DRIVE AXLE

H2.00-3.20XM (H40-65XM) [H177];

S2.00-3.20XM (S40-65XM) [D187]

PART NO. 897480

1400 SRM 499

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 Mainte-
nance 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 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 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 condition that can cause immediate death or injury!

CAUTION

Indicates a condition that can cause property damage!

Drive Axle

Table of Contents

TABLE OF CONTENTS

General ...............................................................................................................................................................

1

Description .........................................................................................................................................................

1

Drive Axle Repair...............................................................................................................................................

1

Remove and Disassemble ..............................................................................................................................

1

Clean and Inspect ..........................................................................................................................................

3

Assemble and Install .....................................................................................................................................

3

Torque Specifications .........................................................................................................................................

5

H2.00-3.20XM (H40-65XM)...........................................................................................................................

5

S2.00-3.20XM (S40-65XM) ............................................................................................................................

5

Troubleshooting..................................................................................................................................................

6

This section is for the following models:

H2.00-3.20XM (H40-65XM) [H177];

S2.00-3.20XM (S40-65XM) [D187]

©2004 HYSTER COMPANY

i

"THE

QUALITY

KEEPERS"

HYSTER

APPROVED

PARTS

1400 SRM 499

Drive Axle Repair

General

This section has the description and repair pro-
cedures for the drive axle, wheel bearings, and
mounts for the axle housing. Information for the

differential and the ring and pinion gears is in the
section Single-Speed Powershift Transmission,
Troubleshooting and Repair 1300 SRM 501.

Description

The drive axle is held to the lift truck by axle mounts.
See Figure 1. These axle mounts are fastened to
the frame of the lift truck by nuts and bolts. The
differential housing and spindles can rotate a small
amount in the axle mounts. The outer ends of the
spindles are the mounts for the wheel bearings. The
wheel bearings are tapered roller bearings with the
cups pressed into the hub/brake drum. The nut on
the end of the spindle holds and adjusts the wheel

bearings. The axle shafts are fastened to the hubs
by capscrews.

The back plate and brake assembly are fastened to
the axle housing mounts. The axle housing mounts
are also the hangers for the mast.

The outer wheel bearing is lubricated with gear oil
from the differential housing. The inner wheel bear-
ing is lubricated with wheel bearing grease.

Drive Axle Repair

REMOVE AND DISASSEMBLE

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. See Figure 1.

2.

Raise the lift truck and put blocks under the
frame so that the drive wheels just touch the
floor.

Put blocks under the counterweight for

stability.

3.

Remove the mast assembly as described in the
section Mast, Repairs 4000 SRM 522.

4.

Drain the oil from the differential.

WARNING

Deflate the H2.00-3.20XM (H40-65XM) tires
completely 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.

5.

Remove the wheels. Remove the capscrews that
hold the axle shafts to the brake drums. Remove
the axle shafts.

6.

Bend the lock plate and remove the nut from the
spindle. Remove the washer and bearing cone.
Slide the hub/brake drum from the spindle. If the
assembly cannot be removed easily, loosen the
brake shoes. Put a screwdriver through the hole
in the back plate to turn the adjuster wheel and
loosen the brake shoes. Pull the actuator away
from the adjuster wheel while the adjuster wheel
is turned up.

7.

Disconnect the brake lines to the wheel cylinders.
Disconnect the parking brake cables at the park-
ing brake lever. Loosen the cable clamps for the
parking brake cables.

8.

Put blocks under the differential housing. Re-
move the bolts and nuts that hold the axle hous-
ing mounts to the frame of the lift truck. Remove
the axle housing mounts.

1

Drive Axle Repair

1400 SRM 499

1.

AXLE SHAFT

2.

NUT

3.

LOCK PLATE

4.

WASHER

5.

BEARING CONE

6.

BEARING CUP

7.

HUB/BRAKE DRUM

8.

WHEEL STUD

9.

SEAL

10. BRAKE ASSEMBLY
11. MAST BUSHING
12. GREASE FITTING
13. AXLE HOUSING MOUNT
14. SPINDLE
15. O-RING
16. DIFFERENTIAL HOUSING
17. BREATHER

Figure 1. Drive Axle Parts

9.

Remove the capscrews that hold the spindles to
the differential housing.

Remove the spindle.

See Figure 2.

10. Disassemble the brake assembly as described in

the section Brake System 1800 SRM 506. Re-
move the back plate from the mounts for the axle
housing.

2

1400 SRM 499

Drive Axle Repair

Figure 2. Spindle Removal

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 precau-
tions.

1.

Clean all the parts of the drive axle with solvent.

2.

Inspect the bearings and seals for damage. The
spindles must turn freely in the mounts. The
splines for the axle shafts must not be damaged.

ASSEMBLE AND INSTALL

1.

Install new O-rings on the spindles. See Figure 1
and Figure 3. Install the spindle into the differ-
ential housing. Install the capscrews and lock-
washers. Tighten the capscrews as shown in the
Torque Specifications.

2.

Assemble the brake assembly to the mount for
the axle housing as described in the section
Brake System 1800 SRM 506.

3.

Lubricate the spindles with Never Seez

®

and

slide the mounts with the brake assembly on the
spindle. See Figure 4. Install and tighten the
bolts and nuts as shown in the Torque Specifica-
tions.

4.

Install new grease seals in the hub. See Fig-
ure 5. Install the outer seal with the lip toward

the outer bearing. Install the inner bearing and
seal. See Figure 6. Put wheel bearing grease in
the bearing that is between the seals.

Figure 3. O-Ring Installation

Figure 4. Spindle Lubrication

5.

Install the hub/brake drum assembly on the axle
housing.

6.

Install the outer bearing cone on the axle hous-
ing. Install the washer and lock plate. Install
the nut. Tighten the nut to 205 N•m (150 lbf ft)
torque while rotating the hub. Loosen the nut
until the hub turns freely. The torque must be
less than 25 N•m (20 lbf ft). Tighten the nut
to 35 N•m (25 lbf ft) or until the first alignment
position after 35 N•m (25 lbf ft). Bend the lock
plate over the nut. See Figure 7.

3

Drive Axle Repair

1400 SRM 499

7.

Adjust the clearance of the brake shoes as de-
scribed in the section Brake System 1800 SRM
506.

8.

Install the wheels and nuts and tighten the nuts
for the wheels as shown in the Torque Specifica-
tions.

9.

Put sealant on the flange of the axle shaft. In-
stall the axle shafts and capscrews. Tighten the
capscrews as shown in the Torque Specifications.

10. Install and tighten the drain plug. Fill the differ-

ential housing with SAE 90 EP gear oil through
the fill hole. Install the fill plug. Connect the
brake lines and parking brake cables. Remove
the air from the brake system as described in the
section Brake System 1800 SRM 506.

11. Install the mast as described in the section for

Mast, Repairs 4000 SRM 522.

1.

AXLE SHAFT

2.

NUT

3.

LOCK PLATE

4.

WASHER

5.

BEARING CUP AND CONE

6.

HUB/BRAKE DRUM

7.

INNER SEAL

8.

OUTER SEAL

9.

AXLE HOUSING MOUNT

10. O-RING
11. DIFFERENTIAL HOUSING
12. SPINDLE

Figure 5. Hub Assembly

4

1400 SRM 499

Torque Specifications

Figure 6. Oil Seal Installation

Figure 7. Lock Plate Installation

Torque Specifications

H2.00-3.20XM (H40-65XM)

Back Plate to Axle Mount Capscrews

225 N•m (166 lbf ft)

Wheel Cylinder Capscrews

18 to 27 N•m (13 to 20 lbf ft)

Spindle to Differential Housing

66 N•m (49 lbf ft)

Axle Shaft Capscrews

98 N•m (75 lbf ft)

Axle Mounts to Frame

325 to 380 N•m (240 to 280 lbf ft) Torque
wrench on head of capscrew.

Wheel Nuts

490 to 510 N•m (361 to 376 lbf ft)

S2.00-3.20XM (S40-65XM)

Back Plate to Axle Mount Capscrews

255 N•m (188 lbf ft)

Wheel Cylinder Capscrews

18 to 27 N•m (13 to 20 lbf ft)

Spindle to Differential Housing

90 N•m (66 lbf ft)

Axle Shaft Capscrews

90 N•m (66 lbf ft)

Axle Mounts to Frame

473 N•m (350 lbf ft) Torque wrench on nut.

Wheel Nuts

237 to 305 N•m (175 to 225 lbf ft)

5

Troubleshooting

1400 SRM 499

Troubleshooting

PROBLEM

POSSIBLE CAUSE

PROCEDURE OR ACTION

The lift truck will not move.

An axle shaft is broken.

Install new axle shaft.

The drive axle has leaks.

The drain or fill plug is loose or miss-
ing.

Repair threads. Tighten plug. Install
missing part.

The seals have damage.

Install new seals.

The O-rings have damage.

Install new O-rings.

The drive axle makes noise.

The bearings have damage.

Install new parts.

The brake assembly is damaged.

Repair brake assembly.

The oil level is too low.

Fill as required. Check for leaks.

The axle capscrews are loose.

Tighten

capscrews

to

specified

torque.

6

TECHNICAL PUBLICATIONS

1400 SRM 499

10/04 (1/96)(4/93) Printed in United Kingdom