Yale e216 erp060dh lift truck service repair manual by 163048

ERP040-060DH (E216) SERVICE MANUAL CONTENTS SECTION FRAME............................................................................................................................ DC MOTOR MAINTENANCE.......................................................................................... AC MOTOR MAINTENANCE.......................................................................................... DRIVE AXLE WET BRAKE............................................................................................ STEERING AXLE............................................................................................................ STEERING CONTROL UNIT.......................................................................................... STEERING SYSTEM...................................................................................................... BRAKE PEDAL AND LINKAGE..................................................................................... HYDRAULIC SYSTEM.................................................................................................... MAIN CONTROL VALVE................................................................................................ MAIN CONTROL VALVE E-CONTROLS....................................................................... CYLINDER REPAIR (MAST S/N A551, A555, A559, A661, A662, A663, A66, B507, B508, B509, B551, B555, B559, B562, B563, B564, B661, B662, B663, C515, C551, C555, C559, D507, D508, D509, D515, D562, D563, D564, E509, AND E564).......................................................................................................................... ELECTRICAL SYSTEM.................................................................................................. AC MOTOR CONTROLLER DESC/CHKS/ADJ/TRBSHT/REP&THEORY OF OPERATION/DISPLAY PANEL................................................................................. TROUBLESHOOTING AND ADJUSTMENTS USING THE AC CONTROLS PROGRAM................................................................................................................. INDUSTRIAL BATTERY................................................................................................. MAST - DESCRIPTION................................................................................................... MAST REPAIRS (S/N A551, A555, A559, A661, A662, A663, A664, B507, B508, B509, B551, B555, B559, B562, B563, B564, B661, B662, B663, C515, C551, C555, C559, D507, D508, D509, D515, D562, D563, D564, E509, AND E564)........ METRIC AND INCH (SAE) FASTENERS....................................................................... DIAGRAMS..................................................................................................................... PERIODIC MAINTENANCE............................................................................................ CAPACITIES AND SPECIFICATIONS........................................................................... PART NO. 524256684 (09/14)

PART NUMBER

YRM NUMBER

REV DATE

524256685 524158039 524183080 524256686 524158752 524158753 524183081 524264587 524179945 524179946 524256687

0100 YRM 1222 0620 YRM 0294 0620 YRM 1053 1400 YRM 1223 1600 YRM 0316 1600 YRM 0720 1600 YRM 1054 1800 YRM 1253 1900 YRM 0559 2000 YRM 0562 2000 YRM 1224

05/06 03/08 03/10 03/09 08/06 11/06 11/06 09/06 04/09 02/09 04/08

524223768 524183082

2100 YRM 1139 2200 YRM 1055

02/14 10/09

524183083

2200 YRM 1056

03/09

524183085 524158040 524158890

2200 YRM 1058 2240 YRM 0001 4000 YRM 0521

04/11 09/14 03/06

524223776 524150797 524256688 524256689 524256690

4000 YRM 1148 8000 YRM 0231 8000 YRM 1225 8000 YRM 1226 8000 YRM 1227

02/14 10/13 05/06 08/08 05/06

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 YALE 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 hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury and property damage. On the lift truck, the WARNING symbol and word are on orange background. The CAUTION symbol and word are on yellow background.

Drive Unit Assembly

Table of Contents

TABLE OF CONTENTS General................................................................................................................................................................ Description .......................................................................................................................................................... Wet Disc Brake Repair ........................................................................................................................................ Wet Disc Brakes.............................................................................................................................................. Remove....................................................................................................................................................... Inspect ........................................................................................................................................................ Install .......................................................................................................................................................... Gearbox Replacement......................................................................................................................................... Remove ........................................................................................................................................................... Gearbox Removal ....................................................................................................................................... Intermediate Flange Removal..................................................................................................................... Disassemble.................................................................................................................................................... Intermediate Flange.................................................................................................................................... Assemble ........................................................................................................................................................ Intermediate Flange.................................................................................................................................... Install............................................................................................................................................................... Intermediate Flange Installation.................................................................................................................. Gearbox Installation .................................................................................................................................... Drive Unit Removal.............................................................................................................................................. Main Housing Repair ........................................................................................................................................... Main Housing, Right-Hand Side...................................................................................................................... Remove....................................................................................................................................................... Disassemble ............................................................................................................................................... Clean and Inspect ....................................................................................................................................... Assemble .................................................................................................................................................... Install .......................................................................................................................................................... Main Housing, Left-Hand Side ........................................................................................................................ Remove....................................................................................................................................................... Disassemble ............................................................................................................................................... Clean and Inspect ....................................................................................................................................... Assemble .................................................................................................................................................... Install .......................................................................................................................................................... Differential Assembly Replacement..................................................................................................................... Remove ........................................................................................................................................................... Install............................................................................................................................................................... Traction Motor Repair .......................................................................................................................................... Remove ........................................................................................................................................................... Disassemble.................................................................................................................................................... Assemble ........................................................................................................................................................ Install............................................................................................................................................................... Drive Unit Installation........................................................................................................................................... Torque Specifications .......................................................................................................................................... Troubleshooting ...................................................................................................................................................

1 1 5 5 5 9 9 14 14 14 15 17 17 25 25 38 38 40 42 46 46 46 47 48 49 49 50 50 51 52 52 52 53 53 53 54 54 54 57 57 58 59 60

This section is for the following models: ERP20-30ALF (ERP040-060DH) [E216]

ÂŠ2009 Yale Materials Handling Corp.

1400 YRM 1223

Description

General This section has the description and repair procedures for the differential, drive axle, traction motor, and the wet disc brakes.

Description The drive unit consists of following main components (see Figure 1): • The traction motor with hollow shaft. • Mechanical differential assembly (located on left-hand side of traction motor shaft).

• The gearbox with intermediate flange, containing the wet disc brakes. • Main housings, containing the pistons for the wet disc brakes and the parking brake levers. • Speed sensor and reluctor wheel (located on traction motor shaft, see Figure 8).

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

7. 8. 9. 10. 11.

WHEEL HUB GEARBOX (LH) INTERMEDIATE FLANGE (LH) MAIN HOUSING (LH) PARKING BRAKE LEVER TRACTION MOTOR

MAIN HOUSING (RH) INTERMEDIATE FLANGE (RH) GEARBOX (RH) SPEED SENSOR DIFFERENTIAL ASSEMBLY

Figure 1. Drive Unit 1

Description

1400 YRM 1223

The drive unit assembly is fastened to the frame of the lift truck by the frame mounts of the main housings. See Figure 2.

The traction motor is mounted in between the two main housings. The traction motor generates the power to the differential assembly. See Figure 4.

The mast is mounted on the J-hook mountings of the main housings of the drive unit. See Figure 3.

1. FRAME MOUNTS Figure 2. Drive Unit Frame Mounts

1400 YRM 1223

Description

1. J-HOOK MOUNTINGS Figure 3. Mast Mounting Hooks

1. 2. 3. 4. 5.

WHEEL HUB PLANETARY GEAR INPUT SHAFT (RH) DRIVE GEAR AXLE SHAFT

6. 7. 8. 9. 10.

TRACTION MOTOR SHAFT DIFFERENTIAL ASSEMBLY DRIVE GEAR INPUT SHAFT (LH) SUN PINION

11. 12. 13. 14. 15.

DRIVEN GEAR BRAKE DISC PACK DISC PUSHER PISTON PARK BRAKE LEVER

Figure 4. Drive Unit

Description

1400 YRM 1223

The differential then transfers the power through the axle shaft to the input shafts located in the intermediate flange assemblies. The input shaft drive gears transfer the power to the driven gears. The driven gears then transfer the power to the sun pinion. See Figure 5.

1. 2. 3. 4.

PLANETARY CARRIER PLANETARY GEARS RING GEAR WHEEL HUB Figure 6. Planetary Gears

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

DRIVE GEAR INTERMEDIATE FLANGE INPUT SHAFT AXLE SHAFT DRIVEN GEAR SUN PINION

Figure 5. Drive Gear, Driven Gear, and Sun Pinion The sun pinion then transfers the power to the planetary gears and planetary carrier which then engages the wheel hubs. See Figure 6. The wet brake discs are mounted on the intermediate flanges. The piston, which is located in the main housing (one in each main housing), is activated when the brake pedal is applied. The piston presses against the disc pusher which compresses the brake friction discs and steel discs which causes the braking. See Figure 7.

1. INTERMEDIATE FLANGE 2. DISC PUSHER 3. BRAKE DISC PACK Figure 7. Brake Disc Pack

1400 YRM 1223

Wet Disc Brake Repair

The parking brake levers press against the back of the piston which forces the piston to press against the disc pusher to compress the brakes friction discs and steel discs to mechanically apply the parking brake. The speed sensor is mounted on the main housing on the right-hand side of the drive unit. The reluctor wheel is mounted on the traction motor shaft on the right-hand side of the traction motor. The speed sensor is a hall effect sensor which reads the variation in its magnetic field when a tooth of the reluctor wheel passes the sensor. See Figure 8.

1. SPEED SENSOR 2. RELUCTOR WHEEL Figure 8. Speed Sensor and Reluctor Wheel

Wet Disc Brake Repair WET DISC BRAKES For replacement of the pistons and piston seals, refer to the section Main Housing Repair.

Remove STEP 1. Remove the gearbox. Refer to the section Gearbox Replacement. STEP 2. Press down on the disc pusher device and remove the retaining rings from the studs.

Wet Disc Brake Repair

1400 YRM 1223

STEP 3. Remove the disc pusher device from the studs.

1. DISC PUSHER DEVICE 2. STUDS STEP 4. Remove the springs from the studs. If necessary, remove the studs.

1400 YRM 1223

Wet Disc Brake Repair

1. STUDS 2. SPRINGS STEP 5. Note the position of the notches on the steel discs for correct positioning during assembly. Remove one steel disc.

1. STEEL DISC 2. NOTCH

Wet Disc Brake Repair

1400 YRM 1223

STEP 6. Remove the one friction disc.

1. FRICTION DISC STEP 7. Remove four springs/spacers.

1. SPRINGS/SPACERS

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Wet Disc Brake Repair

STEP 8. Repeat STEP 5 through STEP 7 until the last steel disc is removed. STEP 9. Remove the aluminum reaction disc.

Inspect 1. Inspect the brake friction discs and brake steel discs. The discs must be measured as a pack (6 steel discs and 5 friction discs) to determine if the discs need replaced. Replace discs as a pack when the thickness is less than 23 mm (0.91 in.). A new disc pack will have a thickness of 23.95 to

24.45 mm (0.94 to 0.96 in.). When replacing the disc pack, all springs must also be replaced. 2. Inspect the aluminum reaction disc. Replace the aluminum reaction disc when the thickness is equal or less than 4.5 mm (0.18 in.). A new aluminum reaction disc will have a thickness of 4.95 to 5.05 mm (0.195 to 0.199 in.).

Install STEP 1. If removed, install the four pins.

Wet Disc Brake Repair

1400 YRM 1223

STEP 2. If removed, apply LoctiteÂŽ 242 to the studs and install the studs. Tighten the studs to 2 Nâ&#x20AC;˘m (17.7 lbf in).

STEP 3. Install the aluminum reaction disc.

NOTE: The first and last disc installed must be a smooth steel disc. STEP 4. Align the notch of the steel disc as noted during disassembly. Install one steel disc.

1. NOTCH

1400 YRM 1223

Wet Disc Brake Repair

STEP 5. Install one friction disc.

STEP 6. Install four springs/spacers.

STEP 7. Repeat STEP 4 through STEP 6 until six steel discs and five frictions discs have been installed.

Wet Disc Brake Repair

1400 YRM 1223

STEP 8. Install the springs onto the studs.

1. STUDS 2. SPRINGS STEP 9. Install the disc pusher device onto the studs.

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Wet Disc Brake Repair

1. DISC PUSHER DEVICE 2. STUDS STEP 10. Press down on the disc pusher device and install the retaining rings into the seats on the studs.

STEP 11. Install the gearbox. Refer to the section Gearbox Replacement.

Gearbox Replacement

1400 YRM 1223

Gearbox Replacement REMOVE Gearbox 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.

10. Place a sling connected to an overhead lift around the gearbox and wheel hub assembly and apply light tension to the sling. 11. Remove the socket-head screws retaining the gearbox to the main housing. Note the positions of the short and long socket-head screws for when the gearbox is installed. See Figure 10. 12. Remove the gearbox and wheel hub assembly.

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 YRM 1148. 4. Disconnect the battery connector. 5. Remove the wheel from the wheel hub of the gearbox being replaced. 6. Remove the gearbox oil fill plug. See Figure 9. 7. Remove the gearbox magnetic drain plug to drain the oil from the gearbox into a suitable container. See Figure 9. 8. Remove the brake oil fill/breather plug from main housing. See Figure 9. 9. Remove the brake oil drain plug to drain the oil from the main housing into a suitable container. See Figure 9.

1. 2. 3. 4.

BRAKE OIL FILL/BREATHER PLUG GEARBOX OIL FILL PLUG GEARBOX OIL DRAIN PLUG (MAGNETIC) BRAKE OIL DRAIN PLUG Figure 9. Oil Refill and Drain Plugs

1400 YRM 1223

Gearbox Replacement Legend for Figure 10 1. M8 SOCKET-HEAD SCREWS, 3 EACH 2. M12 X 1.75 X 70 MM LONG SOCKET-HEAD SCREWS, 11 EACH 3. M12 X 1.75 X 40 MM SHORT SOCKET-HEAD SCREWS, 2 EACH

Figure 10. Gearbox Removal/Installation

Intermediate Flange Removal STEP 1. Remove the brake discs and friction plates. Refer to the section Wet Disc Brake Repair. STEP 2. For the left-hand side gearbox only, remove the spacer from the input shaft.

Gearbox Replacement

1400 YRM 1223

STEP 3. Remove the socket-head screws used to retain the intermediate flange to the gearbox housing. Insert a prybar into the pry slots between the intermediate flange and the gearbox housing and pry upwards to break the seal between the flange and housing.

1. SOCKET-HEAD SCREWS 2. PRY SLOTS

1400 YRM 1223

Gearbox Replacement

STEP 4. Remove the intermediate flange assembly from the gearbox housing.

DISASSEMBLE Due to the requirement of specialized tools and equipment (which most service departments do not

possess) to properly service this gearbox, it is highly recommended to replace rather than rebuild this assembly.

Intermediate Flange NOTE: If the inner ring for the needle bearing is being replaced, the needle bearing in the gearbox housing must be replaced. STEP 1. Using an appropriate puller, remove the needle bearing from the gearbox housing.

1. GEARBOX 2. NEEDLE BEARING

Gearbox Replacement

1400 YRM 1223

STEP 2. Remove the snap ring retaining the input shaft into the intermediate flange.

1. SNAP RING 2. INPUT SHAFT

1400 YRM 1223

Gearbox Replacement

STEP 3. Using plastic or hard rubber hammer, tap the input shaft, on the gear side, with drive gear and bearing out of the intermediate flange.

1. INTERMEDIATE FLANGE 2. INPUT SHAFT ASSEMBLY STEP 4. Remove the retaining ring from the input shaft.

Gearbox Replacement

1400 YRM 1223

STEP 5. Place a cylinder on the press workbench as shown. Cylinder dimensions: • Inside diameter - 41 mm (1.61 in.) • Outside diameter - 62 mm (2.44 in.) • Height - minimum 130 mm (5.12 in.)

STEP 6. Place the input shaft assembly with drive gear side up on the cylinder. Place a cylinder (solid shaft) on top of the input shaft and use a press to press the input shaft out of the needle bearing inner ring, the drive gear, and the bearing. Cylinder dimensions: • Diameter - maximum 18.5 mm (0.73 in.) • Height - minimum 45 mm (1.77 in.)

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

CYLINDER NEEDLE BEARING INNER RING DRIVE GEAR BEARING CYLINDER WORKBENCH

1400 YRM 1223

Gearbox Replacement

STEP 7. Remove the square key from the input shaft.

1. 2. 3. 4. 5.

NEEDLE BEARING INNER RING DRIVE GEAR BEARING SQUARE KEY INPUT SHAFT

Gearbox Replacement

1400 YRM 1223

STEP 8. Remove the snap ring from the sun pinion.

1. DRIVEN GEAR 2. SNAP RING 3. SUN PINON

1400 YRM 1223

Gearbox Replacement

STEP 9. Place the intermediate flange on a cylinder with the gear side up and the sun pinion inserted into the cylinder. Using a press, carefully press the sun pinion out of the intermediate flange. Cylinder Dimensions: • Inside diameter - 92 mm (3.62 in.) • Outside diameter - 130 mm (5.12 in.)

1. DRIVEN GEAR 2. INTERMEDIATE FLANGE 3. SUN PINION STEP 10. Remove the square key from the sun pinion.

1. SQUARE KEY 2. SUN PINION

Gearbox Replacement

1400 YRM 1223

STEP 11. Remove the snap ring retaining the bearing in the intermediate flange.

1. SNAP RING 2. INTERMEDIATE FLANGE 3. BEARING STEP 12. Using a press, remove the bearing from the intermediate flange.

1. INTERMEDIATE FLANGE 2. BEARING

1400 YRM 1223

Gearbox Replacement

ASSEMBLE

Intermediate Flange STEP 1. Place a cylinder on the press workbench. Cylinder Dimensions: • Inside diameter - 39.5 mm (1.56 in.) • Outside diameter - 95 mm (3.74 in.) • Height - 55 mm (2.17 in.)

STEP 2. Place the intermediate flange on the cylinder as shown.

Gearbox Replacement STEP 3. Place the bearing in position in the flange.

STEP 4. Position a flanged sleeve on the bearing. Flanged sleeve dimensions: â&#x20AC;˘ Outside diameter - 79 mm (3.11 in.)

STEP 5. Using a press, press the bearing into the intermediate flange.

1400 YRM 1223

Gearbox Replacement

STEP 6. Install the snap ring to retain the bearing.

STEP 7. Position the sun pinion on the cylinder. Cylinder Dimensions: • Inside diameter - 39.5 mm (1.56 in.) • Outside diameter - 95 mm (3.74 in.) • Height - 55 mm (2.17 in.)

STEP 8. Position a cylinder on the inner ring of the bearing as shown. Cylinder Dimensions: • Inside diameter - 42.5 mm (1.67 in.) • Outside diameter - 61 mm (2.4 in.) • Height - minimum 85 mm (3.35 in.)

Gearbox Replacement STEP 9. Using a press, press on the inner ring of the bearing until the sun pinion is fully seated in the intermediate flange and bearing.

STEP 10. Install the square key in the slot of the sun pinion.

WARNING Hot parts. Wear protective clothing and gloves to prevent burns. STEP 11. Heat the driven gear to approximately 100 to 120 C (212 to 248 F). Position the driven gear on the sun pinion and align the slot in the driven gear with the square key on the sun pinion.

1400 YRM 1223

Gearbox Replacement

STEP 12. Place a cylinder over the sun pinion onto the driven gear as shown. Cylinder Dimensions: • Inside diameter - 42.5 mm (1.67 in.) • Outside diameter - 61 mm (2.4 in.) • Height - minimum 85 mm (3.35 in.)

STEP 13. Using a press, press the driven gear onto the sun pinon until the driven gear is fully seated.

Gearbox Replacement

1400 YRM 1223

STEP 14. Install the snap ring onto the sun pinion to retain the driven gear.

1. DRIVEN GEAR 2. SNAP RING 3. SUN PINON

1400 YRM 1223

Gearbox Replacement

STEP 15. Place a cylinder on the press workbench as shown. Cylinder dimensions: • Inside diameter - 25.5 mm (1.004 in.) • Outside diameter - 34 mm (1.34 in.) • Height - minimum 50 mm (1.97 in.)

STEP 16. Place the input shaft bearing on the cylinder.

STEP 17. Install the square key into the slot on the input shaft.

Gearbox Replacement

1400 YRM 1223

STEP 18. Insert the input shaft into the bearing.

NOTE: Right-hand side input shaft shown.

NOTE: Left-hand side input shaft shown. STEP 19. Using a press, press the input shaft into the bearing.

1400 YRM 1223

Gearbox Replacement

STEP 20. Apply a coat of oil, use gear lube 80W or gear oil SAE 80W-90 or equivalent, to the end of the input shaft as shown.

STEP 21. Place the drive gear on the cylinder as shown. Cylinder dimensions: • Inside diameter - 25.5 mm (1.004 in.) • Outside diameter - 34 mm (1.34 in.) • Height - 150 mm (5.9 in.)

STEP 22. Insert the input shaft into the drive gear while aligning the slot in the drive gear with the square key on the input shaft.

Gearbox Replacement STEP 23. Using a press, press the input shaft into the drive gear until the input shaft is fully seated against the drive gear.

STEP 24. Place the inner ring of the needle bearing in position on the input shaft.

STEP 25. Place a cylinder in position on the inner ring for the needle bearing. Using a press, press the inner ring onto the input shaft until the inner ring is fully seated against the drive gear. Cylinder dimensions: • Inside diameter - 20.3 mm (0.80 in.) • Outside diameter - 25 mm (0.98 in.) • Height for inside diameter end - minimum 20 mm (0.79 in.)

1400 YRM 1223

Gearbox Replacement

STEP 26. Install the retaining ring.

STEP 27. Verify the retaining ring is fully seated.

STEP 28. Place the input shaft assembly in position in the intermediate flange.

Gearbox Replacement STEP 29. Place a cylinder over the input shaft assembly as shown. Cylinder dimensions: • Inside diameter - 42 mm (1.65 in.) • Outside diameter - 60 mm (2.36 in.) • Height for inside diameter end - 120 mm (4.72 in.)

STEP 30. Using a hard plastic or rubber hammer, tap the input shaft assembly into the intermediate flange.

STEP 31. Install the snap ring to retain the input shaft assembly into the intermediate flange.

1400 YRM 1223

Gearbox Replacement

STEP 32. Apply a coat of oil, use gear lube 80W or gear oil SAE 80W-90 or equivalent, to the housing of the input shaft needle bearing.

STEP 33. Insert the needle bearing into the housing. Using a hard plastic or rubber hammer, tap the needle bearing into the housing until it is fully seated.

Gearbox Replacement

INSTALL

Intermediate Flange Installation STEP 1. Apply sealant (Yale Part Number 580074175) to the mating surface of the gearbox housing.

STEP 2. Place the intermediate flange assembly in position on the gearbox housing. Using a hard plastic or rubber hammer, tap the intermediate flange assembly down to the gearbox housing until it is fully seated against the gearbox housing mating surface.

1400 YRM 1223

Gearbox Replacement

STEP 3. If removed, install the alignment pins into the intermediate flange and gearbox housing.

STEP 4. Apply LoctiteÂŽ 242 to the threads of the socket-head screws used to retain the intermediate flange to the gearbox housing. Install the socket-head screws and tighten to 40 Nâ&#x20AC;˘m (29.5 lbf ft).

Gearbox Replacement STEP 5. For the left-hand side gearbox only, install the spacer on the input shaft.

STEP 6. Install the brake discs and friction plates. Refer to the section Wet Disc Brake Repair.

Gearbox Installation 1. Apply sealant (Yale Part Number 580074175) to the mating surface of the intermediate flange and drive unit main housing as shown in Figure 11.

1. SEALANT (YALE PART NUMBER 580074175) Figure 11. Intermediate Flange and Main Housing Sealing Surfaces

1400 YRM 1223

Gearbox Replacement

2. Place a sling connected to an overhead lift around the new gearbox and wheel hub assembly and place the assembly in position onto the main housing. 3. On the RH side gearbox only, apply multipurpose grease to the splined socket. 4. Apply Loctite® 242 to the socket-head screws used to retain the gearbox to the main housing. 5. Install the socket-head screws in the positions noted in Remove, Step 11. 6. Tighten the three M8 socket-head screws (item 1, Figure 10) to 40 N•m (29.5 lbf ft). 7. Tighten the M12 socket-head screws (items 2 and 3, Figure 10) to 80 N•m (59 lbf ft).

9. Clean and install the gearbox magnetic drain plug and tighten to 18 to 23 N•m (13.3 to 16.96 lbf ft). See Figure 9. 10. Remove the oil level/check plugs for the brake chamber and the gearbox. See Figure 12. NOTE: Wait 5 to 10 minutes after fill to allow oil to lubricate parts within the brake chambers and top off the brake oil. 11. Add oil, use John Deere JDM J20C, to the brake chamber until the oil level check port has overflowed. NOTE: Wait 5 to 10 minutes after fill to allow oil to lubricate parts within the gearbox chambers and top off gearbox.

8. Install the brake oil drain plug and tighten to 18 to 23 N•m (13.3 to 16.96 lbf ft). See Figure 9.

12. Add oil, use gear lube 80W or gear oil SAE 80W-90 or equivalent, to the gearbox chamber until the oil check port has overflowed.

A. AXLE TOP VIEW

B. AXLE BOTTOM VIEW

1. BRAKE OIL FILL PLUG (BREATHER) 2. BRAKE OIL DRAIN PLUG 3. BRAKE OIL LEVEL/CHECK PLUG

4. GEARBOX OIL FILL PLUG 5. GEARBOX OIL DRAIN PLUG 6. GEARBOX OIL LEVEL/CHECK PLUG

Figure 12. Gearbox Oil and Brake Oil Replacement

Drive Unit Removal

1400 YRM 1223

13. Install the brake oil fill plug/breather and tighten to 15 N•m (11 lbf ft). 14. Install the brake oil level/check plug and tighten to 18 to 23 N•m (13.3 to 16.96 lbf ft). 15. Install the gearbox oil fill plug and tighten to 7 N•m (62 lbf in). 16. Install the gearbox oil level/check plug and tighten to 18 to 23 N•m (13.3 to 16.96 lbf ft). 17. Install the wheel on the wheel hub of the gearbox replaced. Tighten wheel nuts to 155 to 175 N•m (114 to 166 lbf ft).

18. Connect the battery connector. 19. Install the mast assembly as described in the section Mast Repairs, 2, 3, and 4-Stage Masts 4000 YRM 1148. 20. Raise the lift truck and remove blocks from under frame and from under the counterweight. Lower the lift truck. 21. Remove the blocks on each side (front and back) of the steering tires. 22. Operate the lift truck and check for proper operation and leaks.

Drive Unit 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.

10. Remove the brake oil drain plug to drain the oil from the main housing into a suitable container. See Figure 13.

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 YRM 1148. 4. Disconnect the battery connector. 5. Remove the wheels. 6. Remove the parking brake cables. Refer to the section Brake Pedal and Linkage 1800 YRM 1253. 7. Remove the gearbox oil fill plug. See Figure 13. 8. Remove the gearbox magnetic drain plug to drain the oil from the gearbox into a suitable container. See Figure 13. 9. Remove the brake oil fill/breather plug from main housing. See Figure 13.

1. 2. 3. 4.

BRAKE OIL FILL/BREATHER PLUG GEARBOX OIL FILL PLUG GEARBOX OIL DRAIN PLUG (MAGNETIC) BRAKE OIL DRAIN PLUG Figure 13. Oil Refill and Drain Plugs

1400 YRM 1223

Drive Unit Removal

11. Repeat Step 7 through Step 10 on the other side of the drive unit.

terminal block and disconnect the electrical cables. See Figure 15.

12. Disconnect the brake lines from the drive unit. See Figure 14.

16. Place blocks under the drive unit and connect slings and lifting device.

13. Disconnect the electrical connector from the speed sensor. See Figure 15.

17. Remove the bolts, washers, and nuts retaining the drive unit to the frame. See Figure 16.

14. Disconnect the electrical connector from the traction motor.

18. Remove blocks and lower the drive unit. Pull drive unit forward and away from frame.

15. Tag the electrical cables connecting to the traction motor. Remove the nuts retaining the cables to the

19. Place blocks under the drive unit.

1. BRAKE LINE (RH)

2. BRAKE LINE (LH) Figure 14. Drive Unit Brake Lines

Drive Unit Removal

1. 2. 3. 4.

1400 YRM 1223

ELECTRICAL CABLE NUT TRACTION MOTOR ELECTRICAL CONNECTOR SPEED SENSOR ELECTRICAL CONNECTOR Figure 15. Speed Sensor and Traction Motor Electrical Connectors

1400 YRM 1223

1. NUT

Drive Unit Removal

2. WASHER

3. BOLT

Figure 16. Drive Unit Mounting Bolts and Nuts

Main Housing Repair

1400 YRM 1223

Main Housing Repair MAIN HOUSING, RIGHT-HAND SIDE Remove 1. Remove the gearbox. See Gearbox Replacement. 2. Slide the axle shaft out of the drive unit from the right-hand side of the drive unit. See Figure 17.

1. MAIN HOUSING (LH) 2. TRACTION MOTOR 3. SOCKET-HEAD SCREW

3. Place a sling connected to an overhead lift around the main housing (RH) and apply light tension to the sling. 4. Remove the socket-head screws retaining the main housing (RH) to the traction motor and remove the main housing (RH). See Figure 18.

4. MAIN HOUSING (RH) 5. AXLE SHAFT Figure 17. Axle Shaft Removal

1400 YRM 1223

Main Housing Repair

1. TRACTION MOTOR 2. RELUCTOR WHEEL

3. MAIN HOUSING (RH) 4. SOCKET-HEAD SCREW (14 EACH) Figure 18. Main Housing (RH) Removal/Installation

Disassemble 1. Pulling the parking brake lever, push the piston out of the brake disc side of the main housing. See Figure 19. 2. Remove the gaskets and O-rings (items 4, 5, 6, and 7 in Figure 19) from the piston housing.

4. Remove the socket-head screw retaining the speed sensor and remove the speed sensor. See Figure 19. 5. Remove the socket-head screw retaining the parking brake lever in the main housing (RH) and remove the parking brake lever. See Figure 20.

3. Remove the seal from the main housing (RH). See Figure 19.

Main Housing Repair

1. 2. 3. 4. 5.

1400 YRM 1223

SOCKET-HEAD SCREW SPEED SENSOR MAIN HOUSING (RH) O-RING GASKET

6. 7. 8. 9.

O-RINGS GASKET PISTON SEAL

Figure 19. Main Housing (RH)

Clean and Inspect WARNING Cleaning solvents can be flammable and toxic and can cause skin irritation. When using cleaning solvents, always follow the recommendations of the manufacturer.

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

Make sure that the path of the compressed air is away from all personnel. Wear protective goggles or a face shield to prevent injury to the eyes. Clean the parts of the main housing with solvent and dry with compressed air. Inspect all machined surfaces of the main housing and the piston for wear and damage. Parts that are damaged must be replaced.

1400 YRM 1223

Main Housing Repair 4. Bend and insert the second small gasket over the O-ring in the groove. Verify that the gasket completely covers the O-ring. See Figure 19. 5. Insert the two large O-rings in the first groove. Verify the O-rings are seated properly. See Figure 19. NOTE: The lip on the internal side of the gasket faces the traction motor side. 6. Bend and insert the large gasket over the O-rings in the groove. Verify that the gasket completely covers both O-rings. See Figure 19. 7. Lubricate the piston with John Deere JDM J20C. 8. Insert the piston into the housing from the brake disc side of the main housing until it is fully inserted. See Figure 19.

1. PARKING BRAKE LEVER 2. MAIN HOUSING (RH) 3. SOCKET-HEAD SCREW Figure 20. Parking Brake Lever Removal/ Installation

Assemble NOTE: Always use new O-rings, gaskets, and seals when assembling the main housing. 1. Insert the first small O-ring in the back groove of the piston housing. Verify the O-ring is seated properly. See Figure 19. NOTE: The lip on the internal side of the gasket faces the disc brakes side. 2. Bend and insert the first small gasket over the O-ring in the back groove. Verify that the gasket completely covers the O-ring. See Figure 19. 3. Insert the second small O-ring in the next groove of the piston housing. Verify the O-ring is seated properly. See Figure 19.

9. Place the parking brake lever in position in the main housing (RH) and install the socket-head screw to retain the parking brake lever in the housing. Tighten the socket-head screw to 40 N•m (29.5 lbf ft). See Figure 20. 10. Place the seal in position in the main housing (RH). Using a seal driver, drive the seal into the housing until the seal is fully seated. See Figure 19. 11. Install the speed sensor into the main housing (RH). Install the socket-head screw to retain the speed sensor and tighten the socket-head screw to 5 N•m (44 lbf in). See Figure 19.

Install 1. Place a sling connected to an overhead lift around the main housing and place the main housing in position onto the traction motor. 2. Install the socket-head screws to secure the main housing to the traction motor. Tighten the sockethead screws to 40 N•m (29.5 lbf ft). See Figure 18. 3. Slide the axle shaft into the drive unit from the righthand side of the drive unit. See Figure 17. 4. Install the gearbox. See Gearbox Replacement.

NOTE: The lip on the internal side of the gasket faces the disc brakes side.

Main Housing Repair

1400 YRM 1223

MAIN HOUSING, LEFT-HAND SIDE Remove 1. Remove the gearbox. See Gearbox Replacement. 2. Place a sling connected to an overhead lift around the main housing (LH) and apply light tension to the sling.

1. TRACTION MOTOR 2. DIFFERENTIAL

3. Remove the socket-head screws retaining the main housing (LH) to the traction motor and remove the main housing (LH). See Figure 21. 4. Remove and discard the two O-rings from the main housing (LH). See Figure 22.

3. MAIN HOUSING (RH) 4. SOCKET-HEAD SCREW (14 EACH) Figure 21. Main Housing (LH) Removal/Installation

1400 YRM 1223

Main Housing Repair Legend for Figure 22 1. O-RING 2. O-RING 3. MAIN HOUSING (LH)

Disassemble 1. Pulling the parking brake lever, push the piston out of the brake disc side of the main housing (LH). See Figure 23. 2. Remove the gaskets and O-rings (items 2, 3, 4, and 5 in Figure 23) from the piston housing.

Figure 22. Main Housing (LH) O-rings

1. MAIN HOUSING (LH) 2. O-RING

3. GASKET 4. O-RINGS

5. GASKET 6. PISTON

Figure 23. Main Housing (LH)

Main Housing Repair 3. Remove the socket-head screw retaining the parking brake lever in the main housing (LH) and remove the parking brake lever. See Figure 24.

1400 YRM 1223

Assemble NOTE: Always use new O-rings, gaskets, and seals when assembling the main housing. 1. Insert the first small O-ring in the back groove of the piston housing. Verify the O-ring is seated properly. See Figure 23. NOTE: The lip on the internal side of the gasket faces the disc brakes side. 2. Bend and insert the first small gasket over the O-ring in the back groove. Verify that the gasket completely covers the O-ring. See Figure 23. 3. Insert the second small O-ring in the next groove of the piston housing. Verify the O-ring is seated properly. See Figure 23. NOTE: The lip on the internal side of the gasket faces the disc brakes side. 4. Bend and insert the second small gasket over the O-ring in the groove. Verify that the gasket completely covers the O-ring. See Figure 23.

1. MAIN HOUSING (LH) 2. PARKING BRAKE LEVER 3. SOCKET-HEAD SCREW Figure 24. Parking Brake Lever (LH) Removal/Installation

Clean and Inspect

5. Insert the two large O-rings in the first groove. Verify the O-rings are seated properly. See Figure 23. NOTE: The lip on the internal side of the gasket faces the traction motor side. 6. Bend and insert the large gasket over the O-rings in the groove. Verify that the gasket completely covers both O-rings. See Figure 23. 7. Lubricate the piston with John Deere JDM J20C.

WARNING Cleaning solvents can be flammable and toxic and can cause skin irritation. When using cleaning solvents, always follow the recommendations of the manufacturer.

WARNING Compressed air can move particles so that they cause injury to the user or to other personnel. Make sure that the path of the compressed air is away from all personnel. Wear protective goggles or a face shield to prevent injury to the eyes. Clean the parts of the main housing with solvent and dry with compressed air. Inspect all machined surfaces of the main housing and the piston for wear and damage. Parts that are damaged must be replaced.

8. Insert the piston into the housing from the brake disc side of the main housing until it is fully inserted. See Figure 23. 9. Place the parking brake lever in position in the main housing (LH) and install the socket-head screw to retain the parking brake lever in the housing. Tighten the socket-head screw to 40 Nâ&#x20AC;˘m (29.5 lbf ft). See Figure 24.

Install 1. Place new O-rings in proper grooves on the main housing (LH). See Figure 22. 2. Place a sling connected to an overhead lift around the main housing and place the main housing in position onto the traction motor.

1400 YRM 1223

Differential Assembly Replacement

3. Install the socket-head screws to secure the main housing to the traction motor. Tighten the sockethead screws to 40 Nâ&#x20AC;˘m (29.5 lbf ft). See Figure 21.

4. Install the gearbox. See Gearbox Replacement.

Differential Assembly Replacement REMOVE

INSTALL

NOTE: Do not disassemble the differential assembly. The differential assembly cannot be repaired and must be replaced as an assembly.

1. Slide the differential assembly onto the splines of the traction motor shaft and the axle shaft. See Figure 25.

1. Remove the gearbox from the left-hand side of the drive unit. See Gearbox Replacement.

2. Install the main housing onto the left-hand side of the traction motor. See Main Housing, Left-Hand Side, Install.

2. Remove the main housing from the left-hand side of the traction motor. See Main Housing, Left-Hand Side, Remove.

3. Install the gearbox onto the left-hand side of the drive unit. See Gearbox Replacement.

3. Slide the differential assembly off the splines of the traction motor shaft and the axle shaft. See Figure 25.

1. TRACTION MOTOR 2. TRACTION MOTOR SHAFT

3. DIFFERENTIAL ASSEMBLY 4. AXLE SHAFT Figure 25. Differential Removal

Traction Motor Repair

1400 YRM 1223

Traction Motor Repair REMOVE 1. Remove the gearbox from the right-hand side of the drive unit. See Gearbox Replacement. 2. Remove the main housing from the right-hand side of the traction motor. See Main Housing, RightHand Side, Remove. 3. Remove the gearbox from the left-hand side of the drive unit. See Gearbox Replacement. 4. Remove the main housing from the left-hand side of the traction motor. See Main Housing, Left-Hand Side, Remove. 5. Remove the differential assembly. See Differential Assembly Replacement.

DISASSEMBLE 1. Remove the seal from inside the hollow end of the left-hand side traction motor shaft. See Figure 26.

1. 2. 3. 4. 5.

TORX-HEAD SCREWS TERMINAL BLOCK NUT ELECTRICAL CABLE SEAL Figure 27. Terminal Block

4. Remove the snap ring from the left-hand side traction motor shaft. See Figure 26. 5. Remove the socket-head screws retaining the lefthand side traction motor end plate and remove the end plate with seal. See Figure 28.

1. TRACTION MOTOR SHAFT 2. SNAP RING 3. SEAL Figure 26. Seal and Snap Ring 2. Remove the nuts retaining the electrical cables to the terminal block and disconnect the electrical cables. See Figure 27. 3. Remove the torx-head screws retaining the terminal block to the traction motor and remove the terminal block. See Figure 27.

1. SOCKET-HEAD SCREW 2. END PLATE 3. TRACTION MOTOR Figure 28. Left-Hand Side End Plate

1400 YRM 1223

Traction Motor Repair

6. If necessary, remove the seal for the electrical cables. See Figure 29.

CAUTION Do not damage the sealing surface of the traction motor shaft when removing the bearing. 8. Using an appropriate bearing puller, remove the bearing from the left-hand side traction motor shaft. See Figure 31.

1. SEAL 2. TRACTION MOTOR Figure 29. Electrical Cable Seal 7. Remove the seal from the end plate. See Figure 30. 1. 2. 3. 4.

BEARING TRACTION MOTOR SHAFT TRACTION MOTOR SEALING SURFACE Figure 31. Left-Hand Side Bearing

9. Loosen the setscrew in the reluctor wheel located on the right-hand side of the traction motor shaft. See Figure 32. 10. Using a puller, remove the reluctor wheel. See Figure 32. 11. Remove the socket-head screws retaining the righthand side traction motor end plate and remove the end plate with spring. See Figure 33. 12. Remove and discard spring. See Figure 34.

1. SEAL 2. END PLATE

13. Using an appropriate bearing puller, remove the bearing from the right-hand side traction motor shaft. See Figure 35.

Figure 30. Left-Hand Side End Plate Seal

Traction Motor Repair

1. FLAT SPOT ON TRACTION MOTOR SHAFT 2. SETSCREW 3. RELUCTOR WHEEL

1400 YRM 1223

1. SPRING 2. END PLATE Figure 34. End Plate Spring

Figure 32. Reluctor Wheel

1. TRACTION MOTOR 2. END PLATE 3. SOCKET-HEAD SCREW Figure 33. Right-Hand Side End Plate

1. TRACTION MOTOR 2. TRACTION MOTOR SHAFT 3. BEARING Figure 35. Right-Hand Side Bearing

1400 YRM 1223

ASSEMBLE 1. Install the new bearing onto the right-hand side traction motor shaft. See Figure 35. 2. Place a new spring in the right-hand side traction motor end plate. See Figure 34. 3. Apply Loctite 243 to the threads of socket-head screws used to retain the end plate. 4. Place the right-hand side traction motor end plate in position on the traction motor and install the socket-head screws to retain the end plate. Tighten the socket head screws to 45 to 58 N•m (33.2 to 42.8 lbf ft). See Figure 33. 5. Align the hole for the setscrew in the reluctor wheel with the flat spot on the traction motor shaft and press the reluctor wheel onto the traction motor shaft. See Figure 32. 6. Tighten the setscrew to 4.7 to 5.3 N•m (41.6 to 46.9 lbf in). See Figure 32. 7. Install the new bearing onto the left-hand side traction motor shaft. See Figure 31. 8. Install a new seal into the left-hand side end plate. See Figure 30. 9. If removed, install the seal for the electrical cables. See Figure 29. 10. Apply Loctite 243 to the threads of socket-head screws used to retain the end plate.

CAUTION Do not damage the seal when assembling the traction motor end plate on the traction motor shaft.

Traction Motor Repair See Figure 31. Place the left-hand side traction motor end plate in position on the traction motor and install the socket-head screws to retain the end plate. Tighten the socket head screws to 45 to 58 N•m (33.2 to 42.8 lbf ft). See Figure 28. 12. Install the snap ring onto the left-hand side traction motor shaft. See Figure 26. 13. Place the terminal block in position on the traction motor and install the torx-head screws to retain the terminal block. Tighten the torx-head screws to 0.73 to 1.02 N•m (6.50 to 9.03 lbf in). See Figure 27. 14. Connect the electrical cables to the terminal block and install nuts to retain cables. See Figure 27. 15. Apply a thin coat of multipurpose grease to the inner lip of the seal and install the seal into the hollow end of the left-hand side traction motor shaft. See Figure 26.

INSTALL 1. Install the differential assembly. See Differential Assembly Replacement. 2. Install the main housing onto the left-hand side of the traction motor. See Main Housing, Left-Hand Side, Install. 3. Install the gearbox onto the left-hand side of the drive unit. See Gearbox Replacement. 4. Install the main housing onto the right-hand side of the traction motor. See Main Housing, Right-Hand Side, Install. 5. Install the gearbox onto the right-hand side of the drive unit. See Gearbox Replacement.

11. Apply a thin coat of multipurpose grease to the sealing surface of the left-hand side traction motor shaft.

Drive Unit Installation

1400 YRM 1223

Drive Unit Installation 1. Connect slings and lifting device to drive unit. NOTE: When installing the drive unit, ensure the drive unit is held with the upper surface of the drive unit against the frame. This will prevent any gap between the frame and the drive unit mount, and will ensure even weight distribution. See Figure 36. 2. Position the drive unit in the lift truck.

7. Connect the brake lines to the drive unit. See Figure 14. 8. Install the brake oil drain plug and tighten to 18 to 23 N•m (13.3 to 16.96 lbf ft). See Figure 9. 9. Clean and install the gearbox magnetic drain plug and tighten to 18 to 23 N•m (13.3 to 16.96 lbf ft). See Figure 9. 10. Remove the oil level/check plugs for the brake chamber and the gearbox. See Figure 12. NOTE: Wait 5 to 10 minutes after fill to allow oil to lubricate parts within the brake chambers and top off brake oil. 11. Add oil, use John Deere JDM J20C, to the brake chamber until the oil level check port has overflowed. NOTE: Wait 5 to 10 minutes after fill to allow oil to lubricate parts within the gearbox chambers and top off gearbox. 12. Add oil, use gear lube 80W or gear oil SAE 80W-90 or equivalent, to the gearbox chamber until the oil check port has overflowed. 13. Install the brake oil fill plug/breather and tighten to 15 N•m (11 lbf ft).

A. THE TOP SURFACE OF THE DRIVE UNIT SHOULD BE IN CONTACT WITH THE HANGER WHEN THE MOUNTING BOLTS ARE TIGHTENED. Figure 36. Drive Unit Mounting NOTE: It is recommended to use a torque multiplier to achieve the torque specification in Step 3. 3. Install the four mounting bolts, washers, and nuts. Tighten the bolts and nuts to 820 to 902 N•m (605 to 665 lbf ft). See Figure 16. 4. Connect the electrical cables to the traction motor terminal block. Install the nuts to retain the cables to the terminal block and tighten to 21 to 25 N•m (15.5 to 18.4 lbf in). See Figure 15.

14. Install the brake oil level/check plug and tighten to 18 to 23 N•m (13.3 to 16.96 lbf ft). 15. Install the gearbox oil fill plug and tighten to 7 N•m (62 lbf in). 16. Install the gearbox oil level/check plug and tighten to 18 to 23 N•m (13.3 to 16.96 lbf ft). 17. Repeat Step 8 through Step 16 on the opposite side. 18. Install the parking brake cables. Refer to the section Brake Pedal and Linkage 1800 YRM 1253. 19. Install the wheels. Tighten wheel nuts to 155 to 175 N•m (114 to 166 lbf ft).

5. Connect the electrical connector to the traction motor. See Figure 15.

20. Connect the battery connector.

6. Connect the electrical connector to the speed sensor. See Figure 15.

21. Remove the air from the brake system as described in the section Brake Pedal and Linkage 1800 YRM 1253.

1400 YRM 1223

Torque Specifications

22. Install the mast assembly as described in the section Mast Repairs, 2, 3, and 4-Stage Masts 4000 YRM 1148. 23. Raise the lift truck and remove blocks from under frame and from under the counterweight. Lower the lift truck.

24. Remove the blocks on each side (front and back) of the steering tires. 25. Operate the lift truck and check for proper operation and leaks.

Torque Specifications Brake Oil Drain Plug 18 to 23 N•m (13.3 to 16.96 lbf ft) Brake Oil Fill Plug/Breather 15 N•m (11 lbf ft) Brake Oil Level/Check Plug 18 to 23 N•m (13.3 to 16.96 lbf ft) Disc Pusher Studs 2 N•m (17.7 lbf in) Drive Unit Mounting Bolts and Nuts 820 to 902 N•m (605 to 665 lbf ft) Gearbox to Main Housing Socket-head Screws M8 40 N•m (29.5 lbf ft) M12 80 N•m (59 lbf ft) Gearbox Magnetic Drain Plug 18 to 23 N•m (13.3 to 16.96 lbf ft) Gearbox Oil Fill Plug 7 N•m (62 lbf in) Gearbox Oil Level/Check Plug 18 to 23 N•m (13.3 to 16.96 lbf ft)

Intermediate Flange to Gearbox Socket-head Screws 40 N•m (29.5 lbf ft) Main Housing to Traction Motor Socket-head Screws 40 N•m (29.5 lbf ft) Parking Brake Lever Socket-head Screw 40 N•m (29.5 lbf ft) Reluctor Wheel Setscrew 4.7 to 5.3 N•m (41.6 to 46.9 lbf in) Speed Sensor Socket-head Screw 5 N•m (44 lbf in) Terminal Block Electrical Cable Retaining Nuts 21 to 25 N•m (15.5 to 18.4 lbf in) Terminal Block Torx-head Screws 0.73 to 1.02 N•m (6.50 to 9.03 lbf in) Traction Motor End Plate Socket-head Screws 45 to 58 N•m (33.2 to 42.8 lbf ft) Wheel Nuts 155 to 175 N•m (114 to 166 lbf ft)

Troubleshooting

1400 YRM 1223

Troubleshooting PROBLEM

POSSIBLE CAUSE

PROCEDURE OR ACTION

Truck moves slow or in a jerky motion.

Speed sensor detects no pulses.

Replace speed sensor.

Traction motor fails to operate.

There is an inter-turn short circuit (between different phases) or there is a bad crimp of the bundle of wires to the terminal block or a circuit interruption.

Measure the resistance between two terminals (U-V, V-W or W-U). The resistance should be 5.2 milliohm with a measuring current of 1.00 A and accurately measure 5.2 mV.

The lift truck will not move.

An axle shaft is broken.

Install new axle shaft.

An input shaft is damaged or broken.

Install new input shaft.

The differential is damaged.

Replace differential.

Sun pinion is damaged.

Install a new sun pinion.

Reduction gears are damaged.

Install new gearbox assembly.

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

Replace copper Repair threads. washer. Tighten plug. Install missing part.

The O-rings or seals have damage.

Install new O-rings and seals.

Main housing is cracked.

Install a new main housing.

The bearings have damage.

Install new parts.

The brake assembly is damaged.

Repair brake assembly.

The oil level is low.

Fill as required. Check for leaks.

The drive unit mounting capscrews are loose.

Tighten capscrews to specified torque.

Reducer gears are damaged.

Install new gearbox assembly.

The drive axle has leaks.

The drive axle makes noise.

1600 YRM 316

Description

General This section has the description and repair procedures for the steering axle. See the following sections for additional information on the parts of the steering system: Steering Housing and Control Unit and Hydraulic System.

Description The steering axle assembly includes an axle frame, steering cylinder, and two spindle and hub assemblies. See Figure 1. The steering axle is connected to the frame with center pivot mounts. The center pivot mounts on the axle frame are fastened to the lift truck frame with rubber mounts. The steering axle can make an articulated motion and gives the lift truck a smoother travel over rough surfaces. The end caps of the steering cylinder are also the mounts for the cylinder and are held to the shell by the mount capscrews. O-rings, seals, and wipers in the end caps are used to keep the oil inside the steering

1. SPINDLE AND HUB ASSEMBLY 2. AXLE FRAME 3. BRACKET

cylinder. The ends of the piston rod extend from both ends of the cylinder. A single piston and the seal are at the center of the rod. Oil pressure on one side of the piston moves the piston in the bore. When the piston moves in the bore, it pushes an equal amount of oil from the opposite end of the cylinder. This oil returns to the steering control unit. When the piston reaches the end of the stroke, a relief valve controls the oil pressure so the components are not damaged. Tie rods connect the spindle arms to the cylinder.

4. RUBBER MOUNT 5. STEERING CYLINDER 6. NUT AND BOLT Figure 1. Steering Axle

Steering Axle Assembly Repair Each spindle turns on two tapered roller bearings. The spindle and bearings are held in the axle frame by a kingpin. The preload on the bearings is controlled by a threaded nut on the bottom of the kingpin.

1600 YRM 316 The wheel or hub rotates on two tapered roller bearings and is held on the spindle by a castle nut. The preload on the bearings in the hub is adjusted by the castle nut. A grease seal in the inner hub and a hub cap protect the bearings from dirt and water. A wear sleeve in the inner hub protects the hub from wear by the seal.

Steering Axle Assembly Repair REMOVE WARNING PUTTING THE LIFT TRUCK ON BLOCKS The lift truck must be put on blocks for some types of maintenance and repair. The removal of the following assemblies will cause large changes in the center of gravity: drive axle, battery, or counterweight. When the lift truck is put on blocks, put additional blocks in the following positions: 1. If the mast and drive axle are removed, put blocks under the counterweight so the lift truck cannot fall backward. 2. If the battery (electric lift trucks) or counterweight is removed, put blocks under the mast so the lift truck cannot fall forward.

2. Disconnect hydraulic lines at steering cylinder. Install caps on cylinder and put plugs in hydraulic lines. The caps will prevent spindles from turning when axle is removed from under lift truck. 3. Slide a floor jack or forks of another lift truck under steering axle. Raise lifting device until it holds the weight of the axle assembly. Remove four capscrews and nuts that fasten two brackets under rubber mounts. Remove brackets and slowly lower axle assembly onto wheels. Carefully roll axle assembly from under lift truck.

INSTALL 1. Install rubber mounts on axle. Make sure the PART NO. on the mounts is right side up and facing away from axle frame.

Put the lift truck on blocks on a solid, even, and level surface. Make sure the blocks of stands have enough capacity to hold the lift truck. Use additional blocks next to the tires as necessary to prevent movement of the lift truck. Make sure the lifting devices used during repairs can lift the weight of the parts and assemblies.

2. Apply a lubricant that is approved for use with rubber to rubber mount. The lubricant is used where the rubber mount fits into the frame brackets.

NOTE: The steering axle assembly without the wheels weighs approximately 115 kg (250 lb).

4. Install bottom brackets. Tighten four bracket capscrews and nuts to 88 Nâ&#x20AC;˘m (65 lbf ft).

The steering axle can be removed without removing the counterweight. If necessary, remove counterweight as described in the Frame section.

5. Remove plugs and caps and connect hydraulic lines to steering cylinder.

1. Make sure wheels are set for straight travel. Put lift truck on blocks so steering axle can be removed. The top of the axle frame must have clearance under the counterweight so the steering axle can be removed. See Figure 1.

3. Use a floor jack or another lift truck to put steering axle into position in frame. Make sure rubber mounts fit inside frame brackets for mounts.

6. Operate steering system to remove air from system. Turn steering wheel several times from one stop to the other stop. Check for hydraulic leaks.

1600 YRM 316

Wheels and Hubs Repair

Wheels and Hubs Repair REMOVE AND DISASSEMBLE WARNING PUTTING THE LIFT TRUCK ON BLOCKS The lift truck must be put on blocks for some types of maintenance and repair. The removal of the following assemblies will cause large changes in the center of gravity: drive axle, battery, or counterweight. When the lift truck is put on blocks, put additional blocks in the following positions: 1. If the mast and drive axle are removed, put blocks under the counterweight so the lift truck cannot fall backward. 2. If the battery (electric lift trucks) or counterweight is removed, put blocks under the mast so that the lift truck cannot fall forward. Put the lift truck on blocks on a solid, even, and level surface. Make sure the blocks of stands have enough capacity to hold the lift truck. Use additional blocks next to the tires as necessary to prevent movement of the lift truck. Make sure the lifting devices used during repairs can lift the weight of the parts and assemblies.

WARNING Completely deflate the tires before removing them from the lift truck. Air pressure in the tires can cause the tire and rim parts to explode, causing serious injury or death. Never loosen the nuts that hold the inner and outer wheel halves together when there is air pressure in the tire. 1. Put axle on blocks so tires are raised from floor. Remove grease cap. Remove cotter pin and castle nut. Remove outer bearing cone. Slide wheel from spindle. Remove inner bearing cone and seal from spindle. See Figure 2.

2. If the wheel bearings must be replaced, use a brass drift to remove bearing cups and wear sleeve. 3. Repeat procedure for other wheel.

CLEAN WARNING Cleaning solvents can be flammable and toxic and can cause skin irritation. When using cleaning solvents, always follow the solvent manufacturer’s recommended safety procedures. Clean all parts with solvent. Make sure bearings are clean.

ASSEMBLE AND INSTALL CAUTION Do not damage the seals during installation. 1. If wheel bearings must be replaced, use a press to install new bearing cups in wheel or hub. See Figure 2. Install new wear sleeve in wheel or hub. Install grease seal on spindle. Lubricate bearing cones with grease. Make sure bearings are filled with grease. Install bearing cone on spindle. 2. Carefully slide wheel or hub onto spindle. Install outer bearing cone. 3. Install castle nut. Tighten castle nut to 200 N•m (150 lbf ft) while wheel is rotated. Loosen nut to less than 27 N•m (20 lbf ft). Tighten nut to 34 N•m (25 lbf ft). If cotter pin cannot be installed with nut tightened to 34 N•m (25 lbf ft), tighten castle nut until cotter pin can be installed. Install cotter pin. 4. Repeat procedure for other wheel.

Wheels and Hubs Repair

1600 YRM 316

NOTE: GP2.00-3.00RF/TF (GP040-060RG/TG/ZG) SHOWN, OTHERS SIMILAR. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.

AXLE FRAME WASHER BOLT BELLEVILLE WASHER RUBBER MOUNT BRACKET NUT STEERING CYLINDER PIN SNAP RING BUSHING TIE ROD GREASE FITTING CASTLE NUT SLEEVE

16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29.

SEAL BEARING CONE BEARING CUP SPINDLE SPACER O-RING KINGPIN GROOVE PIN WEAR SLEEVE HUB* STUD* WHEEL NUT* COTTER PIN GREASE CAP

*PNEUMATIC TIRES ONLY Figure 2. Steering Axle

1600 YRM 316

Spindles, Bearings, and Tie Rods Repair

Spindles, Bearings, and Tie Rods Repair REMOVE

If cotter pin cannot be installed with nut tightened to 34 N•m (25 lbf ft), tighten castle nut until cotter pin can be installed. Install cotter pin.

WARNING PUTTING THE LIFT TRUCK ON BLOCKS The lift truck must be put on blocks for some types of maintenance and repair. The removal of the following assemblies will cause large changes in the center of gravity: drive axle, battery, or counterweight. When the lift truck is put on blocks, put additional blocks in the following positions: 1. If the mast and drive axle are removed, put blocks under the counterweight so the lift truck cannot fall backward. 2. If the battery (electric lift trucks) or counterweight is removed, put blocks under the mast so the lift truck cannot fall forward. Put the lift truck on blocks on a solid, even, and level surface. Verify the blocks of stands have enough capacity to hold the lift truck. Use additional blocks next to the tires as necessary to prevent movement of the lift truck. Verify the lifting devices used during repairs can lift the weight of the parts and assemblies. NOTE: Dirt and corrosion can make the spacer difficult to remove from the steering axle frame. A machined space is made in the top of the spacer so that the spacer can be removed with a bearing puller. Remove wheel or hub from steering axle spindle. See Figure 3. Remove pin to disconnect tie rod from spindle. Remove cotter pin and castle nut from bottom of kingpin. Use a driver to remove kingpin. Remove sleeve and then spindle from axle. Use a driver to remove bearings and seals from spindle.

INSTALL 1. Use new bearings and seals. See Figure 2 and Figure 3. Apply grease to bearings and kingpin as they are installed in axle. Install bearings in spindle. Install seals in correct position. Align spindle in axle and install kingpin. Make sure new O-ring is installed at top of kingpin. Install sleeve on bottom of kingpin. Install castle nut and tighten it to 90 N•m (66 lbf ft). Loosen castle nut to less than 34 N•m (25 lbf ft). Tighten nut to 34 N•m (25 lbf ft).

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

O-RING KINGPIN GROOVE PIN SPACER SEAL BEARING CONE BEARING CUP

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

SPINDLE SEAL WEAR SLEEVE CASTLE NUT COTTER PIN GREASE CAP SLEEVE

Figure 3. Spindle Assembly 2. Connect tie rods. Verify belleville washers are installed on both sides of bushings. 3. Install wheels or hubs. See the section Wheels and Hubs Repair for proper installation procedure. Tighten wheel nuts to 237 to 305 N•m (175 to 225 lbf ft).

Steering Cylinder Repair

1600 YRM 316

Steering Cylinder Repair REMOVE AND DISASSEMBLE WARNING PUTTING THE LIFT TRUCK ON BLOCKS The lift truck must be put on blocks for some types of maintenance and repair. The removal of the following assemblies will cause large changes in the center of gravity: drive axle, battery, or counterweight. When the lift truck is put on blocks, put additional blocks in the following positions: 1. If the mast and drive axle are removed, put blocks under the counterweight so the lift truck cannot fall backward. 2. If the battery (electric lift trucks) or counterweight is removed, put blocks under the mast so the lift truck cannot fall forward. Put the lift truck on blocks on a solid, even, and level surface. Make sure the blocks of stands have

1. ROD 2. WIPER 3. END CAP

enough capacity to hold the lift truck. Use additional blocks next to the tires as necessary to prevent movement of the lift truck. Make sure the lifting devices used during repairs can lift the weight of the parts and assemblies. NOTE: The end caps of the steering cylinder are held in the shell by the cylinder mount capscrews. To prevent oil leaks at the caps, hold caps on shell during removal. 1. Disconnect hydraulic lines at steering cylinder. See Figure 4. Install caps in fittings on cylinders and put caps on hydraulic lines. 2. Remove snap rings from pins in tie rods. Remove pins. 3. Remove capscrews or nuts and bolts that fasten cylinder to axle frame. Hold end caps on shell and remove steering cylinder.

4. O-RING 5. BACKUP RING 6. SHELL Figure 4. Steering Cylinder

7. PISTON SEAL 8. ROD SEAL 9. QUADRANT RING

1600 YRM 316

Torque Specifications

4. Hold end of steering cylinder over drain pan. Remove cap for hydraulic fitting from each end cap. Push rod toward end of shell that is over drain pan. Oil will drain from cylinder. Repeat procedure for other end. 5. Carefully slide one end cap from shell. Carefully pull cylinder rod and piston from shell. Keep cylinder rod aligned in center of shell during removal so parts are not damaged. Remove end cap from rod. Remove other end cap from shell. Remove all seals, wipers, and O-rings.

CLEAN AND INSPECT WARNING Cleaning solvents can be flammable and toxic and can cause skin irritation. When using cleaning solvents, always follow the solvent manufacturer’s recommended safety procedures. 1. Clean all parts in solvent. 2. Inspect piston rod for grooves or damage. Remove small scratches with fine emery cloth. Inspect cylinder bore for damage. Inspect mounts for cracks.

ASSEMBLE AND INSTALL

CAUTION Do not damage the O-rings, seals, or wipers during installation. 2. Lubricate O-rings, seals, and wipers with O-ring lubricant and install them in end caps. Install one end cap on cylinder rod. 3. Carefully slide cylinder rod and piston into shell. Keep cylinder rod aligned in center of shell during installation so parts are not damaged. Carefully slide end cap into shell. Carefully install other end cap on rod and shell. Put caps on hydraulic fittings of end caps. 4. Hold end caps and install cylinder on axle frame using capscrews or nuts and capscrews. Tighten capscrews to 225 N•m (166 lbf ft). 5. Install tie rods between cylinder and spindles. Make sure belleville washers are on each side of the bushings in the tie rods. Install pins and snap rings. 6. Remove caps and connect hydraulic lines to steering cylinder. Operate steering system to remove air from cylinder and hydraulic system. Turn steering wheel several times from one stop to the other.

1. Put seals and wipers in warm hydraulic oil. Install quadrant ring and piston seal as shown in Figure 4.

Torque Specifications Steer Axle Mount Bracket Hardware 88 N•m (65 lbf ft)

Wheel Nuts 237 to 305 N•m (175 to 225 lbf ft)

Wheel/Hub Nut Initial Torque 200 N•m (150 lbf ft) Final Torque 34 N•m (25 lbf ft)

Steer Cylinder Mount Hardware 225 N•m (166 lbf ft)

Kingpin Nut Initial Torque 90 N•m (66 lbf ft) Final Torque 34 N•m (25 lbf ft)

Troubleshooting

1600 YRM 316

Troubleshooting PROBLEM There is no action when the steering wheel is turned.

The lift truck steers slowly. The steering wheel is hard to turn.

The steering wheel turns the tires in the wrong direction.

POSSIBLE CAUSE

PROCEDURE OR ACTION

There is no oil or not enough oil in the hydraulic tank.

Fill tank to correct level.

The lines are loose at the control unit or manifold block.

Tighten fittings.

The sleeve and spool in the control unit will not move.

Repair steering control unit.

Steering cylinder leaks.

Repair steering cylinder.

Spacer for center pin is not installed.

Assemble steering control unit correctly.

The oil level is low. There is no oil in the tank.

Fill tank to correct level.

The lines to the control unit are damaged.

Repair oil lines.

The sleeve and spool in the control unit are worn.

Repair steering control unit.

The parts of the metering section are worn.

Repair steering control unit.

The check valve in the control unit does not open.

Clean or repair steering control unit.

The check valve or relief valve in the manifold block is damaged or is not adjusted correctly.

Clean or replace manifold block.

Priority valve is not operating correctly.

Clean or repair priority valve.

Steering relief pressure is too low.

Adjust relief pressure.

Engine idle speed is too low.

Adjust idle speed to specifications.

The lines at the control unit are not correctly connected.

Connect lines correctly.

1600 YRM 316

PROBLEM The tires continue to turn after the steering wheel stops.

Steering wheel kicks back in both directions.

Troubleshooting

POSSIBLE CAUSE

PROCEDURE OR ACTION

The neutral position springs are broken.

Repair steering control unit.

The sleeve or spool has damage.

Repair steering control unit.

Center shaft is not correctly aligned with metering section.

Correctly assemble steering control unit.

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