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1400 SRM 575

Drive Axle, Speed Reducer, and Differential Repair

A. REMOVAL

B. INSTALLATION

1.

FRAME

2.

AXLE MOUNT

3.

BOLT

4.

SPACER (CUP)

5.

ALIGNMENT PIN

Figure 4. Axle Mount Arrangement (Method 1)

A. REMOVAL

B. INSTALLATION

1.

FRAME

2.

AXLE MOUNT

3.

BOLT

4.

SPACER (CUP)

5.

ALIGNMENT PIN

6.

HYDRAULIC CYLINDER (WITH HOLLOW
PISTON)

Figure 5. Axle Mount Arrangement (Method 2)

3

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Summary of Contents for J2.00-3.20XM

Page 1: ...Hyster A216 J2 00XM J2 50XM J3 00XM J3 20XM Europe ...

Page 2: ...DRIVE AXLE SPEED REDUCER AND DIFFERENTIAL J2 00 3 20XM J40 60XM J40 60XM2 A216 J2 00 3 20XM J40 60Z A416 PART NO 897670 1400 SRM 575 ...

Page 3: ...d condition Always use HYSTER APPROVED parts when making repairs Replacement parts must meet or exceed the specifications of the original equipment manufacturer Make sure all nuts bolts snap rings and other fastening devices are removed before using force to remove parts Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs or if the unit needs repairs Be sure to follo...

Page 4: ...ription 1 Drive Axle Speed Reducer and Differential Repair 2 Remove 2 Disassemble 4 Clean 6 Inspect 7 Assemble 7 Install 10 Torque Specifications 11 Troubleshooting 12 This section is for the following models J2 00 3 20XM J40 60XM J40 60XM2 A216 J2 00 3 20XM J40 60Z A416 2003 HYSTER COMPANY i ...

Page 5: ...more information Please click here Then get the complete manual NOTE If there is no response to click on the link above please download the PDF document first and then click on it Have any questions please write to me admin servicemanualperfect com ...

Page 6: ... THE QUALITY KEEPERS HYSTER APPROVED PARTS ...

Page 7: ... to the hubs by capscrews Studs and nuts fasten the wheel to the hub and brake drum The back plate and brake assemblies are fastened to the axle mounts 1 DIFFERENTIAL 2 SPINDLE AXLE HOUSING 3 AXLE MOUNT 4 SPEED REDUCER 5 TRACTION MOTOR Figure 1 Drive Unit Assembly J2 00 3 20XM J40 60XM J40 60XM2 A216 The speed reducer and differential are assembled as a single unit See Figure 8 The pinion in the s...

Page 8: ... 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 alignm...

Page 9: ...INSTALLATION 1 FRAME 2 AXLE MOUNT 3 BOLT 4 SPACER CUP 5 ALIGNMENT PIN Figure 4 Axle Mount Arrangement Method 1 A REMOVAL B INSTALLATION 1 FRAME 2 AXLE MOUNT 3 BOLT 4 SPACER CUP 5 ALIGNMENT PIN 6 HYDRAULIC CYLINDER WITH HOLLOW PISTON Figure 5 Axle Mount Arrangement Method 2 3 ...

Page 10: ... the expansion plug from the differential housing Remove the nuts and washer from the reduction gear 4 Remove the capscrews that hold the speed re ducer housing to the differential housing Sep arate the housings 1 OIL LEVEL PLUG 2 DRIVE AXLE HOUSING 3 O RING 4 SPINDLE 5 RH AXLE MOUNT 6 ALIGNMENT PIN 7 WASHER 8 ISOLATOR 9 SPACER 10 SPEED REDUCER HOUSING 11 NUTS AND BOLT MOTOR SUPPORT 12 DC TRACTION...

Page 11: ...Unit Parts J2 00 3 20XM J40 60Z A416 5 Remove the bearing caps from the speed reducer housing Remove the capscrews that hold the halves of the speed reducer housing together Separate the housings 6 Remove the gears bearings and shims from the speed reducer housing 7 Remove the lock plates for the adjustment nuts for the differential Remove the capscrews for the differential bearing caps Remove the...

Page 12: ... Speed Reducer and Differential Assembly CLEAN WARNING Always wear safety glasses Cleaning solvents may be flammable and toxic and can cause severe skin irritation When us ing cleaning solvents always comply with the solvent manufacturer s recommended safety precautions Compressed air can move particles so that they cause injury to the user or to other personnel Make sure that the path of the comp...

Page 13: ... N m 82 lbf ft Make sure the drive gear is in the cor rect position against the flange of the differential case 2 Lubricate and install a side gear and thrust washer in the differential case as shown in Fig ure 10 Make sure the side of the thrust washer with dents is toward the side gear 3 Install the spider cross differential pinions and thrust washers into the differential case as shown in Figur...

Page 14: ...ating torque is 1 7 to 4 0 N m 15 to 35 lbf in 11 Install the retainers for the adjustment nuts Tighten the hex capscrews to 19 N m 14 lbf ft 12 Install the bearing cup and O ring in the differ ential housing Apply a bead of sealant Loctite 515 or equivalent to the flange of the differen tial housing Install the speed reducer housing to the differential housing Tighten the capscrews to 52 N m 38 l...

Page 15: ...age of the three measurements Add 0 15 mm 0 006 in to the average measurement Sub tract this dimension from 2 54 mm 0 100 in to obtain the required shim pack Install the shims O ring and bearing cap Use a thread sealant on the capscrews and tighten the capscrews to 19 N m 14 lbf ft 16 Adjust and install the bearing cap for the pinion using the procedures described in Step 15 17 Apply a bead of sea...

Page 16: ...z and install them The alignment pins can be a tight fit See the procedures in Figure 4 and Figure 5 Install the bolts that fasten the axle mounts to the frame Tighten the nuts and bolts as follows a If the torque wrench is on the head of the bolt tighten the bolt to 780 N m 575 lbf ft b If the torque wrench is on the nut tighten the nut to 715 N m 528 lbf ft 3 Assemble the brake assembly to the a...

Page 17: ...ance 8000 SRM 1060 Re move the blocks so the lift truck is on its tires Figure 16 Lock Plate Installation Torque Specifications Axle Mounts to Frame Torque Wrench on Head of Bolt 780 N m 575 lbf ft Torque Wrench on Nut of Bolt 715 N m 527 lbf ft Axle Housing to Differential Housing 38 N m 28 lbf ft Axle Shaft Capscrews 98 N m 72 lbf ft Back Plate to Axle Mount Capscrews 5 8 in Capscrews 245 N m 18...

Page 18: ...ed threads is loose or is missing Repair threads Tighten plug Install missing part The O rings or seals have damage Install new O rings and seals The drive axle housing is cracked Install new drive axle housing Speed reducer housing is cracked Install a new housing The drive axle makes noise The bearings have damage Install new parts The brake assembly is damaged Repair brake assembly The oil leve...

Page 19: ......

Page 20: ...TECHNICAL PUBLICATIONS 1400 SRM 575 3 03 5 95 Printed in United Kingdom ...

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