Drive Axle, Speed Reducer, and Differential Repair
1400 SRM 575
Drive Axle, Speed Reducer, and Differential Repair
REMOVE
NOTE: The traction motor can be removed as a sep-
arate unit. See the section Frame 100 SRM 582 for
the procedure to remove the traction motor.
WARNING
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: attachment,
mast, drive axle, battery, and the counter-
weight. When the lift truck is put on blocks,
put additional blocks in the following posi-
tions:
a. Before removing the drive axle, put blocks
under the counterweight so the lift truck
cannot tip backward.
b. Before removing the battery or counter-
weight, put blocks under the mast assem-
bly so the lift truck cannot tip forward.
Put the lift truck on blocks only if the surface
is solid, even, and level. Make sure that any
blocks used to support the lift truck are solid,
one-piece units.
1.
Disconnect the battery connector.
2.
Remove the mast assembly as described in Mast
Repair 4000 SRM 522.
Figure 3. Put Lift Truck on Blocks
3.
Use a crane and chains to put the lift truck on
blocks as shown in Figure 3. Make sure the crane
has the capacity to lift the weight of the lift truck.
See the nameplate for the weight of the lift truck.
4.
Remove the floor plates.
Remove the drive
wheels. Disconnect the brake lines to the wheel
cylinders. Put caps on the open fittings.
5.
Disconnect the parking brake cables from the
levers of the service brakes. Drain the oil from
the differential.
6.
Put a floor jack under the drive unit assembly.
Make sure the drive unit assembly has stability;
then, remove the nuts and bolts from the axle
mounts. Remove the alignment pins from the
frame. The alignment pins can be a tight fit. See
the procedures in Figure 4 and Figure 5. Slide
the drive unit assembly from the lift truck.
a. Method 1. See Figure 4.
(1)
Use a grade 8 bolt that is the maximum
diameter possible and long enough to go
through the spacer (cup) and pin. Put
a washer and nut on the threaded end
against the alignment pin. The washer
and nut must be smaller than the holes
in the frame and axle mount.
(2)
Install the spacer and bolt through the
pin from the frame side. Use a wrench
to pull the alignment pin out of (re-
moval) or into (installation) the axle
mount and frame members.
b. Method 2. See Figure 5.
(1)
Use a threaded rod (bolt) as described
in Method 1, but long enough to go
through the alignment pin,
spacer
(cup), and hydraulic cylinder with a
hollow piston. The washer and nut on
the end of the bolt must be smaller than
the holes in the frame and axle mount
when the pin is removed.
(2)
Install the spacer (cup), hydraulic cylin-
der, and threaded rod through the
alignment pin from the frame side.
Operate the hydraulic cylinder in the
direction away from the frame and pull
the pin out of (removal) or into (in-
stallation) the axle mount and frame
members.
2