PLANETARY GEAR

AXLE

H36.00-48.00E (H800-1050E) [D117];

RS45-27CH, RS45-30CH, RS45-27IH, RS46-33CH,

RS46-30IH, RS46-36CH, RS46-33IH [A222];

HR45-25, HR45-27, HR45-31, HR45-40S, HR45-36L,

HR45-40LS, HR45-45LSX, HR45H [A227, B227];

H40.00-52.00XM-16CH

(H1050HD-CH, 1150HD-CH) [E117, F117]

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 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!

Planetary Gear Axle

Table of Contents

TABLE OF CONTENTS

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

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

Operation............................................................................................................................................................

Planetary Gear Axle Repair ..............................................................................................................................

Remove ...........................................................................................................................................................

Drive Wheels and Tires.............................................................................................................................

Disassemble ...................................................................................................................................................

Drive Axle ..................................................................................................................................................

Planetary Gear Carrier .............................................................................................................................

Ring Gear, Ring Gear Hub, and Wheel Hub ............................................................................................

Hub Oil Seal and Bearings .......................................................................................................................

Axle Shaft ..................................................................................................................................................

Spindle .......................................................................................................................................................

Repair .............................................................................................................................................................

Repairing or Replacing Parts....................................................................................................................

Welding ......................................................................................................................................................

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

Ground or Polished Parts..........................................................................................................................

Parts With Rough Finishes.......................................................................................................................

Axle Assemblies.........................................................................................................................................

Drying Cleaned Parts................................................................................................................................

Preventing Corrosion.....................................................................................................................................

Parts Inspection.............................................................................................................................................

Assemble ........................................................................................................................................................

Spindle .......................................................................................................................................................

Axle Shaft ..................................................................................................................................................

Hub Oil Seal and Bearings .......................................................................................................................

Ring Gear, Ring Gear Hub, and Wheel Hub ............................................................................................

Wheel Bearing Preload .............................................................................................................................

Adjust.....................................................................................................................................................

Planetary Gear Carrier .............................................................................................................................

Drive Axle ..................................................................................................................................................

Wheel Ends ................................................................................................................................................

Fill..........................................................................................................................................................

Install .............................................................................................................................................................

Drive Wheels and Tires.............................................................................................................................

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

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

This section is for the following models:

H36.00-48.00E (H800-1050E) [D117];

RS45-27CH, RS45-30CH, RS45-27IH, RS46-33CH, RS46-30IH,

RS46-36CH, RS46-33IH [A222];

HR45-25, HR45-27, HR45-31, HR45-40S, HR45-36L, HR45-40LS,

HR45-45LSX, HR45H [A227, B227];

H40.00-52.00XM-16CH (H1050HD-CH, 1150HD-CH) [E117, F117]

"THE

QUALITY

KEEPERS"

HYSTER

APPROVED

PARTS

1400 SRM 1171

General

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

Figure 1. Planetary Axle With Oil-Cooled Brakes

General

1400 SRM 1171

Legend for Figure 1

AXLE HOUSING

SPINDLE

SEAL

ROTOR

OIL SEAL

BEARING CONE

BEARING CUP

WHEEL HUB

RING GEAR HUB

10. RING GEAR

11. INNER HUB
12. WHEEL BEARING ADJUSTMENT NUT
13. WHEEL BEARING ADJUSTING LOCK NUT
14. AXLE
15. THRUST BUTTON
16. PLANETARY GEAR CARRIER
17. COVER
18. PINION SHAFT (3)
19. PINION THRUST WASHER
20. PINION GEAR (3)

Figure 2. Planetary Axle Components

1400 SRM 1171

Planetary Gear Axle Repair

Legend for Figure 2

DRAIN/FILL PLUG

COVER

AXLE SHAFT THRUST BUTTON

CAPSCREW

PLANETARY GEAR CARRIER

SNAP RING

SUN GEAR

THRUST WASHER

WHEEL BEARING ADJUSTING NUT

10. WHEEL BEARING ADJUSTING LOCK NUT
11. CAPSCREW
12. WHEEL BEARING ADJUSTING LOCK NUT
13. RING GEAR
14. RING GEAR HUB

15. RETAINER PLATE
16. CAPSCREW
17. CAPSCREW
18. WHEEL STUD NUT
19. WHEEL STUD NUT WASHER
20. WHEEL RIM CLAMP
21. WHEEL STUD
22. WHEEL STUD WASHER
23. OIL DRAIN PLUG
24. PINION SHAFT
25. PINION OUTER THRUST WASHER
26. PINION GEAR
27. PINION INNER THRUST WASHER

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 1800 SRM 1038 for repair in-
structions 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 pin-
ions causes the planetary spiders to rotate the hubs

and the drive wheels. The ring gear and the ring gear
hub do not rotate.

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.

Place lift truck on solid, level surface.

Put blocks on each side (front and back) of the
steer tires to prevent movement of the lift truck.
See Figure 3.

Put mast in a vertical position.

Put a block under each outer mast channel.

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.

Put additional blocks under frame behind the
drive tires.

Planetary Gear Axle Repair

1400 SRM 1171

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.

Remove air from tire.

Remove valve core to verify that all air is out of
inner tube.

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.

STEER AXLE/STEER TIRES

DRIVE AXLE/DRIVE TIRES

Figure 3. Put the Lift Truck on Blocks

DISASSEMBLE

Drive Axle

Apply brakes ten to twenty times until accumu-
lated hydraulic brake pressure is released.

Drain oil from the end of axle housing.

Rotate hub assembly until oil drain plug in plan-
etary gear carrier is at the bottom.

Remove oil drain plug and drain oil.

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
(fixed and rotating discs) of the oil-cooled brakes are
replaced when the drive axle is disassembled.

Disconnect service brake lines.

Disconnect brake lines for parking brake at the
differential.

Disconnect cooling oil lines for oil-cooled brakes.

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.

12. Remove bolts and nuts that hold the axle to the

frame.

1400 SRM 1171

Planetary Gear Axle Repair

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

Align marks on planetary gear carrier and wheel
hub for correct alignment when reassembling the
unit. See Figure 4.

A. RIM MOUNTED

ALIGNMENT MARKS

Figure 4. Alignment Marks

Remove cover from planetary gear carrier. See
Figure 5.

HUB

COVER

PLANETARY GEAR CARRIER

Figure 5. Planetary Gear Carrier Cover

Remove planetary gear carrier capscrews.

NOTE: Do not remove planetary gear carrier at this
time.

Insert a pry bar into assembly notches and sep-
arate planetary gear carrier from wheel hub as-
sembly. See Figure 6.

Figure 6. Planetary Gear Carrier Separation

Planetary Gear Axle Repair

1400 SRM 1171

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.

Use a lifting device to remove planetary gear car-
rier from wheel hub assembly. See Figure 7.

Figure 7. Planetary Gear Carrier Removal

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
installation procedures.

NOTE: If a press is not available, use a brass drift
and mallet to remove pinion shafts.

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.

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.

Press each pinion shaft out of planetary gear car-
rier and planetary gear. See Figure 8.

SPIDER

PINION SHAFT

OUTER THRUST WASHER

PLANETARY GEAR

SMALL BORE INNER THRUST WASHER

Figure 8. Pinion Shaft

Remove planetary gears and thrust washers
from planetary gear carrier.

Ring Gear, Ring Gear Hub, and Wheel Hub

Remove snap ring from end of axle shaft. See
Figure 9.

Remove sun gear. See Figure 9

Remove sun gear thrust washer assembly. See
Figure 10.

1400 SRM 1171

Planetary Gear Axle Repair

SUN GEAR

SNAP RING

AXLE SHAFT

RING GEAR

Figure 9. Sun Gear

WHEEL BEARING ADJUSTING NUT

WHEEL BEARING ADJUSTING LOCK NUT

CAPSCREW

AXLE SHAFT

THRUST WASHER

Figure 10. Thrust Washer Assembly

Remove capscrews from wheel bearing adjusting
lock nut. See Figure 2 and Figure 10.

Remove wheel bearing adjusting lock nut and
wheel bearing adjusting nut. See Figure 2 and
Figure 10.

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 11.

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
in the ring hub flange. Tighten each capscrew the
same amount to separate ring gear hub from spindle
and wheel hub.

Remove ring gear hub by pulling it straight out
of wheel hub and off of spindle.

Figure 11. Ring Gear Hub

Remove retainer plate capscrews to remove ring
gear from ring gear hub. See Figure 12.

Planetary Gear Axle Repair

1400 SRM 1171

RING GEAR HUB

OUTER WHEEL BEARING

RETAINER PLATE

RING GEAR

Figure 12. Retainer Plate

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.

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 13.

Figure 13. Wheel Hub and Drum

10. Remove wheel hub assembly from wheel hub

spindle.

Hub Oil Seal and Bearings

Position wheel hub with brake end UP to remove
hub oil seal and bearings.

Remove rotor mounting capscrews and washers.

Remove the rotor.

CAUTION

Do not scratch hub seal bore surface.

Remove bearing cups with a suitable puller.

Remove bearing cone with a suitable puller.

Remove wheel hub oil seal.

Axle Shaft

Remove axle shaft from spindle bore and hous-
ing.

Disassemble oil-cooled brakes as described in the
section Service Brake 1800 SRM 1038.

Spindle

NOTE: The spindle and brake cover are assembled to
the axle housing with the same capscrews.

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 14.

Remove the remaining capscrews.

Hold the spindle against the axle housing.

WARNING

Verify the lifting device has the rated capacity
to lift the spindle.

Use a lifting device to remove the spindle. See
Figure 15.

1400 SRM 1171

Planetary Gear Axle Repair

STUD

Figure 14. Brake Housing Studs

LIFTING DEVICE

SPINDLE

Figure 15. Spindle

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 per-
formance 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.

Planetary Gear Axle Repair

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.

Use a cleaning solvent, kerosene, or diesel fuel
to clean ground or polished parts or surfaces.
NEVER USE GASOLINE.

Remove gasket material from parts. Take care
not to damage ground surfaces with grease to
prevent corrosion.

DO NOT clean ground or polished parts in a hot
solution tank, water, steam, or alkaline solution.

Parts With Rough Finishes

Use a cleaning solvent or a hot solution tank with
a weak alkaline solution to clean parts with a
rough finish.

Leave parts in the hot solution tank until they
are completely cleaned and heated. When the
parts are clean, remove them from the tank.

Wash the parts with water until you completely
remove the alkaline solution.

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 lubricat-
ing them.

If assembling the parts immediately after clean-
ing them, lubricate the clean, dry parts with
grease to prevent corrosion.

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.

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.

1400 SRM 1171

Planetary Gear Axle Repair

ASSEMBLE

Spindle

Install two studs opposite each other on the axle
housing flange. Verify the studs are long enough
to support the spindle.

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 16.

AXLE FLANGE

SILICONE BEAD

Figure 16. Axle Flange

WARNING

Verify the lifting device has the rated capacity
to lift the spindle.

Use a lifting device to install the spindle on the
guide studs. Verify the spindle cannot fall before
removing the lifting device. See Figure 16.

Tighten the capscrews to the torque specified.
See Table 2.

Axle Shaft

Replace oil-cooled brake as described in the sec-
tion Service Brake 1800 SRM 1038.

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

Position wheel hub with brake end UP to install
hub oil seal and bearings.

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.

Carefully install a new oil seal wear sleeve on the
spindle.

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.

Apply a thin coat of lubricant to the oil seal jour-
nal surface of the spindle.

Apply lubricant to the inner bearing cone rollers.

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.

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.

Install brake rotor or drum and oil slinger.

10. Install drum or rotor mounting capscrews and

washers.

Planetary Gear Axle Repair

1400 SRM 1171

Ring Gear, Ring Gear Hub, and Wheel Hub

WARNING

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 13.

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 12.

Install retainer plate with bolts.

Install ring gear assembly, which includes outer
bearing cone, on wheel hub spindle. See Fig-
ure 12.

Install wheel bearing adjusting lock nut and
wheel bearing nut on spindle. See Figure 2 and
Figure 10.

Wheel Bearing Preload

Adjust

NOTE: Rotate wheel hub a minimum of one full rev-
olution in both directions after tightening the wheel
bearing adjusting nut.

Tighten the wheel bearing adjusting nut to the
initial seating torque, listed in Table 1, while ro-
tating the wheel hub.

NOTE: Repeat Step 1 and Step 2 until wheel bearing
adjusting nut cannot be tightened without the initial
seating torque, listed in Table 1, being exceeded.

Loosen the wheel bearing adjusting nut and
tighten it again to the initial seating torque
listed in Table 1, while rotating the wheel hub in
both directions.

Loosen the wheel bearing adjusting nut 1/8 to 1/4
turn.

Tighten the wheel bearing adjusting nut to the fi-
nal adjustment nut torque listed in Table 1, while
rotating the wheel hub.

WARNING

Use caution when using Loctite to avoid seri-
ous personal injury. Follow the manufacturer’s
instructions to prevent irritation to the eyes
and skin. If Loctite gets into eyes, flush them
with water for 15 minutes. Have eyes checked
by a doctor as soon as possible.

NOTE: Do not loosen the wheel bearing adjusting nut
from the setting in Step 4. Loosening the wheel bear-
ing adjusting nut can result in an incorrect bearing
preload.

NOTE: If necessary, tighten the wheel bearing adjust-
ing nut to align the lock plate holes with the threaded
holes in the ring gear hub. Do not loosen the wheel
bearing adjusting nut.

Install lock plate capscrews with locking agent
on the threads.

If the original capscrews are

used, apply two or three drops of Loctite 277
or equivalent to the internal threads of the
ring gear hub. Tighten the capscrews to 81 to
102 N•m (60 to 75 lbf ft).

Table 1. Wheel Bearing Adjustment Torque

Adjusting Nut Torque

Axle Models

Initial Seating

Final Adjustment

PRC-5324 to 7314

813 N•m (600 lbf ft)

678 N•m (500 lbf ft)

PRC-7534

949 N•m (700 lbf ft)

746 N•m (550 lbf ft)

1400 SRM 1171

Planetary Gear Axle Repair

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 sur-
face.

Inspect large bore chambers.

NOTE: Do not use planetary gears with rough bore
surfaces.

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
installation procedures.

Place planetary gear carrier in press with flange
side UP. Support planetary gear carrier as re-
quired.

Install inner thrust washer (small bore). Place
washer tab into spider indent and align washer
bore with planetary gear carrier bore.

Apply thin coat of same gear lubricant used in
the wheel end to the planetary gear bore.

Slide planetary gear and outer thrust washer
into planetary gear carrier. Align the bores of
the parts and place outer thrust washer tab into
planetary gear carrier indent.

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 outside of wheel hub circle.
This alignment provides clearance for planetary gear
carrier cover and prevents shaft from rotating when
you install planetary gear carrier cover.

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. See Figure 17.

PINION SHAFT

PLANETARY GEAR CARRIER

INNER THRUST WASHER (SMALL BORE)

PINION GEAR

OUTER THRUST WASHER

Figure 17. Planetary Pinion Shaft

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.

Planetary Gear Axle Repair

1400 SRM 1171

WARNING

Small amounts of acid vapor are present when
applying some silicone gasket materials.

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 matchmarks previously marked at disas-
sembly. See Figure 4.

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)

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.

Carefully move drive axle assembly into position
under lift truck using another lift truck.

Align axle assembly to the frame.

Install nuts and bolts that hold axle to the
frame and tighten to 1650 to 2050 N•m (1217 to
1512 lbf ft).

Connect drive shaft at differential.

WARNING

Connect service brake lines.

Connect brake lines for parking brake at differ-
ential.

Connect cooling oil lines for oil-cooled brakes.

1400 SRM 1171

Planetary Gear Axle Repair

Wheel Ends

Fill

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.

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.

Add oil to each wheel end and then to the bowl.
See the section Periodic Maintenance 8000
SRM 1154 (E117) and Periodic Maintenance
8000 SRM 1237 (F117) for recommended lubri-
cant specifications.

Replace and securely tighten all plugs.

INSTALL

Drive Wheels and Tires

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.

Put tire in a safety cage. See Figure 18.

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
pressure.

Verify all wheel parts are correctly installed. See
Figure 19.

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

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.

Install wheels on lift truck.

CAUTION

Check all wheel nuts after 2 to 5 hours of opera-
tion: 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 20, Figure 21, Figure 22, and
Figure 23. When the nuts stay tight for eight
hours, the interval for checking the torque can
be extended to 500 hours.

Tighten the wheel nuts as shown in Figure 20,
Figure 21, Figure 22, and Figure 23.

First,

tighten the nuts to 35 N•m (26 lbf ft), then
tighten to 100 N•m (74 lbf ft).

Check for

correct 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 20, Figure 21, Figure 22,
and Figure 23.

Figure 18. Add Air to the Tires

Planetary Gear Axle Repair

1400 SRM 1171

SIDE FLANGE

WHEEL RIM

FLANGE SEAT

VALVE STEM

LOCK RING

O-RING

RIM CLAMP

HUB

WEDGE BAND

10. SPACER
11. DRIVER

Figure 19. Wheel Arrangement

1400 SRM 1171

Planetary Gear Axle Repair

A. STEER WHEEL
B. DRIVE WHEEL

Figure 20. Wheel Nut Tightening Sequence

(A222)

Figure 21. Wheel Nut Tightening Sequence

(A227, B227)

A. STEER WHEEL
B. DRIVE WHEEL

Figure 22. Wheel Nut Tightening Sequence

(D117)

Planetary Gear Axle Repair

1400 SRM 1171

Figure 23. Wheel Nut Tightening Sequence

(E117, F117)

Legend for Figure 23

A. STEER WHEEL
B. DRIVE WHEEL

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
1/4-28

UNC
UNF

12 to 15
13 to 18

9 to 11

10 to 13

13 to 18
13 to 18

10 to 13
10 to 13

5/16-18
5/16-24

UNC
UNF

24 to 33
27 to 40

18 to 24
20 to 30

27 to 40
27 to 40

20 to 30
20 to 30

3/8-16
3/8-24

UNC
UNF

40 to 54
48 to 68

30 to 40
35 to 50

48 to 68
48 to 68

35 to 50
40 to 50

7/16-14
7/16-20

UNC
UNF

68 to 88

81 to 102

50 to 65
60 to 75

81 to 102

88 to 115

60 to 75
65 to 85

9/16-12
9/16-18

UNC
UNF

102 to 135
115 to 155

75 to 100
85 to 115

115 to 155

135 to 175

85 to 115

100 to 130

5/8-11
5/8-18

UNC
UNF

150 to 195
175 to 225

110 to 145
130 to 165

175 to 225
200 to 260

130 to 165
150 to 190

5/8-11
5/8-18

UNC
UNF

200 to 260
245 to 310

150 to 190
180 to 230

245 to 310
285 to 365

180 to 230
210 to 270

3/4-10
3/4-16

UNC
UNF

265 to 475
420 to 540

200 to 350
310 to 400

420 to 540
490 to 640

310 to 400
360 to 470

7/8-9

7/8-14

UNC
UNF

595 to 785
680 to 880

440 to 580
500 to 650

680 to 860

780 to 1015

500 to 630
575 to 750

1.0-8

1.0-12
1.0-14

1-1/4-12

UNC
UNF

UNC

880 to 1185
985 to 1290
985 to 1290

N/A

650 to 875
725 to 950
725 to 950

N/A

1050 to 1355
1150 to 1490
1150 to 1490
2305 to 2983

775 to 1000
850 to 1100
850 to 1100

1700 to 2200

NOTE: Torque values are for parts lubricated with a lightweight oil.

Troubleshooting

1400 SRM 1171

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-
aged.

Replace gears.

The final drive makes noise.

The gears or shafts in the final drive
are damaged.

Replace gears.

There is no oil in the axle.

Fill axle with oil.

The final drive has leaks.

There is no sealant between the
joints of the planetary assembly.

Replace sealant.

There are capscrews missing from
the cover of the planetary assembly.

Replace missing capscrews.

There are plugs missing from the
cover or housing of the planetary
axle.

Replace missing plugs.

Oil seals are worn or damaged.

Replace oil seals.

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

Tighten fittings or oil lines.

TECHNICAL PUBLICATIONS

1400 SRM 1171

8/05 (3/05)(8/04)(7/04) Printed in United Kingdom

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