service repair manual

1. SERVICE REPAIR
H40FT H50FT H60FT H70FT [L177]

2. 1400 SRM 1215 Drive Axle Removal
General
This manual covers the repair of the drive axle, dif-
ferential, and the wet disc brake.
IDENTIFICATION PLATE
See Figure 1.
1. CARRARO PART NUMBER 2. HYSTER PART NUMBER 3. CARRARO SERIAL NUMBER
Figure 1. Identification Plate
Drive Axle Removal
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.
1. Put blocks on each side (front and back) of the
steering tires to prevent movement of the lift
truck.
2. Raise the lift truck and put blocks under the
frame so that the drive wheels do not touch the
floor. Put blocks under the counterweight for
stability.
3. Remove the mast assembly as described in the
section Mast Repairs, 2, 3, and 4-Stage Masts
4000 SRM 1148.
WARNING
On lift trucks with pneumatic tires, completely
remove air from tires before removing them
from lift truck. Air pressure in tires can cause
tire and rim parts to explode, which can cause
serious injury or death. Never loosen nuts that
hold together inner and outer wheel halves
when there is air pressure in tire.
4. Remove the wheels.
5. Remove the oil fill/level plugs on both sides of the
drive axle. See Figure 2.
6. Remove the oil drain plug (LH) from the drive
axle to drain the oil from the left-hand side of the
drive axle into a suitable container. See Figure 2.
7. Remove the oil drain plug (RH and center sec-
tion) to drain the oil from the right-hand side
and center section of the drive axle into a suit-
able container. See Figure 2.
8. Remove the brake discs oil drain plug from the
drive axle to drain the brake oil into a suitable
container. See Figure 2.
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3. Drive Axle Removal 1400 SRM 1215
1. OIL FILL/LEVEL PLUG (LH)
2. OIL DRAIN PLUG (LH)
3. OIL BREATHER (LH)
4. OIL FILL/LEVEL PLUG (RH)
5. OIL DRAIN PLUG (RH AND CENTER SECTION)
6. OIL BREATHER (RH)
7. COOLING OIL INLET PORT
8. COOLING OIL OUTLET PORT
9. MASTER CYLINDER RELIEF PORT
10. SERVICE BRAKE INLET PORT
11. BRAKE DISCS OIL DRAIN PLUG
12. BRAKE OIL BLEEDER VALVE
Figure 2. Oil Fill Plugs and Drain Plugs
9. Remove the parking brake cable. Refer to the
section Brake System 1800 SRM 1135.
10. Disconnect the cooling inlet hose from the mani-
fold on top of the drive axle. See Figure 3.
11. Disconnect the brake inlet hose from the drive
axle. See Figure 3.
12. Disconnect the brake return hose from the drive
axle. See Figure 3.
13. Disconnect the cooling return hose from the man-
ifold on top of the drive axle. See Figure 3.
14. Place blocks under the axle assembly and con-
nect slings and lifting device.
15. Place blocks under the transmission to support
the transmission while removing the drive axle.
16. Remove the capscrews retaining the drive shaft
and remove the drive shaft.
17. Remove the transmission isolator mounting bolt
located on top of the assembly. See Figure 4.
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4. 1400 SRM 1215 Drive Axle Removal
A. DRIVE AXLE COOLING RETURN HOSE TO TRANSMISSION SUMP
1. HOSE CLAMP
2. BRAKE INLET HOSE
3. COOLING RETURN HOSE
4. BRAKE RETURN HOSE
5. COOLING INLET HOSE
Figure 3. Drive Axle Cooling Hoses and Brake Lines
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5. Drive Axle Removal 1400 SRM 1215
Figure 4. Transmission to Differential
Mounting Bolt
Legend for Figure 4
1. ISOLATORS
2. WASHER
3. WASHER
4. CAPSCREW
5. TRANSMISSION
6. DRIVE AXLE
18. Remove the four mounting capscrews and wash-
ers from the drive axle. See Figure 5.
19. Remove blocks and lower the drive axle assem-
bly. Pull axle forward and away from frame.
20. Place blocks under the differential assembly.
21. Disconnect the cooling outlet crossover hose from
the manifold and the drive axle and remove the
hose. See Figure 6.
22. If necessary, remove the capscrews retaining the
manifold to the center section of the drive axle
and remove the manifold. See Figure 6.
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6. 1400 SRM 1215 Drive Axle Removal
1. WASHER
2. CAPSCREW
3. TRUMPET ARM (LH)
4. TRUMPET ARM (RH)
Figure 5. Drive Axle Mounting Capscrews
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7. Drive Axle Removal 1400 SRM 1215
1. HOSE CLAMP
2. MANIFOLD
3. CAPSCREWS
4. CENTER SECTION
5. COOLING OUTLET CROSSOVER HOSE
Figure 6. Manifold and Cooling Outlet Crossover Hose
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8. 1400 SRM 1215 Reduction Gear Assembly
Reduction Gear Assembly
REDUCTION GEAR ASSEMBLY REPAIR
See Figure 7 and Figure 8.
1. PLUG
2. RETAINING NUT
3. LOCKWASHER
4. WASHER
5. WHEEL HUB
6. STUD
7. SEAL RING
8. TAPERED ROLLER BEARING
9. SPACER
10. SUPPORT
11. SOCKET-HEAD SCREW
12. O-RING
13. TAPERED ROLLER BEARING
14. RING GEAR
15. PLANETARY CARRIER
16. WASHER
17. PIN
18. NEEDLE BEARINGS
19. SPACER
20. REDUCTION GEAR
21. NEEDLE BEARINGS
22. WASHER
23. SNAP RING
24. DISK
Figure 7. Reduction Gear Assembly Left-Hand Side
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9. Reduction Gear Assembly 1400 SRM 1215
1. PLUG
2. RETAINING NUT
3. LOCKWASHER
4. WASHER
5. WHEEL HUB
6. STUD
7. SEAL RING
8. BEARING
9. SPACER
10. SUPPORT
11. SOCKET-HEAD SCREW
12. O-RING
13. BEARING
14. RING GEAR
15. PLANETARY CARRIER
16. WASHER
17. PIN
18. NEEDLE BEARINGS
19. SPACER
20. REDUCTION GEAR
21. NEEDLE BEARINGS
22. WASHER
23. SNAP RING
24. DISK
25. AXLE SHAFT
Figure 8. Reduction Gear Assembly Right-Hand Side
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10. 1400 SRM 1215 Reduction Gear Assembly
Remove
STEP 1.
Remove the plug using a prybar.
NOTE: Once the lockwasher has been flattened, a new lockwasher must be used.
STEP 2.
Flatten the lockwasher using a punch and hammer.
9

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12. Reduction Gear Assembly 1400 SRM 1215
CAUTION
Install two nuts or suitable plastic pipes on the studs to prevent damage to the threads of the studs
from the support bar.
STEP 3.
Install a support bar on the studs to hold the wheel
hub in place as shown. Using a torque multiplier,
loosen the reduction gear assembly retaining nut.
STEP 4.
Remove the socket-head screws fastening the reduc-
tion gear assembly to the wheel hub support.
STEP 5.
Remove the reduction gear assembly from the wheel
hub support.
10

13. 1400 SRM 1215 Reduction Gear Assembly
STEP 6.
Remove and discard the O-ring.
STEP 7.
Remove the ring gear.
1. AXLE SHAFT
2. RING GEAR
STEP 8.
Place the reduction gear assembly in a soft jawed vise
and lock the wheel hub. Remove the retaining nut.
1. RETAINING NUT
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14. Reduction Gear Assembly 1400 SRM 1215
STEP 9.
Remove the lockwasher.
1. LOCKWASHER
STEP 10.
Remove the washer.
1. WASHER
STEP 11.
Remove the planetary carrier from the wheel hub.
1. PLANETARY CARRIER
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15. 1400 SRM 1215 Reduction Gear Assembly
STEP 12.
Remove the snap rings.
1. SNAP RING
STEP 13.
Remove the pins with a punch and hammer as shown.
STEP 14.
Remove the reduction gears.
Remove the needle bearings, spacer, and washers
from each reduction gear.
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16. Reduction Gear Assembly 1400 SRM 1215
STEP 15.
Remove the disk from the planetary carrier.
1. PLANETARY CARRIER
2. DISK
STEP 16.
Remove the wheel hub from the support using a suit-
able extractor and special tool driver ( Hyster Part
Number 1641516). Refer to the section Special Tools.
1. SUPPORT
2. WHEEL HUB
STEP 17.
Remove the bearing cone.
1. BEARING CONE
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