Planetary Gear Axle

PLANETARY GEAR
AXLE
H40.00-48.00XM-12 (H800-1050HD/HDS) [A917];
H36.00-48.00E (H800-1050E) [D117];
RS45-27CH, RS45-30CH, RS45-27IH, RS46-33CH,
RS46-30IH, RS46-36CH, RS46-33IH [A222];
RS45-27CH, RS45-31CH, RS46-36CH, RS46-40CH, RS46-41S
CH, RS46-41L CH, RS46-41LS CH, RS45-24IH, RS45-28IH,
RS46-33IH, RS46-37IH, RS46-38S IH, RS46-38L IH,
RS46-38LS IH (HR45-27, HR45-31, HR45-36, HR45-40,
HR45-41S, HR45-41L, HR45-41LS) [B222];
HR45-25, HR45-27, HR45-31, HR45-40S, HR45-36L,
HR45-40LS, HR45-45LSX [A227, B227, C227];
H40.00-52.00XM-16CH (H1050HD-CH, 1150HD-CH)
[E117, F117];
RS45-27CH, RS45-31CH, RS46-36CH, RS46-41L CH,
RS46-41S CH, RS46-41LS CH, RS45-24IH, RS45-28IH,
RS46-33IH, RS46-38L IH, RS46-38S IH, RS46-38LS IH
(RS45-27, RS45-31, RS46-36, RS46-41L, RS46-41S,
RS46-41LS) [C222];
H40XM-16CH, H44XM-16CH, H48-16CH,
H50-16CH, H52XM-16CH
(H1050HD, H1150HD) [G117]
PART NO. 1574068 1400 SRM 1171

SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• The Service Manuals are updated on a regular basis, but may not reflect recent design changes to the
product. Updated technical service information may be available from your local authorized Hyster®
dealer. Service Manuals provide general guidelines for maintenance and service and are intended for
use by trained and experienced technicians. Failure to properly maintain equipment or to follow in-
structions contained in the Service Manual could result in damage to the products, personal injury,
property damage or death.
• 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 HYSTER APPROVED parts when making repairs. Replacement parts must meet or ex-
ceed 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 flamma-
ble. 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 back-
ground. The CAUTION symbol and word are on yellow background.
Table of Contents
TABLE OF CONTENTS
General .....................................................................................................................................................................1
Description ...............................................................................................................................................................1
Operation ................................................................................................................................................................. 5
Planetary Gear Axle Repair ....................................................................................................................................5
Remove ................................................................................................................................................................ 5
Drive Wheels and Tires .................................................................................................................................. 5
Disassemble .........................................................................................................................................................7
Drive Axle ........................................................................................................................................................7
Planetary Gear Carrier .................................................................................................................................. 8
Ring Gear, Ring Gear Hub, and Wheel Hub ................................................................................................. 9
Hub Oil Seal and Bearings ...........................................................................................................................11
Axle Shaft ......................................................................................................................................................11
Spindle ...........................................................................................................................................................11
Repair ................................................................................................................................................................ 12
Repairing or Replacing Parts .......................................................................................................................12
Welding ......................................................................................................................................................... 12
Clean ..................................................................................................................................................................12
Ground or Polished Parts ............................................................................................................................. 12
Parts With Rough Finishes .......................................................................................................................... 13
Axle Assemblies ............................................................................................................................................ 13
Drying Cleaned Parts ................................................................................................................................... 13
Preventing Corrosion ........................................................................................................................................ 13
Parts Inspection ................................................................................................................................................ 13
Assemble ............................................................................................................................................................13
Spindle ...........................................................................................................................................................13
Axle Shaft ......................................................................................................................................................14
Hub Oil Seal and Bearings ...........................................................................................................................14
Ring Gear, Ring Gear Hub, and Wheel Hub ............................................................................................... 14
Wheel Bearing Preload .................................................................................................................................14
Adjust ........................................................................................................................................................14
Planetary Gear Carrier ................................................................................................................................ 15
Drive Axle ......................................................................................................................................................17
Wheel Ends ................................................................................................................................................... 17
Fill ............................................................................................................................................................. 17
Install .................................................................................................................................................................17
Drive Wheels and Tires ................................................................................................................................ 17
Torque Specifications ............................................................................................................................................ 22
Troubleshooting .....................................................................................................................................................23
©2014 HYSTER COMPANY i

Table of Contents
This section is for the following models:
H40.00-48.00XM-12 (H800-1050HD/HDS) [A917];

H36.00-48.00E (H800-1050E) [D117];
(RS45-27CH, RS45-30CH, RS45-27IH, RS46-33CH, RS46-30IH, RS46-36CH,
RS46-33IH) [A222];
RS45-27CH, RS45-31CH, RS46-36CH, RS46-40CH, RS46-41S CH, RS46-41L CH,
RS46-41LS CH, RS45-24IH, RS45-28IH, RS46-33IH, RS46-37IH, RS46-38S IH,
RS46-38L IH, RS46-38LS IH (HR45-27, HR45-31, HR45-36, HR45-40, HR45-41S,
HR45-41L, HR45-41LS) [B222];
(HR45-25, HR45-27, HR45-31, HR45-40S, HR45-36L, HR45-40LS, HR45-45LSX)
[A227, B227, C227];
H40.00-52.00XM-16CH (H1050HD-CH, 1150HD-CH) [E117, F117];
RS45-27CH, RS45-31CH, RS46-36CH, RS46-41L CH, RS46-41S CH, RS46-41LS
CH, RS45-24IH, RS45-28IH, RS46-33IH, RS46-38L IH, RS46-38S IH, RS46-38LS
IH (RS45-27, RS45-31, RS46-36, RS46-41L, RS46-41S, RS46-41LS) [C222];
H40XM-16CH, H44XM-16CH, H48-16CH, H50-16CH, H52XM-16CH (H1050HD,
H1150HD) [G117]
ii
1400 SRM 1171 General
General
This section has a description and the repair procedures for the planetary gear axle.
Description
The planetary gear axle has an axle housing and ring gear hub, and ring gear. There are also three
two final drive assemblies. See Figure 1 and Fig- planetary pinions, a planetary spider, and a hous-
ure 2. Each final drive assembly is a planetary gear ing. The differential is also installed in the axle
unit. The planetary gear assembly changes the fi- housing. The service brake is also installed on the
nal drive ratio, which increases the torque to the drive axle. See the section Service Brake for your
drive wheels. Each unit has a drive axle, sun gear, lift truck, for repair instructions of the brakes.
1
Description 1400 SRM 1171
Figure 1. Planetary Axle With Oil-Cooled Brakes
2
1400 SRM 1171 Description
Legend for Figure 1
1. AXLE HOUSING 11. INNER HUB

2. SPINDLE 12. WHEEL BEARING ADJUSTMENT NUT
3. SEAL 13. WHEEL BEARING ADJUSTING LOCK NUT
4. ROTOR 14. AXLE
5. OIL SEAL 15. THRUST BUTTON
6. BEARING CONE 16. PLANETARY GEAR CARRIER
7. BEARING CUP 17. COVER
8. WHEEL HUB 18. PINION SHAFT (3)
9. RING GEAR HUB 19. PINION THRUST WASHER
10. RING GEAR 20. PINION GEAR (3)
3
Description 1400 SRM 1171
1. DRAIN/FILL PLUG 15. RETAINER PLATE

2. COVER 16. CAPSCREW
3. AXLE SHAFT THRUST BUTTON 17. CAPSCREW
4. CAPSCREW 18. WHEEL STUD NUT
5. PLANETARY GEAR CARRIER 19. WHEEL STUD NUT WASHER
6. SNAP RING 20. WHEEL RIM CLAMP
7. SUN GEAR 21. WHEEL STUD
8. THRUST WASHER 22. WHEEL STUD WASHER
9. WHEEL BEARING ADJUSTING NUT 23. OIL DRAIN PLUG
10. LOCK NUT LOCK PLATE 24. PINION SHAFT
11. LOCK PLATE CAPSCREW 25. PINION OUTER THRUST WASHER
12. LOCK NUT LOCK PLATE 26. PINION GEAR
13. RING GEAR 27. PINION INNER THRUST WASHER
14. RING GEAR HUB
Figure 2. Planetary Axle Components
4
1400 SRM 1171 Operation
Operation
The rotation of the differential causes the axle of the pinions causes the planetary spiders to rotate
shafts and the sun gears to rotate. The sun gears the hubs and the drive wheels. The ring gear and
then cause the planetary pinions to rotate. Rotation the ring gear hub do not rotate.
Planetary Gear Axle Repair

REMOVE
WARNING
Drive Wheels and Tires Completely remove air pressure from tire before it
is removed from lift truck. Because dual wheels
NOTE: The final drive assemblies can be removed are installed, remove air pressure from both tires.
with the drive axle installed in the lift truck. If the Air pressure in tires can cause tire and wheel
drive axle must be removed, do the following steps. parts to explode, causing serious injury or death.
If the drive axle will not be removed, do only the re-
quired steps. 7. Remove air from tire.
1. Place lift truck on solid, level surface. 8. Remove valve core to verify that all air is out of
inner tube.
2. Put blocks on each side (front and back) of the
steer tires to prevent movement of the lift 9. Push a wire through valve stem to verify the
truck. See Figure 3, Figure 4, and Figure 5. stem does not have a restriction.
3. Put mast in a vertical position. 10. Remove wheel nuts and clamps.
4. Put a block under each outer mast channel.

WARNING
5. Tilt mast fully forward until drive tires are The tires and wheels can weigh approximately
raised from the surface. 875 kg (1929 lb). Verify the lifting device has the
rated capacity to lift the tires and wheels or per-
CAUTION sonal injury may occur.
Do not place blocks under fuel and hydraulic ho- 11. Remove wheel and tire from lift truck.
ses or fuel and hydraulic tank. Damage to the lift
truck may occur.
6. Put additional blocks under frame behind the

drive tires.
5
Planetary Gear Axle Repair 1400 SRM 1171
1. STEER AXLE/STEER TIRES 2. DRIVE AXLE/DRIVE TIRES
Figure 3. Put Lift Truck on Blocks (A917)
1. STEER AXLE/STEER TIRES

2. DRIVE AXLE/DRIVE TIRES
Figure 4. Put the Lift Truck on Blocks (B222)
6
1400 SRM 1171 Planetary Gear Axle Repair
Do not sand, grind, chisel, hammer, or change lin-

ings in any way that will create dust. Any changes
to linings must be done in a restricted area with
special ventilation. Protective clothing and a res-
pirator must be used.
NOTE: Under normal conditions, the disc assembly

(fixed and rotating discs) of the oil-cooled brakes is
replaced when the drive axle is disassembled.
6. Disconnect service brake lines.
7. Disconnect brake lines for parking brake at the

differential.
8. Disconnect cooling oil lines for oil-cooled

brakes.
9. Put caps on all hydraulic lines, ports, and fit-

tings.
10. Disconnect drive shaft at differential.
1. STEER AXLE/STEER TIRES 11. Put forks of another lift truck under the axle
2. DRIVE AXLE/DRIVE TIRES for support.
Figure 5. Put the Lift Truck on Blocks (E117 and 12. Remove bolts and nuts that hold the axle to the
F117) frame.
DISASSEMBLE WARNING
Verify the lifting device has the rated capacity of
Drive Axle 4500 kg (9921 lb) when moving the drive axle.
1. Apply brakes ten to twenty times until accumu- 13. Remove drive axle from lift truck frame.
lated hydraulic brake pressure is released.
2. Drain oil from the end of axle housing. WARNING

Cleaning solvents are flammable and toxic and
3. Rotate hub assembly until oil drain plug in can cause skin irritation. When using cleaning
planetary gear carrier is at the bottom. solvents, always follow the solvent manufactur-
er's recommended safety precautions.
4. Remove oil drain plug and drain oil.
5. Drain cooling oil from service brakes. WARNING

Compressed air can move particles so that they
WARNING cause injury to the user or to other personnel.
Brake linings can contain dangerous fibers. Verify that the path of the compressed air is away
Breathing dust from these linings is a cancer or from all personnel. Wear protective goggles or a
lung disease hazard. Do not create dust! Do not face shield to prevent injury to the eyes.
clean brake parts with compressed air or by 14. Clean all parts in solvent and dry with com-
brushing. Use vacuum equipment approved for pressed air.
brake dust or follow the cleaning procedure in
this section. When the brake drums are removed,
do not create dust.
7
Planetary Gear Carrier Legend for Figure 7
1. Align marks on planetary gear carrier and 1. HUB

wheel hub for correct alignment when reassem- 2. COVER
bling the unit. See Figure 6. 3. PLANETARY GEAR CARRIER
3. Remove planetary gear carrier capscrews.
NOTE: Do not remove planetary gear carrier at

this time.
4. Insert a pry bar into assembly notches and sep-

arate planetary gear carrier from wheel hub as-
sembly. See Figure 8.
A. RIM MOUNTED
1. ALIGNMENT MARKS
Figure 6. Alignment Marks
2. Remove cover from planetary gear carrier. See

Figure 7.
Figure 8. Planetary Gear Carrier Separation
WARNING
Use caution when using lifting devices. When us-
ing a lifting strap, inspect strap for damage before
using. Do not use a lifting strap to shock load or
drop load a component. Serious personal injury
and damage to components may occur.
Verify the lifting device has the rated capacity of

150 kg (331 lb) when moving the planetary gear
carrier.
5. Use a lifting device to remove planetary gear

Figure 7. Planetary Gear Carrier Cover carrier from wheel hub assembly. See Figure 9.
8
1. SPIDER
2. PINION SHAFT
3. OUTER THRUST WASHER
4. PLANETARY GEAR
5. SMALL BORE INNER THRUST WASHER
Figure 10. Pinion Shaft

Figure 9. Planetary Gear Carrier Removal
9. Remove planetary gears and thrust washers

WARNING from planetary gear carrier.
Observe all WARNINGS and CAUTIONS provided
Ring Gear, Ring Gear Hub, and Wheel Hub
by press manufacturer concerning press opera-
tion to avoid serious injury and possible damage 1. Remove snap ring from end of axle shaft. See
to components during assembly and installation Figure 11.
procedures.
2. Remove sun gear. See Figure 11
NOTE: If a press is not available, use a brass drift
and mallet to remove pinion shafts.
6. Place the planetary gear carrier assembly in a

press with flange side DOWN. Support the spi-
der assembly as required.
NOTE: Use a soft material in bottom of the catch

container to prevent damage to the pinion shafts.
7. Place a container under the press to catch the

planetary pinion shafts as they are pressed out
of the planetary gear carrier and planetary pin-
ion gears.
8. Press each pinion shaft out of planetary gear

carrier and planetary gear. See Figure 10.
1. SUN GEAR 3. AXLE SHAFT

2. SNAP RING 4. RING GEAR
Figure 11. Sun Gear
9
3. Remove sun gear thrust washer assembly. See 6. Remove ring gear hub by pulling it straight out
Figure 12. of wheel hub and off of spindle.
1. WHEEL BEARING ADJUSTING NUT

2. WHEEL BEARING ADJUSTING LOCK NUT
3. CAPSCREW
4. AXLE SHAFT
5. THRUST WASHER Figure 13. Ring Gear Hub
Figure 12. Thrust Washer Assembly

7. Remove retainer plate capscrews to remove
ring gear from ring gear hub. See Figure 14.
4. Remove capscrews from wheel bearing adjust-
ing lock nut. See Figure 2 and Figure 12.
5. Remove wheel bearing adjusting lock nut and

wheel bearing adjusting nut. See Figure 2 and
Figure 12.
WARNING
Support the wheel hub before you remove ring
gear and ring gear hub assembly. Do not remove
ring gear and ring gear hub assembly without
supporting the wheel hub. Serious injury and
damage to components may occur. See Figure 13.
NOTE: To avoid dropping and possibly damaging

the outer wheel bearing cone, verify the outer
wheel bearing cone remains in place as you remove 1. RING GEAR HUB
the ring gear hub. 2. OUTER WHEEL BEARING
3. RETAINER PLATE
NOTE: If the ring gear hub cannot be removed by 4. RING GEAR
hand, install capscrews into the puller screw holes
in the ring hub flange. Tighten each capscrew the Figure 14. Retainer Plate
same amount to separate ring gear hub from spin-
dle and wheel hub.
8. Remove outer wheel bearing from ring gear
hub.
10
NOTE: The ring gear hub assembly includes the Axle Shaft
hub and ring sleeve insert. You cannot service
these components separately. 1. Remove axle shaft from spindle bore and hous-
ing.
9. Use a hoist or similar device to lift the wheel
hub and drum slightly to relieve the hub weight 2. Disassemble oil-cooled brakes as described in
and drum-to-brake shoe drag. See Figure 15. the section Service Brake for your lift truck.
10. Remove wheel hub assembly from wheel hub Spindle

spindle.
NOTE: The spindle and brake cover are assembled
to the axle housing with the same capscrews.
1. Remove two of the capscrews (opposite each

other) that fasten the spindle to the axle hous-
ing. Replace with two studs, which are long
enough to support the spindle. See Figure 16.
Figure 15. Wheel Hub and Drum
1. STUD
Hub Oil Seal and Bearings Figure 16. Brake Housing Studs
1. Position wheel hub with brake end UP to re-
move hub oil seal and bearings. 2. Remove the remaining capscrews.
2. Remove rotor mounting capscrews and wash- 3. Hold the spindle against the axle housing.
ers.
3. Remove the rotor. WARNING

Verify the lifting device has the rated capacity to
CAUTION lift the spindle.
Do not scratch hub seal bore surface. 4. Use a lifting device to remove the spindle. See
Figure 17.
4. Remove bearing cups with a suitable puller.
5. Remove bearing cone with a suitable puller.
6. Remove wheel hub oil seal.
11
Welding
Do not repair the drive axle assemblies by welding.

Welding can detract from the structural integrity of
a component, particularly to heat-treated parts
where the benefit of heat treatment can be nullified
by welding.
CLEAN
Ground or Polished Parts
WARNING
To prevent serious eye injury, always wear safe
eye protection when performing vehicle mainte-
1. LIFTING DEVICE 2. SPINDLE nance or service.
Figure 17. Spindle
WARNING
Solvent cleaners are flammable, poisonous, and
REPAIR can cause burns. Examples of solvent cleaners
are carbon tetrachloride, emulsion-type cleaners,
Repairing or Replacing Parts and petroleum-based cleaners. To avoid serious
personal injury when using solvent cleaners,
WARNING carefully follow the manufacturer's product in-
Do not repair axle housings by bending or structions and these procedures.
straightening. Repair of axle housings by bending • Wear safe eye protection.
or straightening can cause poor performance and • Wear clothing that protects your skin.
possible unsafe operation of the axle. This can
cause serious personal injury. • Work in a well-ventilated area.
• Do not use gasoline or solvents that con-
NOTE: Threads must be without damage and tain gasoline. Gasoline can explode.
clean, so accurate adjustment and correct torque
values can be applied to fasteners and parts. • Use hot solution tanks or alkaline solutions
correctly. Follow the manufacturer's in-
Replace worn or damaged parts of an axle assem- structions carefully.
bly. The following are some examples for possible
repair and replacement: CAUTION
• Replace any fastener if corners of wrench
• Use only solvent cleaners to clean ground
flats are worn.
or polished metal parts. Hot solution tanks
• Replace washers if damaged. or water and alkaline solutions will damage
• Replace gaskets, oil seals, and grease seals. these parts. Isopropyl alcohol, kerosene, or
diesel fuel can be used for this purpose.
• Clean parts and apply silicon gasket mate-
rial, where required. • If required, use a sharp knife to remove
gasket material from parts. Be careful not to
• Remove nicks, marks, and burrs from parts
damage the ground or polished surfaces.
having machined or ground surfaces. Use a
fine file, India stone, emery cloth, or crocus 1. Use a cleaning solvent, kerosene, or diesel fuel
cloth. to clean ground or polished parts or surfaces.
• Clean and repair threads of fasteners and NEVER USE GASOLINE.
holes. Use a die or tap of correct size or a fine
file.
12
2. Remove gasket material from parts. Use cau- PARTS INSPECTION

tion not to damage ground surfaces. Apply
grease to prevent corrosion. It is very important to inspect all parts carefully
and completely before axle or carrier is assembled.
3. DO NOT clean ground or polished parts in a Check all parts for wear and replace damaged
hot solution tank, water, steam, or alkaline sol- parts. Replacement of damaged or worn parts will
ution. prevent breakdown of assembly later.
Parts With Rough Finishes ASSEMBLE

1. Use a cleaning solvent or a hot solution tank
Spindle
with a weak alkaline solution to clean parts
with a rough finish. 1. Install two studs opposite each other on the
axle housing flange. Verify the studs are long
2. Leave parts in the hot solution tank until they
enough to support the spindle.
are completely cleaned and heated. When the
parts are clean, remove them from the tank. 2. Apply a bead of silicone gasket material on the
mounting surface of the axle housing flange.
3. Wash the parts with water until alkaline solu-
The bead must go around each capscrew hole.
tion is completely removed.
See Figure 18.
Axle Assemblies
NOTE: A complete axle assembly can be steam
cleaned on the outside to remove dirt.
NOTE: Before the axle is steam cleaned, close or

put a cover over all the openings in the axle assem-
bly. Examples of openings are the breathers or
vents in air chambers.
Drying Cleaned Parts
CAUTION
Dry bearings with clean paper or rags. Do not use
compressed air, which can cause abrasive parti-
cles to contaminate the bearings. Damage to com- 1. AXLE FLANGE
2. SILICONE BEAD
ponents and reduced lining life can result.
Figure 18. Axle Flange
Immediately after cleaning, use clean paper, rags,
or compressed air to dry parts.
PREVENTING CORROSION WARNING

Verify the lifting device has the rated capacity to
NOTE: Parts must be clean and dry before lubri-
lift the spindle.
cating them.
3. Use a lifting device to install the spindle on the
1. If assembling the parts immediately after
guide studs. Verify the spindle cannot fall be-
cleaning them, lubricate the clean, dry parts
fore removing the lifting device. See Figure 18.
with grease to prevent corrosion.
4. Tighten the capscrews to the torque specified.
2. If storing the parts after cleaning them, apply a
See Table 2.
corrosion-preventive material to all machined
surfaces. Store the parts in a special paper or
other material that prevents corrosion.
13
Axle Shaft NOTE: If slinger fits loosely between wheel hub

and drum, apply a bead of liquid gasket material to
1. Replace oil-cooled brake as described in the sec- prevent rattling.
tion Service Brake for your lift truck.
9. Install brake rotor or drum and oil slinger.
2. Install axle shaft through the spindle bore and
housing until it engages the differential side 10. Install drum or rotor mounting capscrews and
gear. The shaft end with the snap ring groove washers.
must extend beyond the outer end of the spin-
dle. Ring Gear, Ring Gear Hub, and Wheel Hub
Hub Oil Seal and Bearings

WARNING
1. Position wheel hub with brake end UP to in- Use caution when using lifting devices. When us-
stall hub oil seal and bearings. ing a lifting strap, inspect strap for damage before
using. Do not use a lifting strap to shock load or
2. Position new wheel hub oil seal so that the drop load a component. Serious personal injury
spring lip of the seal faces the wheel bearing. and damage to components may occur.
Use a suitable seal driver to drive seal into
same location as original wheel hub oil seal. 1. Using a hoist or similar device, carefully lift the
wheel hub assembly over wheel hub spindle.
Keep the wheel hub assembly aligned with
CAUTION wheel hub spindle to avoid oil seal damage. See
Use caution not to nick the seal oil wear sleeve Figure 15.
end when installing the oil seal wear sleeve. A
nicked oil seal wear sleeve end can damage the 2. Install outer wheel bearing cone on the ring
seal lip when installing the wheel hub. Lubricant gear hub journal squarely against hub shoul-
loss and damage to components may occur. der. Apply the same lubricant used in the wheel
ends to the rollers. Slip fit outer wheel bearing
3. Carefully install a new oil seal wear sleeve on cone over ring gear hub journal. See Figure 14.
the spindle.
3. Install retainer plate with bolts.
4. Lubricate new seals as follows:
• Lubricate the oil seal lips of conventional 4. Install ring gear assembly, which includes
seals. outer bearing cone, on wheel hub spindle.
• Lubricate the inside diameter of unitized 5. Install wheel bearing adjusting lock nut and
seals. wheel bearing nut on spindle. See Figure 2 and
• Lubricate contact surfaces of the metal Figure 12.
rings on face seals. Do not apply lubri-
cant to any other part of the face seal. Wheel Bearing Preload
5. Apply a thin coat of lubricant to the oil seal Adjust

journal surface of the spindle.
1. Tighten the wheel bearing adjusting nut to the
6. Apply lubricant to the inner bearing cone roll- initial seating torque listed in Table 1.
ers.
2. Rotate the wheel hub, a minimum of two full
7. Install the inner bearing cone into wheel hub. revolutions in both directions.
NOTE: If the hub bearing cups need to be replaced, 3. Using a suitable bar and not to exceed
install the new cups with a suitable driver. 5 kg (10 lb) of force, tap the ring gear hub to as-
sist in seating the wheel hub. For location of
8. Install bearing cups into wheel hub. tapping of suitable bar, see Figure 19.
14
6. Tap the ring gear hub to assist in seating the

wheel hub.
7. Loosen the adjusting nut ⅛ to ¼ turn.
8. Tighten the adjusting nut to the final adjust-

ment nut torque listed in Table 1.

revolutions in both directions.
10. Tap the ring gear hub to assist in seating the

wheel hub.
11. Tighten the adjusting nut to the final adjust-

ment nut torque listed in Table 1.
Figure 19. Location of tapping the ring gear hub 12. Repeat Step 9 thru Step 11 until the adjusting
nut can no longer be turned.
4. Repeat tightening the wheel bearing adjusting 13. Install the lock plate. If the lock plate cannot be
nut to the initial seating torque listed in Ta- assembled, tighten the adjusting nut further to
ble 1. the next position so that the locking plate can
be installed.
revolutions in both directions.
Table 1. Wheel Bearing Adjustment Torque
Adjusting Nut Torque

Axle Models
Initial Seating Final Adjustment
PRC-5324 to 7314 813 N•m (600 lbf ft) 678 N•m (500 lbf ft)
PRC-7534 949 N•m (700 lbf ft) 746 N•m (550 lbf ft)
Planetary Gear Carrier 3. Place planetary gear carrier in press with

flange side UP. Support planetary gear carrier
NOTE: The chambers must be smooth to prevent as required.
damage to nylon coating on planetary pinion shaft
during installation. If large bore chambers are not 4. Install inner thrust washer (small bore). Place
smooth, use an emery cloth to clean chamber sur- washer tab in spider indent and align washer
face. bore with planetary gear carrier bore.
1. Inspect large bore chambers. 5. Apply thin coat of same gear lubricant used in
the wheel end to the planetary gear bore.
NOTE: Do not use planetary gears with rough bore
surfaces. 6. Slide planetary gear and outer thrust washer
into planetary gear carrier. Align the bores of
2. Inspect planetary gear bores. the parts and place outer thrust washer tab in
planetary gear carrier indent.
WARNING 7. Apply thin coat of gear lube to nylon coating on
Observe all WARNINGS and CAUTIONS provided pinion shaft.
by press manufacturer concerning press opera-
tion to avoid serious injury and possible damage
to components during assembly and installation
procedures.
15
NOTE: The pinion shaft must be aligned so flat NOTE: If you cannot install pinion shaft into plan-
surface on large end faces toward outside of wheel etary gear carrier assembly by hand, use a press to
hub circle. This alignment provides clearance for install pinion shaft into planetary gear carrier as-
planetary gear carrier cover and prevents shaft sembly until shoulder bottoms against inner (bot-
from rotating when planetary gear carrier cover is tom) thrust washer. When a press is not available,
installed. use a brass drift and a mallet to install pinion
shafts.
8. Install planetary pinion shaft in planetary gear
carrier and through planetary gear and thrust 11. Install each pinion shaft into planetary gear
washer. Allow large end of shaft to extend from carrier assembly by hand.
the spider assembly. See Figure 20.
WARNING
Small amounts of acid vapor are present when ap-
plying some silicone gasket materials. To prevent
personal injury, verify there is good ventilation in
work area. If silicone gasket material gets in eyes,
flush eyes with water for 15 minutes. Have eyes
checked by a doctor.
CAUTION
Use only correct gasket material. Do not use non-
approved gasket material. Lubricant loss and
damage to components may occur.
12. Apply silicone gasket material to planetary

gear carrier flange at wheel hub mounting face.
13. Install planetary gear carrier and pinion as-

sembly in wheel hub.
1. PINION SHAFT
2. PLANETARY GEAR CARRIER/SPIDER ASSEM- 14. Align planetary gear teeth with the sun gear
BLY and ring gear teeth.
3. INNER THRUST WASHER (SMALL BORE)
4. PINION GEAR 15. Align planetary gear carrier flange and wheel
5. OUTER THRUST WASHER hub alignment marks previously marked at dis-
Figure 20. Planetary Pinion Shaft assembly. See Figure 6.
16. Correctly align planetary gear carrier mounting

holes with wheel hub holes or studs.
9. Repeat Step 1 through Step 8 to install second
and third set of planetary pinion shafts, gears, 17. Push planetary gear carrier assembly against
and washers. wheel hub.
NOTE: When necessary, rotate shafts so the plane- 18. Install nuts and washers.
tary gear carrier cover fits over the flats. After you
align shafts, remove cover. 19. Tighten wheel studs and nuts according to tor-
que specifications as shown in Table 2.
10. Check alignment of pinion shafts by placing
planetary gear carrier cover over shaft ends.
16
Do not sand, grind, chisel, hammer, or change lin-

Table 2. Planetary Gear Carrier Capscrew and ings in any way that will create dust. Any changes
Stud Torque Specifications to linings must be done in a restricted area with
special ventilation. Protective clothing and a res-
Size Torque pirator must be used.
1/2"-13 115 to 156 N•m
(85 to 115 lbf ft) 5. Connect service brake lines.
9/16"-12 176 to 224 N•m 6. Connect brake lines for parking brake at differ-
(130 to 165 lbf ft) ential.
3/4"-10 420 to 542 N•m 7. Connect cooling oil lines for oil-cooled brakes.
(310 to 400 lbf ft)
7/8"-14 780 to 1017 N•m Wheel Ends
(575 to 750 lbf ft)
Fill
20. Apply silicone gasket material to cover flange 1. Rotate wheel end until oil fill line and oil level
at planetary gear carrier mounting face. line are parallel to ground.
21. Align drain arrow on planetary gear carrier NOTE: Clean all magnetic plugs and install oil
cover with drain plug. drain plug in spider prior to filling wheel end with
lubricant.
22. Install planetary gear carrier cover and cap-
screws. 2. Remove oil fill plug from cover.
23. Tighten cover capscrews to 115 to 156 N•m (85 NOTE: The rigid axle wheel end and housing bowl
to 115 lbf ft). share the same oil and oil level.
Drive Axle Do not fill through axle housing bowl only. For
axles with a common level, fill axle at each wheel
end and axle housing bowl to the bottom of the fill
WARNING plug hole with specific oil. Wait to allow the oil to
Verify lifting device has the rated capacity of flow through the axle. Check oil level again and fill
4500 kg (9921 lb) when installing the drive axle. to specified level if necessary.
1. Carefully move drive axle assembly into posi- 3. Add oil to each wheel end and then to the bowl.
tion under lift truck using another lift truck. See the section Periodic Maintenance for
your lift truck.
2. Align axle assembly to the frame.
4. Replace and securely tighten all plugs.
3. Install nuts and bolts that hold axle to the
frame and tighten to 1650 to 2050 N•m (1217 INSTALL
to 1512 lbf ft).
4. Connect drive shaft at differential.

Drive Wheels and Tires
WARNING WARNING
Add air pressure to the tires only in a safety cage.
Brake linings can contain dangerous fibers.
Inspect safety cage for damage before use. When
Breathing dust from these linings is a cancer or
air pressure is added to the tire, use a chuck that
lung disease hazard. Do not create dust! Do not
fastens onto valve stem of inner tube. Verify there
clean brake parts with compressed air or by
is enough air hose to permit the operator to stand
brushing. Use vacuum equipment approved for
away from the safety cage when air pressure is
brake dust or follow the cleaning procedure in
added to the tire.
this section. When the brake drums are removed,
do not create dust. 1. Put tire in a safety cage. See Figure 21.
17
NOTE: If installation is not correct, remove all air ure 27. When the nuts stay tight for eight hours,
pressure from the tire. Remove valve core to verify the interval for checking the torque can be exten-
all air pressure has been removed and make adjust- ded to 500 hours.
ments. Clearance at ends of lock ring should be 13
to 25 mm (0.5 to 1 in.) when tire has the correct air 5. Tighten the wheel nuts as shown in Figure 23,
pressure. Figure 24, Figure 25, Figure 26, and Figure 27.
First, tighten the nuts to 35 N•m (26 lbf ft),
2. Verify all wheel parts are correctly installed. then tighten to 100 N•m (74 lbf ft). Check for
See Figure 22. correct alignment of wheel parts and inside
wheel-to-hub alignment after tightening nuts 1
3. Tap lock ring lightly to verify it is in the seat. through 4. Finally, tighten the nuts to the tor-
que value shown in Figure 23, Figure 24, Fig-
WARNING ure 25, Figure 26, and Figure 27.
The tires and wheels can weigh approximately
750 kg (1653 lb). Verify the lifting device has the
rated capacity to lift the tires and wheels or per-
sonal injury may occur.
4. Install wheels on lift truck.
CAUTION
Check all wheel nuts after 2 to 5 hours of opera-
tion, when new lift trucks begin operation and on
all lift trucks when the wheels have been removed
and installed. Tighten the nuts as shown in Fig-
ure 23, Figure 24, Figure 25, Figure 26, and Fig-
Figure 21. Add Air to the Tires
18
1. SIDE FLANGE 7. RIM CLAMP

2. WHEEL RIM 8. HUB
3. FLANGE SEAT 9. WEDGE BAND
4. VALVE STEM 10. SPACER
5. LOCK RING 11. DRIVER
6. O-RING
Figure 22. Wheel Arrangement
19
Figure 24. Wheel Nut Tightening Sequence (A227

and B227)
A. STEER WHEEL
B. DRIVE WHEEL
Figure 23. Wheel Nut Tightening Sequence (A222)
NOTE: REFER TO THE SECTION PERIODIC MAIN-

TENANCE FOR THE FINAL TORQUE VALUES.
Figure 25. Wheel Nut Tightening Sequence (C227)
20
A. STEER WHEEL
B. DRIVE WHEEL
Figure 26. Wheel Nut Tightening Sequence (D117)
A. STEER WHEEL
B. DRIVE WHEEL
Figure 27. Wheel Nut Tightening Sequence (A917,

B222, E117, and F117)
21
Torque Specifications 1400 SRM 1171
Torque Specifications
Table 3. Standard Torque Values for Axle Fasteners
Lock Nuts Capscrews, Studs, and Nuts

Size
N•m lbf ft N•m lbf ft
1/4-20 1/4-28 UNC UNF 12 to 15 13 to 18 9 to 11 10 to 13 13 to 18 13 to 18 10 to 13 10 to 13
5/16-18 UNC UNF 24 to 33 27 to 40 18 to 24 20 to 30 27 to 40 27 to 40 20 to 30 20 to 30
5/16-24
3/8-16 3/8-24 UNC UNF 40 to 54 48 to 68 30 to 40 35 to 50 48 to 68 48 to 68 35 to 50 35 to 50
7/16-14 UNC UNF 68 to 88 81 to 102 50 to 65 60 to 75 81 to 102 88 to 115 60 to 75 65 to 85
7/16-20
9/16-12 UNC UNF 102 to 135 115 to 75 to 100 85 to 115 to 155 135 to 85 to 114 100 to
9/16-18 155 114 175 130
5/8-11 5/8-18 UNC UNF 150 to 195 175 to 110 to 144 130 to 175 to 225 200 to 130 to 166 148 to
225 166 260 192
310 229 365 269
540 398 640 472
880 649 1015 749
1.0-8 1.0-12 UNC UNF 880 to 1185 985 649 to 874 726 to 1050 to 1355 1150 774 to 999 848 to
1.0-14 UN UNC to 1290 985 to 951 726 to 951 to 1490 1150 to 1099 848 to 1099
1-1/4-12 1290 N/A N/A 1490 2305 to 2983 1700 to 2200
NOTE: Torque values are for parts lubricated with a lightweight oil.
22
1400 SRM 1171 Troubleshooting
Troubleshooting
PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION
The lift truck will not move. The axle shaft is broken. Replace axle shaft.
The gears in the final drive are Replace gears.

damaged.
The final drive makes noise. The gears or shafts in the final Replace gears.
drive are damaged.
There is no oil in the axle. Fill axle with oil.
The final drive has leaks. There is no sealant between the Replace sealant.
joints of the planetary assembly.
There are capscrews missing Replace missing capscrews.

from the cover of the planetary
assembly.
There are plugs missing from the Replace missing plugs.

cover or housing of the planetary
axle.
Oil seals are worn or damaged. Replace oil seals.
Fittings or oil lines are loose or Tighten fittings or oil lines.

damaged (units with oil-cooled
brakes only).
23
NOTES
24
TECHNICAL PUBLICATIONS
1400 SRM 1171 11/14 (1/12)(7/11)(2/08)(7/07)(1/07)

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PLANETARY GEAR

PART NO. 1574068 1400 SRM 1171

©2014 HYSTER COMPANY i

This section is for the following models:

H40.00-48.00XM-12 (H800-1050HD/HDS) [A917];

Figure 1. Planetary Axle With Oil-Cooled Brakes

Legend for Figure 1

1. AXLE HOUSING 11. INNER HUB

1. DRAIN/FILL PLUG 15. RETAINER PLATE

Planetary Gear Axle Repair

4. Put a block under each outer mast channel.

6. Put additional blocks under frame behind the

1. STEER AXLE/STEER TIRES 2. DRIVE AXLE/DRIVE TIRES

Figure 3. Put Lift Truck on Blocks (A917)

1. STEER AXLE/STEER TIRES

Figure 4. Put the Lift Truck on Blocks (B222)

Do not sand, grind, chisel, hammer, or change lin-

NOTE: Under normal conditions, the disc assembly

6. Disconnect service brake lines.

7. Disconnect brake lines for parking brake at the

8. Disconnect cooling oil lines for oil-cooled

9. Put caps on all hydraulic lines, ports, and fit-

10. Disconnect drive shaft at differential.

2. Drain oil from the end of axle housing. WARNING

5. Drain cooling oil from service brakes. WARNING

Planetary Gear Carrier Legend for Figure 7

1. Align marks on planetary gear carrier and 1. HUB

3. Remove planetary gear carrier capscrews.

NOTE: Do not remove planetary gear carrier at

4. Insert a pry bar into assembly notches and sep-

Figure 6. Alignment Marks

2. Remove cover from planetary gear carrier. See

Figure 8. Planetary Gear Carrier Separation

Verify the lifting device has the rated capacity of

5. Use a lifting device to remove planetary gear

Figure 10. Pinion Shaft

9. Remove planetary gears and thrust washers

6. Place the planetary gear carrier assembly in a

NOTE: Use a soft material in bottom of the catch

7. Place a container under the press to catch the

8. Press each pinion shaft out of planetary gear

1. SUN GEAR 3. AXLE SHAFT

Figure 11. Sun Gear

1. WHEEL BEARING ADJUSTING NUT

Figure 12. Thrust Washer Assembly

5. Remove wheel bearing adjusting lock nut and

NOTE: To avoid dropping and possibly damaging

10. Remove wheel hub assembly from wheel hub Spindle

1. Remove two of the capscrews (opposite each

Figure 15. Wheel Hub and Drum

3. Remove the rotor. WARNING

5. Remove bearing cone with a suitable puller.

6. Remove wheel hub oil seal.

Do not repair the drive axle assemblies by welding.

2. Remove gasket material from parts. Use cau- PARTS INSPECTION

Parts With Rough Finishes ASSEMBLE

NOTE: Before the axle is steam cleaned, close or

Drying Cleaned Parts

PREVENTING CORROSION WARNING