.

Clean the parts of the axle with solvent. Dry the
parts with compressed air.

INSPECT

Inspect all machined surfaces and bearings for wear
and damage.

5

Drive Axle Repair

1400 SRM 49

ASSEMBLE (TYPE 1 SHOWN)

NOTE:

Some hubs (see Figure 1) (Type 1) have an outer oil seal between the inner and outer bearings. For this

type of hub, the inner bearings are lubricated with grease. The outer bearings are lubricated with oil from the
differential. Other hubs, (Type 2) have an outer oil seal outside of both the inner and outer bearings. For this
type of hub, both sets of bearings are lubricated with grease.

Some hubs have only an inner oil seal (some Type 2). Both bearings are lubricated with oil from the differential.

STEP 1.

Install the bearing cups, if removed during disassem-
bly. If used, install the outer oil seal between the in-
ner and outer bearings. Lubricate the inner bearings
with grease. If the axle has only one oil seal, lubri-
cate the bearings with differential oil. Install the oil
seal in the hub.

1.

AXLE HOUSING

2.

WHEEL HUB

3.

OUTER SEAL

4.

INNER BEARING

5.

INNER SEAL

6.

WEAR SLEEVE

STEP 2.

Install the brake drum (Type 2). Carefully install the
hub on the axle housing. Lubricate the outer bearing
and install it into the hub. If used, install the wear
sleeves and outer oil seal.

6

1400 SRM 49

Drive Axle Repair

STEP 3.

Install the adjustment nut. Tighten the adjustment
nut to 200 N•m (150 lbf ft) while rotating the hub.
Loosen the adjustment nut to 35 N•m (25 lbf ft).

STEP 4.

If used, install the lock plate at the first position for
alignment at or above 35 N•m (25 lbf ft). Install the
lock nut and tighten it as shown in Torque Specifica-
tions.

STEP 5.

If used, install the oil seal and wear sleeve in the end
of the hub. Use grease to hold the O-ring in position.
For axles that do not use an oil seal, use a sealant.
Apply the sealant to the axle fittings.

7

Drive Axle Repair

1400 SRM 49

STEP 6.

Install the axle shaft. Install the tapered sleeves,
nuts or tapered capscrews in the hub. Tighten the
nuts or tapered capscrews as shown in Torque Spec-
ifications.

WARNING

Add air to the tires only in a safety cage. Inspect safety cage for damage before use. When adding
air, use a clip on chuck with enough hose to let the operator stand clear of the cage.

NOTE:

When tightening the wheel nuts, DO NOT use any lubricant on the studs or nuts.

STEP 7.

Inflate the tires. Install the brake drum (Type 1) and install the wheels. Tighten the wheel nuts to the spec-
ifications shown in Torque Specifications. Re-torque wheel nuts after 2 to 5 hours of operation. Check the oil
level in the axle housing.

1.

AXLE HOUSING

2.

WHEEL HUB

3.

OUTER SEAL

4.

INNER BEARING

5.

INNER SEAL

6.

OUTER BEARING

7.

BRAKE DRUM

8.

ADJUSTMENT NUT

9.

LOCK NUT

10. AXLE SHAFT
11. O-RING
12. WHEEL

8

1400 SRM 49

Torque Specifications

Torque Specifications

Axle Housing

to Frame Nuts

Brake Drum

Nuts

Axle Lock Nut

Axle Shaft Nuts

or Capscrews

Wheel Nuts

Unit

N•m

lbf ft

N•m

lbf ft

N•m

lbf ft

N•m

lbf ft

N•m

lbf ft

E20-30B/BH

220

160

-

-

Lockplate

-

-

200

150

H20-30E

95

70

-

-

Lockplate

80

60

240 to

300

175 to

225

S20-30A

95

70

-

-

Lockplate

80

60

240 to

300

175 to

225

H30-60H

60**

80**

-

-

135

100

80

60

610 to

680

450 to

500

H40-50J,
60JS

60**

80**

-

-

135

100

80

60

610 to

680

450 to

500

Top

200 to

225

150 to

165

Bottom

J40-60A
J50-60AS

475 to

540

350 to

400

-

-

135

100

80

60

610 to

680

450 to

500

P40-50A

-

-

-

-

135

100

80

60

610 to

680

450 to

500

P60-80A

-

-

300 to

325

220 to

240

135

100

165

120

610 to

680

450 to

500

H60-80C

680

500

300 to

325

220 to

240

135

100

80

60

610 to

680

450 to

500

H60-110E

1000

740

-

-

135

100

165

120

680

500

H110-150F

610

450

300 to

325

220 to

240

135

100

165

120

610 to

680

450 to

500

H135-155XL,
H135-155XL

2

735

540

300 to

325

220 to

240

135

100

165

120

610 to

680

450 to

500

Disc Type Wheels

610 to

670

450 to

500

Wheels w/Rim

Clamps

H150-250H
P150-200B

400

610*

300

450*

220 to

240

160 to

180

340 to

540

250 to

400

120 to

150

90 to

110

200

150

KE

-

-

-

-

135

100

80

60

610 to

680

450 to

500

9

Troubleshooting

1400 SRM 49

Axle Housing

to Frame Nuts

Brake Drum

Nuts

Axle Lock Nut

Axle Shaft Nuts

or Capscrews

Wheel Nuts

Unit

N•m

lbf ft

N•m

lbf ft

N•m

lbf ft

N•m

lbf ft

N•m

lbf ft

S125-150A

970

715

300 to

325

220 to

240

135

100

160

120

610 to

680

450 to

500

*After S/N C7D1710E and C7N1521E.
**The axle housing on these units must be free to rotate in the axle mounts. If, after installation, it does
not move, add shim(s) between the frame mount and the hanger cap.

Troubleshooting

PROBLEM

POSSIBLE CAUSE

PROCEDURE OR ACTION

The lift truck will not move.

An axle shaft is broken.

Install new axle shaft.

The capscrews that hold the axle
shaft to the hub are broken.

Replace the capscrews.

The differential is damaged.

Repair the differential.

Pinion is damaged.

Install a new pinion.

Cluster gear or reduction gear is
damaged.

Install new gear(s).

The drive axle has leaks.

The drain or fill plug has damaged
threads, is loose, or is missing.

Repair threads. Tighten plug. Install
missing part.

The O-rings or seals have damage.

Install new O-rings and seals.

The drive axle housing is cracked.

Install new drive axle housing.

Speed reducer housing is cracked.

Install a new housing.

The drive axle makes noise.

The bearings have damage.

Install new parts.

The brake assembly is damaged.

Repair brake assembly.

The oil level is low.

Fill as required. Check for leaks.

The axle mounting capscrews are
loose.

Tighten

capscrews

to

specified

torque.

Speed reducer gears are damaged.

Install new gears.

10

TECHNICAL PUBLICATIONS

1400 SRM 49

9/03 (3/03)(5/96)(8/82)(9/81)(3/81)(1/80)(4/79) Printed in U.S.A.