PLANETARY GEAR AXLE

H7.00-12.50H (H150-275H) [C007]; P7.00-9.00B (P150-200B) [C007]; H13.50-16.00B (H300-350B) [B019]; H360-620B [B008]; H16.00-30.00C (H360-650C) [C008]; H17.00-32.00C (H370-700C) [C008]; H700-800A [A117]; H32.00-42.00B (H700-920B) [B117]; H36.00-48.00C (H800-1050C) [C117]; H20.00-32.00F (H440-700F/FS) [E008]; HR45-25, HR45-27, HR45-31, HR45-40S, HR45-36L, HR45-40LS, HR45-45LSX, HR45H [A227, B227]

PART NO. 910030

1400 SRM 47

SAFETY PRECAUTIONS MAINTENANCE AND REPAIR

When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and that the load being lifted is balanced. Make sure the crane, cables, and chains have the capacity to support the weight of the load. Do not lift heavy parts by hand, use a lifting mechanism. Wear safety glasses. DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift trucks. Disconnect the battery ground cable on internal combustion lift trucks. Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance section. Keep the unit clean and the working area clean and orderly. Use the correct tools for the job. Keep the tools clean and in good condition. Always use HYSTER APPROVED parts when making repairs. Replacement parts must meet or exceed the specifications of the original equipment manufacturer. Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to remove parts. Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the unit needs repairs. Be sure to follow the WARNING and CAUTION notes in the instructions. Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are flammable. Be sure to follow the necessary safety precautions when handling these fuels and when working on these fuel systems. Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the area. Make sure the area is well ventilated.

NOTE: The following symbols and words indicate safety information in this manual:

WARNING
Indicates a 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 ........................................................................................................................................................... Disassemble ................................................................................................................................................... Planetary Axle, Disassemble .................................................................................................................... Assemble and Install ..................................................................................................................................... Planetary Axle, Assemble ......................................................................................................................... Torque Specifications ......................................................................................................................................... Troubleshooting ................................................................................................................................................. This section is for the following models: H7.00-12.50H (H150-275H) [C007]; P7.00-9.00B (P150-200B) [C007]; H13.50-16.00B (H300-350B) [B019]; H360-620B [B008]; H16.00-30.00C (H360-650C) [C008]; H17.00-32.00C (H370-700C) [C008]; H700-800A [A117]; H32.00-42.00B (H700-920B) [B117]; H36.00-48.00C (H800-1050C) [C117]; H20.00-32.00F (H440-700F/FS) [E008]; HR45-25, HR45-27, HR45-31, HR45-40S, HR45-36L, HR45-40LS, HR45-45LSX, HR45H [A227, B227] 1 1 2 3 3 3 6 10 11 16 19

2011 HYSTER COMPANY

"THE QUALITY KEEPERS" HYSTER APPROVED PARTS

1400 SRM 47

Description

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

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 an axle shaft, sun gear, ring gear hub, and ring gear. There are also three planetary pinions, a planetary gear carrier, and a housing. The differential is also installed in the axle housing. Service, parking, and auxiliary brake assemblies are also installed on the drive axle. See the Brake section for your unit for repair of the brakes.

1. 2. 3. 4. 5. 6. 7.

SPINDLE AXLE SHAFT COVER THRUST WASHER PINION PINION SHAFT PLANETARY GEAR CARRIER

8. 9. 10. 11. 12. 13. 14.

SNAP RING SUN GEAR LOCK PLATE ADJUSTMENT NUT RING GEAR RING GEAR HUB BEARING CONE

15. 16. 17. 18. 19. 20.

HUB SEAL DUST SHIELD BRAKE DRUM CAPSCREW SETSCREW

Figure 1. Planetary Axle With Drum Brakes

Operation

1400 SRM 47

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

1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

AXLE HOUSING AXLE SHAFT SLEEVE BRAKE ROTOR OIL SEAL BEARING CONE BEARING CUP HUB RING GEAR HUB RING GEAR

11. 12. 13. 14. 15. 16. 17. 18. 19.

ADJUSTMENT NUT LOCK PLATE THRUST WASHER SUN GEAR SNAP RING PINION (3) PINION SHAFT (3) PLANETARY GEAR CARRIER COVER

Figure 2. Planetary Axle With Disc Brakes

1400 SRM 47

Planetary Gear Axle Repair

Planetary Gear Axle Repair

REMOVE
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 Step 1 and Step 2. 1. Put blocks under lift truck frame to raise drive wheels from ground. 2. Drain lubricant from axle as described in the section Periodic Maintenance for the specific unit. 3. On units with drum brakes, remove air chambers as described in the section Brakes for the specific unit. 4. If installed, remove mast assembly from lift truck as described in the section Mast for the specific unit. 5. Disconnect service brake lines on models that have hydraulic brakes. Make sure to also disconnect brake lines for auxiliary and parking brakes at drive line and differential. Disconnect cooling oil lines for units with oil-cooled brakes. Put caps on all hydraulic lines and ports or fittings. See Figure 3. 6. Disconnect drive shaft at differential. On units with disc brakes mounted to differential housing, remove disc brake assemblies as described in the section Brakes for the specific unit.

DISASSEMBLE
1. Remove drive wheels and tires. See Figure 1, Figure 2, Figure 3, Figure 4, and Planetary Axle, Disassemble.

WARNING
Completely remove the air pressure from the tires before removing the wheels from the lift truck. Air pressure in the tires can cause the tire and rim parts to explode, causing serious injury or death. Always wear safety glasses. 2. Remove air from tire. Remove valve core to make sure all air is out of inner tube. Push a wire through valve stem to make sure valve stem does not have a restriction.

WARNING
Use a correct lifting device to handle tires and wheels. The tires and wheels on some lift trucks can weigh approximately 750 kg (1650 lb). 3. Remove wheel nuts and clamps, then use lifting device to remove tire and wheel from lift truck. 4. Drain oil from end of axle housing. On units with oil-cooled brakes, drain cooling oil from service brakes. 5. On units with disc brakes, remove brake calipers as follows: a. Remove end plates from calipers. Remove brake pads from calipers. b. Disconnect brake lines at calipers. Remove capscrews that hold calipers to axle housing. Make a note of the location of any shims that are used at the caliper mount.

WARNING
Make sure the lifting device can lift 4500 kg (10,000 lb) when moving the drive axle. 7. Put the forks of a lift truck under axle to give it support. Remove bolts and nuts that hold axle to frame. Remove drive axle from lift truck frame. Clean all parts in solvent and dry with compressed air.

Planetary Gear Axle Repair

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Figure 3. Planetary Axle With Oil-Cooled Brakes

1400 SRM 47 Legend for Figure 3 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. AXLE HOUSING SPINDLE SEAL DRIVER OIL SEAL BEARING CONE BEARING CUP HUB RING GEAR HUB RING GEAR 11. 12. 13. 14. 15. 16. 17. 18. 19. 20.

Planetary Gear Axle Repair

INNER HUB ADJUSTMENT NUT LOCK PLATE AND PIN AXLE THRUST BUTTON PLANETARY GEAR CARRIER COVER PINION SHAFT (3) THRUST WASHER PINION GEAR (3)

1. 2. 3. 4. 5. 6. 7.

AXLE HOUSING COOLING OIL FLOW, RETURN BRAKING HYDRAULIC LINE PISTON BRAKE HOUSING RETURN SPRING STATIONARY DISCS

8. 9. 10. 11. 12. 13.

ROTATING DISCS AXLE SHAFT SPINDLE HUB COOLING OIL COOLING OIL FLOW, SUPPLY

Figure 4. Brake and Axle Assembly, Oil-Cooled Brake

Planetary Gear Axle Repair

1400 SRM 47 changes to linings must be done in a restricted area with special ventilation. Protective clothing and a respirator must be used. NOTE: Normally, the disc assembly (fixed and rotating discs) of the oil-cooled brakes is replaced when the drive axle is disassembled. 6. Disassemble oil-cooled brake as described in the section Oil-Cooled Brakes.

WARNING
Brake linings can contain dangerous fibers. Breathing the 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 procedure 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

Planetary Axle, Disassemble

STEP 1. Remove cover from planetary gear carrier.

NOTE: Disc brake-type axle shown. Others similar. 1. HUB 2. COVER 3. PLANETARY GEAR CARRIER

1400 SRM 47 STEP 2. Put alignment marks on planetary gear carrier and hub. Remove planetary gear carrier capscrews. Remove planetary gear carrier from hub. Use a pry bar or put capscrews in puller holes in planetary gear carrier. Remove ring gear from ring gear hub.

Planetary Gear Axle Repair

NOTE: Disc brake-type axle shown. Others similar. 1. PLANETARY GEAR CARRIER 2. HUB 3. RING GEAR NOTE: Sun gear is part of the axle on axles with oil-cooled brakes. There is no thrust washer or snap ring. STEP 3. Remove axle shaft, sun gear, and thrust washer from housing. If the sun gear is separate, remove it from axle shaft.

NOTE: Disc brake-type axle shown. Others similar. 1. 2. 3. 4. HUB THRUST WASHER SUN GEAR SNAP RING

Planetary Gear Axle Repair STEP 4. Remove lock plate for adjustment nut. Remove adjustment nut. Connect a lifting device to hub for support. Use a puller to remove ring gear hub.

1400 SRM 47

NOTE: Disc brake-type axle shown. Others similar. 1. 2. 3. 4. HUB LOCK PLATE ADJUSTMENT NUT RING GEAR HUB

STEP 5. Attach a lifting device to hub. Carefully remove hub from spindle. Driver splines of hub engage brake discs of oil-cooled brake. See Figure 4.

A. DRUM BRAKE-TYPE AXLE SHOWN. OTHERS SIMILAR. 1. HUB

B. DISC BRAKE-TYPE AXLE SHOWN. OTHERS SIMILAR. 2. SPINDLE

1400 SRM 47

Planetary Gear Axle Repair

STEP 6. Remove brake drum or brake rotor and bearings from hub of drum or disc brake axle as necessary. Remove driver from hub and brake housing, brake discs, piston assembly, and bearings from axle of oil-cooled brake as necessary. See Figure 4.

A. DISC BRAKE-TYPE AXLE SHOWN. OTHERS SIMILAR. 1. 2. 3. 4. HUB BRAKE DRUM BRAKE ROTOR BEARING CONE

B. DRUM BRAKE-TYPE AXLE SHOWN. OTHERS SIMILAR. 5. DUST SEAL 6. OIL SEAL 7. BEARING CUP

Planetary Gear Axle Repair

1400 SRM 47

STEP 7. Disassemble planetary gear carrier assembly as necessary. If setscrews are used to hold the pinions in position, put alignment marks on planetary gear carrier and pinion. Use a press to remove pinions.

1. PINION SHAFT 2. PINION 3. PLANETARY GEAR CARRIER

4. THRUST BUTTON 5. THRUST WASHER 6. SETSCREW

ASSEMBLE AND INSTALL

NOTE: Normally, the disc assembly (fixed and rotating discs) of the oil-cooled brakes is replaced when the drive axle is disassembled. 1. Replace disc assembly and assemble oil-cooled brake as described in the section Oil-Cooled Brakes. See Figure 1, Figure 2, Figure 3, Figure 4, and Planetary Axle, Assemble. NOTE: During assembly and installation, see Table 2 for torque specifications. Lubricate all parts with clean axle lubricant. 2. If the axle housing was removed, install it as described in Step 3 to Step 7. Assemble planetary gear carrier assemblies. See Planetary Axle, Disassemble. 3. Use a jack or the forks of a lift truck to put axle under frame. Install nuts and bolts. Install plates on H7.00-12.50H (H150-275H), P7.00-9.00B (P150-200B), and H13.50-16.00B (H300-350B) models. Tighten nuts as shown in Table 1.

Table 1. Axle-to-Frame Fasteners Model H7.00-12.50H (H150-275H) P7.00-9.00B (P150-200B) H13.50-16.00B (H300-350B) H360-620B, H16.00-32.00C (H360-700C) H20.00-32.00F (H440-700F/FS) H7.00-800A, H32.00-42.00B (H700-920B), H36.00-48.00C (H800-1050C), Torque 410 Nm (300 lbf ft) 410 Nm (300 lbf ft) 650 Nm (480 lbf ft) 1625 to 2035 Nm (1200 to 1500 lbf ft)

1625 to 2035 Nm (1200 to 1500 lbf ft)

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1400 SRM 47 4. Install service, auxiliary, and parking brake components as described in the section Brakes for the specific unit. 5. Connect drive shaft to differential or to transfer case. 6. Connect brake lines. On units with oil-cooled brakes, also connect hydraulic lines for cooling oil of service brakes.

Planetary Gear Axle Repair 7. Install wheels. Tighten nuts according to specifications in Table 3. 8. Fill axle with lubricant as specified in the section Periodic Maintenance for the specific unit.

Planetary Axle, Assemble

STEP 1. Install new disc set, spacer, piston, and seals in brake housing for oil-cooled brake as described in the section Oil-Cooled Brakes. Install housing assembly on cover. Install bearings and dust shield in hub. Install driver, brake drum, or brake rotor on hub. Tighten capscrews according to specifications in Table 2.

NOTE: Assembly of axle for oil-cooled brake similar. A. DISC BRAKE-TYPE ASSEMBLY SHOWN. 1. 2. 3. 4. HUB BRAKE DRUM BRAKE ROTOR BEARING CONE B. DRUM BRAKE-TYPE ASSEMBLY SHOWN. 5. DUST SEAL 6. OIL SEAL 7. BEARING CUP

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Planetary Gear Axle Repair

1400 SRM 47

STEP 2. Attach a lifting device to hub and install it on spindle. Install outer bearing cone and ring gear hub. Install adjustment nut.

NOTE: Assembly of axle for oil-cooled brake similar. A. DISC BRAKE-TYPE ASSEMBLY SHOWN. 1. SPINDLE 2. HUB 3. BEARING CONE B. DRUM BRAKE-TYPE ASSEMBLY SHOWN. 4. RING GEAR HUB 5. ADJUSTMENT NUT

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1400 SRM 47 STEP 3. Tighten adjustment nut to 540 Nm (400 lbf ft) while rotating hub. Loosen nut and tighten it again to 540 Nm (400 lbf ft). Loosen adjustment nut until it just touches ring gear hub. Install a bar and nut on hub as shown. Use a torque wrench to check rotating torque of hub. This is the initial value. Make sure hub is rotating while checking the torque. Tighten adjustment nut while checking rotating torque again. Tighten adjustment nut so torque value increases by the amount shown in the following table. The final torque value must be the initial value plus the value shown in the following table.

Planetary Gear Axle Repair

NOTE: Drum brake-type axle shown. Others similar. Model H7.00-12.50H (H150-275H) P7.00-9.00B (P150-200B) H13.50-16.00B (H300-350B) H360-460B, H16.00-23.00C (H360-510C) H520-620B, H25.00-32.00C (H520-700C), H20.00-32.00F (H440-700F/FS) H700-800A H32.00-42.00B (H700-920B) H36.00-48.00C (H800-1050C) Nm (lbf ft) 7 to 12 Nm (5 to 9 lbf ft) 11 to 16 Nm (8 to 12 lbf ft) 14 to 19 Nm (10 to 14 lbf ft) 19 to 24 Nm (14 to 18 lbf ft) 1. 2. 3. 4. HUB BAR ADJUSTMENT NUT TORQUE WRENCH

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Planetary Gear Axle Repair

1400 SRM 47

NOTE: Sun gear is part of the axle on axles with oil-cooled brakes. There is no thrust washer or snap ring. STEP 4. Install ring gear, axle shaft, thrust washer, sun gear, and snap ring.

NOTE: Disc brake-type axle shown. Others similar. 1. 2. 3. 4. 5. 6. HUB RING GEAR AXLE SHAFT THRUST WASHER SUN GEAR SNAP RING

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1400 SRM 47

Planetary Gear Axle Repair

STEP 5. Assemble planetary gear carrier assembly. If the pinions have a flat side, the flat side must be toward the outside of the hub circle. When installing the pinions, be sure to align the alignment marks. Use a press to install pinions. After the pinions are installed, install setscrews.

1. PINION SHAFT 2. PINION 3. PLANETARY GEAR CARRIER STEP 6. Use a silicone gasket material between hub and planetary gear carrier assembly. Connect a lifting device to planetary gear carrier assembly and install it on hub. Align the marks between hub and planetary gear carrier assembly during installation. Tighten nuts or capscrews as specified in Table 2.

4. THRUST BUTTON 5. THRUST WASHER 6. SETSCREW

NOTE: Disc brake-type axle shown. Others similar. 1. PLANETARY GEAR CARRIER 2. HUB 3. RING GEAR

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Torque Specifications STEP 7. Use a silicone gasket material between cover and planetary gear carrier. Align the marks and install cover. Tighten capscrews as specified in Table 2.

1400 SRM 47

NOTE: Disc brake-type axle shown. Others similar. 1. HUB 2. COVER 3. PLANETARY GEAR CARRIER

Torque Specifications
Table 2. Standard Torque Values for Axle Fasteners Size 1/4-20 1/4-28 5/16-18 5/16-24 3/8-16 3/8-24 7/16-14 7/16-20 9/16-12 9/16-18 5/8-11 5/8-18 5/8-11 5/8-18 3/4-10 3/4-16 UNC UNF UNC UNF UNC UNF UNC UNF UNC UNF UNC UNF UNC UNF UNC UNF Lock Nuts Nm 12 to 15 13 to 18 24 to 33 27 to 40 40 to 54 48 to 68 68 to 88 81 to 102 102 to 135 115 to 155 150 to 195 175 to 225 200 to 260 245 to 310 265 to 475 420 to 540 lbf ft 9 to 11 10 to 13 18 to 24 20 to 30 30 to 40 35 to 50 50 to 65 60 to 75 75 to 100 85 to 115 110 to 145 130 to 165 150 to 190 180 to 230 200 to 350 310 to 400 Capscrews and Nuts Nm 13 to 18 13 to 18 27 to 40 27 to 40 48 to 68 48 to 68 81 to 102 88 to 115 115 to 155 135 to 175 175 to 225 200 to 260 245 to 310 285 to 365 420 to 540 490 to 640 lbf ft 10 to 13 10 to 13 20 to 30 20 to 30 35 to 50 40 to 50 60 to 75 65 to 85 85 to 115 100 to 130 130 to 165 150 to 190 180 to 230 210 to 270 310 to 400 360 to 470

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

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1400 SRM 47

Torque Specifications

Table 2. Standard Torque Values for Axle Fasteners (Continued) Lock Nuts Nm UNC UNF UNC UNF UN 595 to 785 680 to 880 880 to 1185 985 to 1290 985 to 1290 lbf ft 440 to 580 500 to 650 650 to 875 725 to 950 725 to 950 Capscrews and Nuts Nm 680 to 860 780 to 1015 1050 to 1355 1150 to 1490 1150 to 1490 lbf ft 500 to 630 575 to 750 775 to 1000 850 to 1100 850 to 1100

Size 7/8-9 7/8-14 1.0-8 1.0-12 1.0-14

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

Table 3. Drive Wheel Nut Torque Model H7.00-12.50H (H150-275H), P7.00-9.00B (P150-200B), H13.50-16.00B (H300-350B) Clamp Nuts Disc Clamp Nuts H360-620B, H16.00-32.00C (H360-700C) H700-800A, H32.00-42.00B (H700-920B) H36.00-48.00C (H800-1050C) H20.00-32.00F (H440-700F/FS) 305 to 375 610 to 675 270 to 340 190 to 240 305 to 340 405 to 440 225 to 275 450 to 500 200 to 250 140 to 180 225 to 250 300 to 325 Nm lbf ft

WARNING
Do not use any lubricant on the studs or nuts. When the wheels have been installed, check all wheel nuts after 4 to 8 hours of operation. NOTE: See Figure 5 for wheel nut tightening sequence.

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Torque Specifications

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NOTE: SEE TABLE 3 FOR CORRECT TORQUE VALUES. A. B. C. D. E. F. H13.50-16.00B (H300-350B) H360-460B, H7.00-12.50H (H150-275H), P7.00-9.00B (P150-200B) H520-620B, H25.00-30.00C (H550-650C) H16.00-23.00C (H360-510C) H700-800A, EARLY MODEL H32.00-42.00B (H700-920B) LATE MODEL H32.00-42.00B (H700-920B), H36.00-48.00C (H800-1050C), H20.00-32.00F (H440-700F/FS) Figure 5. Wheel Nut Tightening Sequence

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1400 SRM 47

Troubleshooting

Troubleshooting
PROBLEM The lift truck will not move. POSSIBLE CAUSE The axle shaft is broken. The gears in the final drive are damaged. PROCEDURE OR ACTION Replace axle shaft. Replace gears.

The final drive makes noise.

The gears or shafts in the final drive are damaged. There is no oil in the axle.

Replace gears. Fill axle with oil. Replace sealant. Replace missing capscrews. Replace missing plugs.

The final drive has leaks.

There is no sealant between the joints of the planetary assembly. There are capscrews missing from the cover of the planetary assembly. There are plugs missing from the cover or housing of the planetary axle. Oil seals are worn or damaged. Fittings or oil lines are loose or damaged (units with oil-cooled brakes only).

Replace oil seals. Tighten fittings or oil lines.

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NOTES ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________

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TECHNICAL PUBLICATIONS
1400 SRM 47 10/11 (8/04)(11/03)(1/00)(7/97)(2/97)(10/88)(8/84)(5/80)(2/79) Printed in United Kingdom