This document provides specifications for Cummins engines, lift truck models and their components, including: - Counterweight weights that range from 3,051 kg to 6,985 kg depending on the lift truck model. - Basic lift truck weights that range from 9,400 kg to 15,400 kg depending on options like cab type and tires. - Engine specifications for Cummins QSB4.5 and QSB6.7 engines, including cylinder configuration, displacement, oil pressure and more. - Mast speeds for lifting and lowering loads at different speeds for each lift truck model.

1. SERVICE REPAIR
H2.0FT H2.5FT H3.0FT H3.5FT Europe [L177]

2. Counterweight Weights
Unit Main Counterweight
H190HD/H8.00XM 3051 kg (6,726 lb)
H210HD/H9.00XM 3366 kg (7,420 lb)
H230HD/H10.00XM-6 4276 kg (9,426 lb)
H250HD 4451 kg (9,812 lb)
H280HD/H12.00XM 5131 kg (11,311 lb)
H300HD/H13.00XM 5295 kg (11,673 lb)
H330HD/H14.00XM/H10.00XM-12EC 5930 kg (13,073 lb)
H360HD/H16.00XM-6/H12.00XM-12EC/H360HD-EC 6985 kg (15,399 lb)
Table 1. Counterweight Weights
Model Weight
H8XM-6 (H190HD2) 3051 kg (6,726 lb)
H9XM-6 (H210HD2) 3366 kg (7,420 lb)
H10XM-6 (H230HD2) 4276 kg (9,426 lb)
H10XMS (H250HD2/H230HD2S) 4451 kg (9,812 lb)
H12XM-6 (H280HD2) 5131 kg (11,311 lb)
H13XM-6 (H300HD2) 5295 kg (11,673 lb)
H14XM-6/H10XM-EC (H330HD2) 5930 kg (13,073 lb)
H16XM-6/H12XM-EC (H360HD2 H360HD2-EC) 6985 kg (15,399 lb)
8000 SRM 1937 Counterweight Weights
1

3. Lift Truck Weights
Table 2. Basic Truck
Model "MIN" Weight "MAX" Weight
H190HD2 H8-XM-6 9,400 kg (20,723 lb) 10,150 kg (22,376 lb)
H210HD2 H8-XM-6 9,700 kg (21,384 lb) 10,450 kg (23,038 lb)
H230HD2 H10-XM-6 10,700 kg (23,589 lb) 11,450 kg (25,242 lb)
H250HD2 10,900 kg (24,030 lb) 11,600 kg (25,573 lb)
H280HD2 H12-XM-6 11,550 kg (25,463 lb) 12,300 kg (27,116 lb)
H300HD2 H13-XM-6 12,500 kg (27,557 lb) 13,700 kg (30,203 lb)
H330HD2 H14-XM-6 13,200 kg (29,101 lb) 14,350 kg (31,636 lb)
H360HD2 H16XM-6 14,250 kg (31,415 lb) 15,400 kg (33,951 lb)
NOTE: Add 90 kg (198.4 lb) for a completely topped off fuel tank.
NOTE: The minimum weight indicates the weight for trucks with an open cab and pneumatic tires. The
maximum weight indicates the weight for trucks with an open cab and solid tires. To calculate the total
weight of the basic truck include the weight of following options:
• Add 200 kg (440.9 lb) for a closed cab.
• Add 50 kg (110 lb) for air conditioning.
• Add 90 kg (198.4 lb) for a completely topped up fuel tank.
Capacities
Item Quantity
Engine Oil
Tier 3, QSB6.7L 16 liter (16.9 qt)
Tier 4, QSB4.5L 10.5 liter (11.0 qt)
Tier 4, QSB6.7L 14 liter (14.8 qt)
Lift Truck Weights 8000 SRM 1937
2

4. Item Quantity
Cooling System
Tier 3, QSB6.7L 25.5 liter (27 qt)
Tier 4, QSB4.5L 22.4 liter (23.6 qt)
Tier 4, QSB6.7L 21 liter (22.2 qt)
Hydraulic Tank (FULL mark) 125 liter (33 gal)
Hydraulic System (Total Capacity)
8 to 12 ton 151 liter (39.9 gal)
13 to 16 ton 172 liter (45.4 gal)
Transmission ZF 27 liter (28.5 qt)
Drive Axle and Differential
8 to 12 ton 19 liter (5 gal)
13 to 16 ton 21 liter (5.5 gal)
Planetary Gears
8 to 12 ton 4.4 liter (4.7 qt)
13 to 16 ton 5.5 liter (5.3 qt)
Fuel Tank
8 to 9 ton 108 liter (28.5 gal)
10 to 12 ton 140 liter (37 gal)
13 to 16 ton 158 liter (41.7 gal)
Diesel Exhaust Fluid (DEF) 18.9 liter (5 gal)
Electrical System
All Models 24 Volt, Negative Ground
Alternator Output at 24°C (75°F)
All Engines
21 amps at 750 rpm
76 amps at 2200 rpm
8000 SRM 1937 Capacities
3

5. Engine Specifications
Table 3. Cummins QSB4.5
Item Specification
Type Cummins QSB4.5
Number of Cylinders 4
Firing Order 1-3-2-4
Bore 107 mm (4.2 in.)
Stroke 120 mm (4.7 in.)
Displacment 4.5 liter (275 in.3)
Compression Ratio 17.2:1
Oil Pressure (Minimum, at Low Idle) 52 kPa (7.5 psi)
Oil Pressure (At low idle) 69 kPa (10 psi)
Governed Speed (Full power at Normal Operating
Temperature)
2450 rpm with load
± 50 rpm no load
Idle Speed 800 rpm ±2%
Stall Speed (Broken-in Engine) 2016 + 100/-50 rpm
Thermostat
Begin to open 82°C (179°F)
Fully open 95°C (203°F)
Valve Clearance (Cold)
Intake 0.25 mm (0.01 in.)
Exhaust 0.51 mm (0.02 in.)
Minimum Cranking Speed 120 rpm
Weight (Dry) 371 kg (818 lb)
Table 4. Cummins QSB6.7
Item Specification
Type Cummins QSB6.7
Number of Cylinders 6
Firing Order 1-5-3-6-2-4
Bore 102 mm (4.02 in.)
Stroke 120 mm (4.62 in.)
Displacement 6.7 liter (409 in.3)
Compression Ratio 17.2:1
Oil Pressure (Minimum, at 2500 rpm and normal op-
erating temperature)
69-380 kPa (10-55 psi)
Engine Specifications 8000 SRM 1937
4

6. Table 4. Cummins QSB6.7 (Continued)
Item Specification
Oil Pressure (At low idle) 52 kPa (7.5 psi)
Governed Speed (Full power at Normal Operating
Temperature)
2300 rpm with load
2450 ±30 no load
Idle Speed 800 rpm ±2%
Stall Speed (Broken-in Engine) 1966 to 2116 rpm
Thermostat
Begin to open 82°C (179°F)
Fully open 95°C (203°F)
Valve Clearance (Cold)
Intake 0.25 mm (0.01 in.)
Exhaust 0.51 mm (0.02 in.)
Minimum Cranking Speed 125 rpm
Weight (Dry) 485 kg (1069 lb)
Mast Speeds
Unit
Lifting and Lowering Speeds
90 cc/Rev
@2050 rpm
105 cc/Rev
@2050 rpm
120 cc/Rev
@2050 rpm
m/ sec ft/ min m/ sec ft/ min m/ sec ft/ min
Rated Load Rated Load Rated Load
H190HD2 2 STG NFL 0.47 92.5 0.54 106 0.55 108
H8XM 3 STG FFL
(2ND/FREE)
0.32/0.30 62.9/59 0.37/0.35 72.8/68.8 0.37/0.32 72.8/63
H210HD2 2 STG NFL 0.47 92.5 0.54 106 0.55 108
H9XM 3 STG FFL
(2ND/FREE)
0.32/0.30 62.9/59 0.37/0.35 72.8/68.8 0.37/0.32 72.8/63
H230HD2 2 STG NFL 0.36 70.8 0.41 80 0.42 82.7
H10XM 3 STG FFL
(2ND/FREE)
0.30/0.29 59/57 0.38/0.36 74.8/70.8 0.39/0.34 77/67
H250HD2 2 STG NFL 0.36 70.8 0.41 80 0.42 82.7
3 STG FFL
(2ND/FREE)
0.30/0.29 59/57 0.38/0.36 74.8/70.8 0.39/0.34 77/67
8000 SRM 1937 Engine Specifications
5

7. Unit
Lifting and Lowering Speeds
90 cc/Rev
@2050 rpm
105 cc/Rev
@2050 rpm
120 cc/Rev
@2050 rpm
m/ sec ft/ min m/ sec ft/ min m/ sec ft/ min
Rated Load Rated Load Rated Load
H280HD2 2 STG NFL 0.36 70.8 0.41 80 0.42 82.7
H12XM 3 STG FFL
(2ND/FREE)
0.30/0.29 59/57 0.38/0.36 74.8/70.8 0.39/0.34 77/67
H300HD2 2 STG NFL 0.28 55 - - 0.34 66.9
3 STG FFL
(2ND/FREE)
0.25/0.24 49.2/47.2 - - 0.30/0.29 59/57
H13XM 2 STG NFL 0.28 55 - - 0.34 66.9
3 STG FFL
(2ND/FREE)
0.25/0.24 49.2/47.2 - - 0.30/0.29 59/57
H330HD2 2 STG NFL 0.28 55 - - 0.34 66.9
3 STG FFL
(2ND/FREE)
0.25/0.24 49.2/47.2 - - 0.30/0.29 59/57
H14XM 2 STG NFL 0.28 55 - - 0.34 66.9
3 STG FFL
(2ND/FREE)
0.25/0.24 49.2/47.2 - - 0.30/0.29 59/57
H360HD2 2 STG NFL 0.28 55 - - 0.34 66.9
3 STG FFL
(2ND/FREE)
0.25/0.24 49.2/47.2 - - 0.30/0.29 59/57
H16XM 2 STG NFL 0.28 55 - - 0.34 66.9
3 STG FFL
(2ND/FREE)
0.25/0.24 49.2/47.2 - - 0.30/0.29 59/57
H6XM-12EC 2 STG NFL - - - - 0.52 102.36
H360XM2-EC 2 STG NFL - - - - 0.52 102.36
H7XM-12EC 2 STG NFL - - - - 0.52 102.36
Tire Sizes
NOTE: Refer to Truck Nameplate for correct tire
pressure.
Model Tire Size Tire Pressure
H8.00-9.00XM-6 (H190-210HD2) 9.00 × 20-14 ply 900 kPa (130 psi)
H10.00-12.00XM-6 (H230-280HD2) 10.00 × 20-16 ply 900 kPa (130 psi)
H10.00-12.00XM-EC (H360HD2-EC) 12.00 × 20-16 ply 1000 kPa (145 psi)
H13-14XM-6 (H300-330HD2); H16XM-6
(H360HD2)
12.00 × 20-16 ply 1000 kPa (145 psi)
All Michelin XZM Radial Tires 1000 kPa (145 psi)
Mast Speeds 8000 SRM 1937
6

8. Hydraulic System
Item Quantity
Cummins Diesel Hydraulic Pump Capacity @ 2300 rpm
90 cc (3 oz) 196 liter/min (51.7 gal/min)
120 cc (4 oz) 262 liter/min (69.2 gal/min)
25 cc (0.8 oz)
Wet Brake Cooling Pump
57 liter/min (15.0 gal/min)
Relief Pressures *
Main Control Valve 22.5 MPa (3262.5 psi)
Steering Circuit 16 ±1 MPa (2320 ±145 psi)
*Oil temperature 20°C (68°F)
Torque Specifications, General
TRANSMISSION ZF
Nuts, Locking System Pressure Tubes Into
Rear Transmission Cover
42 N•m (31 lbf ft)
Screw, Holding Segment on Pressure Tubes
23 N•m (17 lbf ft)
Capscrews, Screen Into Front Transmission
Cover
23 N•m (17 lbf ft)
Capscrews, Tubes and Suction Tube Into
Front Transmission Cover
23 N•m (17 lbf ft)
Capscrews, Rear Transmission Cover to Front
Transmission Cover
4 N•m (34 lbf ft)
Capscrews, Output Flange to Transmission
Housing
34 N•m (25 lbf ft)
Capscrews, Torque Converter Bell Housing to
Transmission Housing
46 N•m (34 lbf ft)
Oil Fill Tube with Dipstick and Oil Drain
Plug
80 N•m (59 lbf ft)
Capscrews, Torque Converter Bell Housing to
Transmission Housing
46 N•m (34 lbf ft)
Capscrews, Transmission Oil Filter Head
23 N•m (21 lbf ft)
Capscrews, Torque Converter Housing to Fly-
wheel Housing
46 N•m (34 lbf ft)
Capscrews, Hydraulic Pumps to Transmis-
sion
25 N•m (18 lbf ft)
See the section Transmission Repair (ZF-
WG161) 1300SRM1456 for other torque values.
DRIVELINE AND AXLE
Capscrews, Universal Yoke
50 N•m (37 lbf ft)
Bolts, Axle to Frame
920 N•m (679 lbf ft)
COUNTERWEIGHT
Top Capscrews
1500 N•m (1106 lbf ft)
8000 SRM 1937 Tire Sizes
7

9. Rear Capscrews
1500 N•m (1106 lbf ft)
DIFFERENTIAL
See the section Drive Axle1400SRM1931.
BRAKES - WET
See the sections Brake and Hydraulic Cooling
System 1800SRM1933.
STEERING
Nut, Steering Wheel
68 N•m (50 lbf ft)
Capscrews, Steer Cylinder Mount
435 N•m (321 lbf ft)
Capscrews, Bearing Cap
75 N•m (55 lbf ft)
Nut, Wheel Bearing
Initial 203 N•m (150 lbf ft)
Final 34 N•m (25 lbf ft)
Note: Torque lock nut to Initial torque while
rotating wheel hub. Back off lock nut until wheel
hub turns freely with no end play. (Torque at
this point should be less than 27 N•m (20 lbf ft)).
Retorque to Final torque and lock in place at
first alignment position which occurs at or above
final torque spec.
Capscrews, Steer Axle Mount
270 N•m (199 lbf ft)
WHEEL NUTS
Drive Wheels (Final Torque Value)
615 to 710 N•m (454 to 524 lbf ft)
Steer Wheels (Final Torque Value)
615 to 710 N•m (454 to 524 lbf ft)
HYDRAULIC SYSTEM
Priority Valve (A)
217to 231 N•m (160 to 170 lbf ft)
Check Valve (K)
27 to 34 N•m (20 to 25 lbf ft)
Check Valve (L)
122 to 136 N•m (90 to 100 lbf ft)
Check Valve (Q)
9 to 12 N•m (7 to 9 lbf ft)
Shuttle Valves
26 to 30 N•m (34 to 40 lbf ft)
Full Flow Relief Valve (C) and (G)
217to 231 N•m (160 to 170 lbf ft)
Pilot Supply Valve (F)
45 to 50 N•m (33 to 37 lbf ft)
Load Sense Selector Valve (D)
35 to 40 N•m (26 to 30 lbf ft)
Coil Retaining Nut for Load Sense Selector
Valve (D)
4 to 6 N•m (35 to 53 lbf in)
Lift Pressure Selector Valve (B)
35 to 40 N•m (26 to 30 lbf ft)
Coil Retaining Nut for Lift Pressure Selector
Valve (B)
4 to 6 N•m (35 to 53 lbf in)
Solenoid Capscrews
6.3 N•m (56 lbf in)
Mount Capscrews
14 N•m (124 lbf in)
Pump Flangehead Screws
46 to 49 N•m (34 to 36 lbf ft)
Pump to Motor Capscrews
25 N•m (221 lbf in)
Torque Specifications, General 8000 SRM 1937
8

10. Suction Hose Adapter to Hydraulic Pump
91 to 100 N•m (67 to 74 lbf ft)
Pressure Line Fitting to Hydraulic Pump
49 to 59 N•m (36 to 44 lbf ft)
Counterbalance Valves
60 N•m (44.3 lbf ft)
MAST
Capscrews, Pivot Pin
435 N•m (321 lbf ft)
Capscrew, Bearing Block
9 N•m (7 lbf ft)
Capscrews, Bearing Block Bracket
44 N•m (32 lbf ft)
Nuts, Wear Plate
53 N•m (39 lbf ft)
Retainer, Lift Cylinder
H8-9XM-6 (H170-210HD2) 400 to 475 N•m
(295 to 350 lbf ft)
H10-12XM-6 (H230-280HD2) 475 to 550 N•m
(350 to 406 lbf ft)
H13-14XM-6 (H300-330HD2); H16XM-6
(H360HD2); H10-12XM-12EC (H360HD2-EC)
550 to 625 N•m (406 to 461 lbf ft)
CARRIAGE
Capscrew, Bearing Block
9 N•m (7 lbf ft)
Capscrews, Bearing Block Bracket
44 N•m (32 lbf ft)
Nut, Sideshift Cylinder Rod
675 N•m (498 lbf ft)
TILT CYLINDERS
Nut, Cylinder Rod
H13-14XM-6 (H300-330HD2); H16XM-6
(H360HD2); H10-12XM-12EC (H360HD2-EC)
949 to 983 N•m (700 to 725 lbf ft)
H13-16XM-6 (H300-360HD2) 1105 to 1140 N•m
(815 to 841 lbf ft)
Retainer
H8-12XM-6 (H170-280HD2) 542 to 610 N•m
(400 to 450 lbf ft)
H13-14XM-6 (H300-330HD2); H16XM-6
(H360HD2); H10-12XM-12EC (H360HD2-EC)
610 to 675 N•m (450 to 498 lbf ft)
Lock Nut, Rod End
66 N•m (49 lbf ft)
Capscrew, Pin Anchor
165 N•m (122 lbf ft)
WIPER ARMS, FRONT
Capscrews, Bracket to Cab
20 to 25 N•m (14.7 to 18.4 lbf ft)
Capscrews, Arm to Bracket
22 to 27 N•m (16.2 to 19.9 lbf ft)
Capscrews, Blade to Arm
8 to 10 N•m (6 to 7.4 lbf ft)
Capscrew, Arm Set
35 to 45 N•m (25.8 to 33.2 lbf ft)
Torque Specifications, Cummins Diesel
LUBRICATION SYSTEM
Plug, Oil Sump, Steel Oil Pan
80 N•m (59 lbf ft)
All other Torque Specifications are found in Cummins Engine Manual. Contact Cummins Engine for any
torque specifications not listed for this engine.
8000 SRM 1937 Torque Specifications, General
9

11. General
This manual contains the description and repair
procedures for the components of the planetary
gear drive axle and the drive shaft as equipped on
L007 and K019 series lift trucks. The main parts of
the drive axle include the differential, planetary
gear assembly, and the brake housings. The main
parts of the drive shaft are two universal joints and
a slip yoke. See Figure 1 and Figure 5.
Refer to the following resources for additional
information:
• Periodic Maintenance 8000SRM1939
• 2-Stage Mast 4000SRM1647
Before making repairs to the drive axle it is
important to put the lift truck on blocks.
Identification Plate
The exact axle model specification tag is located on
the axle housing. See Figure 2.
1. PLANETARY GEAR
2. SERVICE BRAKE
3. AXLE HOUSING
4. DIFFERENTIAL
5. PARKING BRAKE
Figure 1. Drive Axle
1400 SRM 1931 General
1

12. Figure 2. Planetary Drive Axle Identification
The AxleTech Model Number in the axle type plate
provides the exact specification of the axle and is as
follows:
Example:
P R C 48 5 W3H 123456
1) 2) 3) 4) 5) 6) 7)
1. P– Planetary
2. R– Rigid
3. C– Integral Cast
4. 48– Wheel End Designation (Model Number)
5. 5– Carrier Designation for Base Model
Number
6. W3H– Wet Disc Brake type
• W – Wet Disc Brake
• 3 – Housing Diameter (3 =
320 mm (13 in.)
• H – Hydraulic Actuation
7. 123456– Exact Specification
General 1400 SRM 1931
2

13. Description and Operation
DRIVE AXLE
Planetary Gear Assembly
The planetary gear assembly increases torque from
the axle shaft to the drive wheels. The axle shaft is
connected with the sun gear through splines. A
thrust button keeps the axle shaft secured at its lo-
cation. The sun gear is connected with three plane-
tary gears, which rotate on shafts that are installed
in the planetary gear carrier. The standard drive
axle has four planetary gears. All other drive axles
have six planetary gears. The planetary gears are
connected with the stationary ring gear. The ring
gear causes the planetary gear carrier to rotate
when the axle shaft turns. The planetary gear car-
rier and drive wheels are installed on the wheel
hub. See Figure 3.
The ring gear is connected with the ring gear hub.
The ring gear hub keeps the ring gear stationary
and supports the outer wheel bearing on the spin-
dle. The wheel bearing adjustment nut pushes
against the ring gear hub, providing the required
bearing pre-load.
The wheel hub rotates on two wheel bearings and
has a splined extension to the service brakes on
which the brake friction discs are installed. The oil
seal behind the inner wheel bearing keeps the gear
oil in the wheel hub separate from the brake cool-
ing oil. Brake cooling oil is retained by the toric
ring face seal between the wheel hub and brake
housing.
1400 SRM 1931 Description and Operation
3

14. 1. TORIC RING FACE SEAL
2. INNER BEARING
3. WHEEL STUD
4. OUTER BEARING
5. LOCK RING
6. RING GEAR HUB
7. NEEDLE ROLLER
8. SPACER
9. O-RING
10. SET SCREW
11. SUN GEAR THRUST WASHER
12. SUN GEAR
13. SNAP RING
14. THRUST BUTTON
15. PLANETARY GEAR SHAFT
16. SPIRAL RETAINING RING
17. MAGNETIC DRAIN PLUG
18. PLANETARY GEAR
19. RING GEAR
20. SPINDLE NUT
21. PLANETARY SPIDER
22. WHEEL HUB
23. O-RING
24. MACHINE SCREW
25. WET BRAKE DISC HOUSING
26. WET BRAKE PISTON HOUSING
27. SPINDLE
28. AXLE SHAFT
29. WEAR SLEEVE
30. OIL SEAL
Figure 3. Wheel End Cross Section
Description and Operation 1400 SRM 1931
4

15. Differential
The differential permits the left-hand and right-
hand drive wheels to rotate at a different speed.
The components of the differential are installed in
the differential carrier that is bolted in the drive
axle housing. Main components of the differential
are the ring gear and pinion, and the differential
case that contains two side gears and four differen-
tial pinions. See Figure 4.
Torque from the pinion is transferred to the ring
gear, which is attached to the differential case. The
differential case transfers torque through the dif-
ferential pinions to the side gears. Splines in the
side gears mesh with the drive shaft, and the drive
shaft transfers torque to the planetary gear assem-
blies. The pinion shaft is additionally supported by
a nose bearing. A thrust screw limits ring gear de-
flection in extreme situations.
Figure 4. Differential Cross-Section
Legend for Figure 4
1. TAPERED ROLLER BEARINGS
2. DIFFERENTIAL CARRIER
3. NOSE BEARING
4. SIDE GEAR
5. DIFFERENTIAL PINION
6. DRIVE AXLE HOUSING
7. AXLE SHAFT
8. RING GEAR
9. DRIVE PINION
10. DIFFERENTIAL CASE
DRIVE SHAFT
The drive shaft transfers power and torque from
the transmission to the drive axle. The drive shaft
includes two universal joints to bridge the different
axis of rotation of the transmission output shaft
and drive axle input shaft. The drive shaft slip yoke
allows changes in the drive shafts length. See Fig-
ure 5.
A seal prevents dirt from entering and retains
grease inside the bearing blocks and the slip yoke.
Lubricate the bearings and slip yoke periodically.
1. DRIVE AXLE
2. UNIVERSAL JOINT
3. SLIP YOKE
4. SPLINED STUB
5. TRANSMISSION
Figure 5. Drive Shaft
1400 SRM 1931 Description and Operation
5

16. Remove and Replace
PRECAUTIONS
Putting the Lift Truck on Blocks
WARNING
When putting the lift truck on blocks, make sure
the surface is solid, even, and level. Any blocks
used to support the lift truck must be solid, one-
piece units.
Before putting the lift truck on blocks, check the
presence of components, hoses or wires mounted
under the frame, to prevent damage to these
parts.
1. Place the lift truck on a solid, level surface.
2. Lower the carriage and forks, stop the engine,
and apply the parking brake.
3. Put blocks on each end (front and back) of the
steering tires to prevent movement of the lift
truck.
4. Put a jack under the drive axle and lift the
truck.
5. Put blocks under the frame behind the tires.
6. Lower the jack and move it away from the
truck. See Figure 6.
Figure 6. Putting Truck Front on Blocks
DRIVE SHAFT
Remove
CAUTION
The drive shaft for this truck is a two piece model,
consisting of a male splined drive shaft, a female
splined slip yoke and a universal joint on both
ends where it connects to the drive axle and
transmission.
Drive shafts are balanced and configured at the
time of manufacture. It is recommended that an
alignment mark is made on the drive shaft indicat-
ing the position of the universal joint and drive
shaft prior to removal.
During removal, it may be possible for the drive
shaft to split apart into two pieces. Reassemble
the drive shaft using the alignment mark made
prior to removal.
Incorrect assembly and/or install of the drive shaft
may lead to:
• Vibration of the drive shaft and/or truck
• Premature failure of the universal joints on
the drive shaft
• Excessive vibration levels in the transmis-
sion
• Excessive vibration levels in the drive axle.
NOTE: The drive shaft does not have to be re-
moved when repairing the wheel hub and only
needs to be removed when repairing the drive shaft
or the differential.
Use a marker of some type to indicate position and
orientation of drive shaft prior to removal.
1. Place the lift truck on a solid, level surface.
2. Apply the parking brake.
3. Lower the mast completely.
4. Tilt the mast completely forward.
Remove and Replace 1400 SRM 1931
6

17. 5. Shut down the engine.
6. Place blocks in front of and behind the tires to
prevent movement of the lift truck.
7. Raise (side tilt) the cab to the fully open posi-
tion to gain access to the drive shaft.
CAUTION
The drive shaft weighs approximately
25 kg (55 lb). Dents and damage to the drive shaft
can cause premature failure.
8. Place a pallet truck with a pallet underneath
the truck to support the drive shaft.
9. Attach a sling to each end of the drive shaft.
Use a lifting device to support the weight of the
drive shaft.
10. Remove the cap screws at each end of the drive
shaft that retain the universal joints to the
drive axle flange and transmission flange. If
needed, use a soft, rubber hammer to loosen the
universal joints from the mounting flanges. See
Figure 7.
11. Lower the drive shaft on the pallet.
12. Lower the pallet with the drive shaft and move
away from the truck.
1. DRIVE AXLE CONNECTION
2. CAP SCREW
3. SLIP YOKE
4. SPLINED STUB
5. UNIVERSAL JOINT
Figure 7. Drive Shaft Assembly
1400 SRM 1931 Remove and Replace
7

18. Disassemble
NOTE: If any component of the universal joint is
damaged or worn, the universal joint must be re-
placed as an assembly.
1. Remove the four cap screws at each universal
joint.
2. Repeat Step 1 for the remaining universal joint.
3. Make alignment marks on the drive shaft as-
sembly for correct alignment during assembly.
See Figure 8.
4. Separate the slip yoke from the splined stub by
sliding them apart.
1. DRIVE SHAFT ASSEMBLY
2. DRIVE SHAFT ALIGNMENT MARKS
Figure 8. Alignment Marks
Clean and Inspect
NOTE: Replace the universal joint if it fails any of
the following inspections.
1. Inspect the bearing seals for damage.
2. Rotate the universal joint back and forth,
checking the universal bearings for backlash or
irregular resistance. If there is any backlash or
irregular resistance, the universal joints must
be replaced.
NOTE: Replace the drive shaft if it fails any of the
following inspections.
3. Inspect the inner and outer splines of the slip
yoke and splined stub for damage.
4. Inspect for backlash when pushing back and
forth at the slip yoke. If there is any backlash
the drive shaft must be replaced.
5. Inspect the seal of the yoke for damage and
tears.
Remove and Replace 1400 SRM 1931
8

19. Assemble
1. Apply a thin coat of grease at the sealing area
of the slip yoke. See Figure 7.
CAUTION
DO NOT force the splines into each other as dam-
age can occur.
NOTE: Incorrect alignment may cause vibrations
during operation.
2. Align the splined stub and slip yoke and insert
the splined stub into the splines of the slip yoke
while aligning the alignment marks. See Fig-
ure 8.
3. Install the two universal joints with the cap
screws. Torque the cap screws to 120-130 N•m
(88.5-95.8 lbf ft).
4. Repeat Step 3 for the remaining universal joint.
Install
WARNING
Use caution when using lifting devices. When us-
ing a lifting strap, inspect the strap for damage
before use. DO NOT use a lifting strap to shock
load or drop load a component. Serious personal
injury and damage to components may occur.
CAUTION
The drive shaft weighs approximately
30 kg (66 lb). Dents or damage to the drive shaft
can cause premature failure.
1. Place the drive shaft in position at the under-
side of the lift truck.
2. Attach a sling to each end of the drive shaft.
Use a lifting device to raise the drive shaft into
place.
3. Apply Loctite 271 to the threads of the cap
screws.
4. Install the cap screws at each end of the drive
shaft that retain the universal joints to the
drive axle flange and transmission flange. Tor-
que the cap screws to 120 to 136 N•m (90 to
100 lbf ft).
5. Install the drive shaft catch.
6. Lower the cab until it is in the fully seated and
latched into position.
PLANETARY GEAR ASSEMBLY
NOTE: The parts of the planetary gear assembly
can be removed with the drive axle installed on the
lift truck.
1400 SRM 1931 Remove and Replace
9

20. 1. SPINDLE
2. FLAT WASHER
3. CAP SCREW
4. WEAR SLEEVE
5. WET DISC BRAKE (NOT SHOWN)
6. TORIC RING FACE SEAL ASSEMBLY
7. OIL SEAL ASSEMBLY
8. INNER BEARING CONE
9. INNER BEARING CUP
10. WHEEL HUB
11. O-RING
12. OUTER BEARING CUP
13. OUTER BEARING CONE
14. WHEEL STUD
15. RING GEAR
16. RING GEAR HUB
17. LOCK RING
18. SPINDLE NUT
19. SET SCREW
20. SUN GEAR THRUST WASHER
21. PLANETARY SUN GEAR
22. SNAP RING
23. PLANETARY GEAR SHAFT
24. NEEDLE ROLLERS
25. SPACER
26. PLANETARY PINION GEAR
27. THRUST PLATE
28. THRUST BUTTON
29. O-RING
30. PLANETARY SPIDER
31. MACHINE SCREW
32. MAGNETIC DRAIN PLUG
33. SPIRAL RETAINING RING
Figure 9. Planetary Gear Assembly
Remove and Replace 1400 SRM 1931
10

21. Planetary Spider
1. MACHINE SCREW
2. PLANETARY SPIDER
3. PLANETARY GEAR
4. MAGNETIC DRAIN PLUG
5. O-RING
6. SPIRAL RETAINING RING
7. PLANETARY PINION SHAFT
8. AXLE SHAFT THRUST WASHER
9. THRUST PLATE
10. NEEDLE ROLLERS
11. SPACER
Figure 10. Planetary Spider
1400 SRM 1931 Remove and Replace
11

22. Remove
WARNING
Use caution when using lifting devices. When us-
ing a lifting strap, inspect the strap for damage
before use. DO NOT use a lifting strap to shock
load or drop load a component. Serious personal
injury and damage to components may occur.
1. Put the lift truck on blocks. See Precautions,
Putting the Lift Truck on Blocks.
2. Remove the drive wheels. See Periodic Main-
tenance 8000SRM1939.
3. Put a drain pan under the planetary housing.
4. Rotate the hub to put the magnetic oil plug in
the lowest position.
5. Remove the magnetic oil plug and drain the oil.
See Figure 11.
1. OIL DRAIN PLUG
2. SLOTTED MACHINE SCREWS
Figure 11. Planetary Spider, Remove
6. Attach a lifting device to the planetary spider.
7. Remove the 3 slotted head machine screws that
attach the planetary spider to the hub.
8. Remove the planetary spider assembly from the
wheel hub and put it on a workbench. Rest the
spider with the large flange ending up.
Disassemble
1. If the original pinion shafts are reused, mark
the planetary pinion shafts and the planetary
spider to aid in reassembly. The slots in the
pinion shafts must face the outside of the hous-
ing to allow entry of the spiral retaining ring.
See Figure 12.
1. SPIRAL RETAINING RING
2. PLANETARY SPIDER
3. LARGE FLANGE
4. THRUST BUTTON
5. O-RING
6. THRUST WASHER
7. PLANETARY PINION GEAR
8. NEEDLE ROLLERS
9. SPACER
10. PINION SHAFT
11. PINION SHAFT SLOT
Figure 12. Planetary Spider Assembly
Remove and Replace 1400 SRM 1931
12

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24. 2. Place the planetary spider assembly on blocks
with the large flange end facing DOWN.
3. Remove the spiral retaining ring by lifting ex-
posed ring end with a screw driver and spira-
ling ring out from slot in pins. If removal is not
possible, the spiral retaining ring may be cut
into sections.
WARNING
Observe all warnings and cautions provided by
the press manufacturer to avoid damage to com-
ponents and serious personal injury.
Use a brass or leather mallet for assembly and
disassembly procedures. Do not hit steel parts
with a steel hammer. Pieces of a part can break
off and cause serious personal injury.
CAUTION
To avoid damage to the pinion shaft, provide a
soft cushioned area to receive pinion shaft when
it is removed from spider.
4. Use a press to remove pinion shafts out of the
spider. If a press is not available, use a brass
drift and mallet to drive out shaft. Press or
drive pinion shaft out toward large flange end
of the planetary spider.
5. Remove the planetary pinions and the thrust
plate from the planetary spider.
Inspect
Replace the axle shaft thrust button if it protrudes
insufficiently from the planetary spider. See Fig-
ure 13.
If axle shaft thrust button is removed, apply adhe-
sive material to the thrust button before placing it
into the spider.
Check the planetary pinions for wear and damage.
Pinions that are worn must be replaced.
A. AXLE SHAFT THRUST BUTTON WEAR
1. AXLE SHAFT THRUST BUTTON
2. PLANETARY SPIDER
3. SUN GEAR SNAP RING
4. SUN GEAR
5. AXLE SHAFT
Figure 13. Axle Shaft Thrust Button Wear
Assemble
WARNING
When applying silicone gasket materials, small
amounts of acid vapor are present. To prevent
possible serious injury, the work area must be
well ventilated. If the silicone gasket material gets
into the eyes, flush with water for 15 minutes.
Have eyes checked by a doctor as soon as possi-
ble.
1. Apply grease to the planetary pinion shafts.
2. Stick 33 needle rollers against the shaft on the
pinion flange.
3. Put a spacer on top of the needles.
4. Stick another 33 needle rollers against the
shaft on top of the spacer.
5. Install a planetary gear over the needle rollers.
1400 SRM 1931 Remove and Replace
13

25. 6. Install an O-ring on each pinion shaft.
7. Repeat Step 1 through Step 6 for the other
three pinion shafts.
8. Position the thrust plate in the planetary spi-
der.
9. Observe the correct position of the slot in the
planetary pinion shaft and insert the shafts
into the planetary gear.
10. Press each shaft into the planetary gear until
the top of the shafts align with the top of the
planetary spider housing.
Install
1. Attach a lifting device to the planetary spider.
2. Install the planetary spider assembly on the
wheel hub.
3. Install the 3 slotted head machine screws.
4. Make sure the magnetic oil plug is at the fill
position.
5. Remove the magnetic oil plug.
6. Fill the planetary spider with 4.4 liter (1.16 gal)
of oil.
7. Install the drive wheels. See Periodic Mainte-
nance 8000SRM1939.
1. SNAP RING
2. SUN GEAR
3. SUN GEAR THRUST WASHER
4. AXLE SHAFT
5. SET SCREW
6. SPINDLE NUT
7. PLANETARY RING GEAR
8. LOCK RING
9. PLANETARY RING GEAR HUB
10. OUTER BEARING
Figure 14. Planetary Sun Gear, Axle Shaft and Ring Gear Hub
Remove and Replace 1400 SRM 1931
14

26. Planetary Sun Gear, Axle Shaft and Ring Gear
Hub
Remove and Disassemble
1. Remove axle shaft, planetary sun gear, and
snap ring assembly. See Figure 14.
NOTE: The sun gear thrust washer may come out
with the axle shaft and sun gear assembly.
2. Remove the sun gear thrust washer from the
axle shaft or if necessary from the end of the
spindle. See Figure 15.
1. SNAP RING
2. PLANETARY SUN GEAR
3. THRUST WASHER
4. AXLE SHAFT
Figure 15. Axle Shaft Assembly
3. Remove the snap ring to allow removal of sun
gear from axle shaft.
4. Remove the lock ring.
5. Remove the set screw from the spindle nut and
remove the spindle nut. See Figure 16.
6. Remove the ring gear hub. The outer wheel
bearing cone will remain on the ring gear hub.
7. Remove the lock ring from the ring gear and
push the ring gear hub out of the ring gear.
8. If damaged, remove the outer wheel bearing
cone from the ring gear hub.
1. SET SCREW
2. SPINDLE NUT
3. LOCK RING
4. RING GEAR HUB
5. RING GEAR
6. OUTER WHEEL BEARING CONE
Figure 16. Ring Gear Hub Assembly
Inspect
Inspect the cup, cone, rollers and cage of the wheel
bearing.
If any of the following conditions exist, replace the
bearing:
• The centers of the large diameter end of the
rollers are worn level with or below the sur-
face. See Figure 17.
• The centers of the large diameter end of the
rollers are worn to a sharp edge.
1. WORN RADIUS 2. WORN SURFACE
Figure 17. Roller Large Diameter End Wear
1400 SRM 1931 Remove and Replace
15