',))(5(17,$/

H60-80C; H110-150F; HR45-25, HR45-31, HR45-40S, HR45-36L,

HR45-40LS, HR45H [A227]; HR45-EC, HR48-EC [A228];
S/H6.00-7.00XL (S/H135-155XL) [B024, F006];
H150-250E; H7.00-12.50H (H150-275H); H8.00-12.00XL
(H165-280XL) [E007]; H13.00-16.00XL (H300-360XL) [D019];
H8.00-12.00XM (H170-280HD) [F007]; H13.00-16.00XM
(H360HD) [E019]; H14.00-20.00XM (H400-450H) [A214]; H250-300A;
H13.50-16.00B (H300-350B); H360-620B; H16.00-32.00C
(H360-650C, H370-700C); H700-800A; H36.00-44.00B (H700-920B);
H36.00-48.00C (H800-1050C); H36.00-48.00E (H800-1050E) [D117];
S125-150A; P40-50A; P60-80A; P125-150A; P7.00-9.00B
(P150-200B); KE; M200-400H; M600A; RS45-30CH; RS46-35CH;
RS45-25IH; RS46-30IH [A222]

PART NO. 910072 1400 SRM 46

1400 SRM 46 Differential Repair

General
This section has the description and repair procedures for the differential. There are Specifications and a
Troubleshooting table at the end of this section.

Description
This differential is fastened to the axle housing of the power from the pinion through the differential as-
lift truck. The differential gives a single-speed re- sembly to the axles. The differential assembly per-
duction for an increase in torque to the drive wheels. mits the drive wheels to rotate at different speeds
There is a housing, a ring and pinion gear set, and during a turn.
the differential assembly. The ring gear transfers

Differential Repair
REMOVE 3. If the ring and pinion gears will be used again,
check the clearance between the gears and make
NOTE: The repair procedures cover all units unless a record of the value. See Figure 5.
otherwise indicated.
4. A complete disassembly is not normally neces-
NOTE: The differential assembly can normally be sary. Disassemble the differential to make nec-
removed without removing the drive axle. On some essary repairs. See Figure 1. Put marks on one
trucks, including the H7.00-12.50H (H150-275H), bearing cap and the case half so that it can be in-
the drive axle must be removed to remove the differ- stalled in the same place. Put marks on each half
ential assembly. of the differential case so that they can be assem-
bled in the same way. Keep the shim set for the
1. Disconnect the drive shaft at the differential. If
pinion carrier assembly.
a speed reducer or gear box is installed, remove
the speed reducer or gear box.
CAUTION
2. Some units have a drum or disc brake attached to
Never use a hammer and chisel to remove the
the output yoke. Be sure to disconnect any brake
rivets. Damage to the holes can occur.
linkage or brake lines. See the brake section for
your unit. 5. If it is necessary, remove the ring gear from
the case. Make sure the rivet holes in the case
3. Remove the axle shafts from the axle housing.
are not damaged. Use a center punch and drill
See the drive axle section for your unit. On
smaller than the rivets to remove the rivets.
STRADDLE TRUCKS, disconnect the drive
Keep the old ring gear and pinion set.
axle universal joints at the differential yokes.
Remove the capscrews that fasten the bearing ASSEMBLE
retainers to the differential housing. Pull the
yoke, stub shaft, and bearing retainer from the Pinion, Bearings, and Pinion Carrier,
housing.
Assemble
DISASSEMBLE 1. Put differential oil on the bearings and cups. In-
stall the cups in the pinion carrier. See Figure 1.
1. Use a lifting device as a support for the differen-
tial. Remove the housing capscrews and remove 2. Install the inner bearing and pilot bearing
the differential from the axle housing. against the pinion shoulders. Use a sleeve and
press to push against the inner bearing race.
2. If the unit has a drum or disc brake attached
to the output yoke, remove it. See the brakes
section for your unit.

1
Differential Repair 1400 SRM 46

1. PINION NUT 11. SIDE GEAR 20. CASE HALF, FLANGE 30. WASHER
2. WASHER* 12. THRUST WASHER 21. NUT* 31. PILOT BEARING
3. INPUT YOKE* 13. CASE HALF 22. NUT 32. PINION
4. DEFLECTOR 14. BEARING CONE 23. WASHER 33. SPACER
5. SEAL 15. BEARING CUP 24. THRUST BLOCK* 34. SHIM
6. HOUSING 16. PINION 25. BEARING CAP 35. PINION CARRIER
7. FILL PLUG 17. SPIDER 26. LOCK PIN
8. ADJUSTMENT RING 18. CAPSCREW OR 27. JAM NUT*
9. LOCK PLATE RIVET* 28. THRUST SCREW*
10. CAPSCREW 19. RING GEAR 29. SNAP RING

*SOME AXLES DO NOT HAVE THE PARTS DESCRIBED

Figure 1. Differential Assembly with Generoid Gears

2
1400 SRM 46 Differential Repair

2. If a press cannot be used for preload, install all

CAUTION the parts that are held by the pinion nut. Tighten
If a new pinion is installed, a new ring gear the pinion nut to the correct torque shown in Ta-
must also be installed. The pinion and ring ble 1. Check the preload as described in Step 1.
gear are a set (see Figure 4) and MUST be in-
stalled together.

3. Install the pilot bearing washer and snap ring.

Put the pinion assembly in the pinion carrier. In-
stall the spacers on the pinion.

NOTE: During assembly at the factory, one spacer is

used. Two thinner spacers are used if the pinion or
bearings are replaced. These spacers are selected for
correct bearing preload.

NOTE: Some pilot bearings are fastened to the pin-

ion with a snap ring, and some are fastened with a
punch. Others can have a two-piece bearing.

4. Use a press to install the outer bearing against 1. PRESS 3. PINION BEARING
the spacer. Rotate the carrier to make sure the 2. SLEEVE
bearings are installed correctly. Use the press
to apply the correct preload. See Specifications, Figure 2. Bearing Preload Check
Rivet Installation Pressure. Check the bearing
preload as described in Pinion Bearings, Adjust Pinion Carrier Shim Set, Adjust Thickness
Preload of this section. (Depth of Pinion)

Pinion Bearings, Adjust Preload NOTE: Use this procedure if a new ring gear and pin-
ion set is installed, or if the depth of the pinion has
1. Wrap a cord several times around the pinion car- to be adjusted.
rier. Fasten a Newton or pound scale to the cord.
See Figure 2. Pull the scale to unwind the cord. 1. After the preload is correctly adjusted using the
Check the reading on the scale as the cord un- spacer set, adjust the pinion. The pinion is ad-
winds smoothly. Do NOT use the reading as the justed using shims on the pinion carrier assem-
cord just begins to unwind. The scale reading bly. If the same ring gear and pinion are used,
must indicate 2.2 to 7.0 kg (5 to 15 lb). use the old shim set. See Figure 3. If a new ring
gear and pinion are used, adjust the pinion as de-
A pinion carrier that has a 76.2 mm (3 in.) ra- scribed.
dius and a 2.2 kg (5 lb) scale reading is equal to
1.70 N•m (15 lbf in). Select a spacer set for the CAUTION
correct preload. A thinner set will increase the Always use a minimum of three shims for the
preload. shim set. Use the thinnest shims on the outside
of the set for a better seal.
CAUTION
2. The correct shim set thickness can be found by
On H7.00-12.50H (H150-275H) trucks, do NOT
using the old and new parts. Use the old shim set
use the washer that is on the new pinion. Use
thickness and the numbers on the old and new
the thicker spacer (Hyster PN 125277). The
pinion and ring gear sets. For the location and
threads can be damaged or the nut can loosen
identification of the numbers, see Figure 4.
if the washer is used.

3
Differential Repair 1400 SRM 46

numbers: ring gear, 36786; drive pinion, 36787.

If a gear set number has a letter that follows the
number, the letters must be the same for both the
ring gear and pinion.

GEAR TEETH NUMBER. The gear teeth

numbers are the numbers of the teeth on the
pinion and ring gear. The number of pinion teeth
is the first number. An example of this number
is 5-37. In the example, the drive pinion has 5
teeth and the ring gear has 37 teeth.

GEAR SET NUMBER. The gear set number

is a letter and number. Make sure the letter and
number are the same on the drive pinion and ring
gear. An example of a gear set number is M29.

PINION CONE NUMBER. The pinion cone

number, is the variation from the design cen-
ter. The design center is the exact design dis-
1. SHIM SET (CONTROLS DEPTH OF PINION) tance from the end of the pinion cone to the
2. BEARING CARRIER ring gear centerline. See Figure 5.
3. DIFFERENTIAL HOUSING
4. SPACER(S) (CONTROLS BEARING PRELOAD)

Figure 3. Shim Set Location

1. PART NUMBERS 1. PINION CONE NUMBER (VARIATION)

2. GEAR TEETH NUMBERS
3. GEAR SET NUMBERS
Figure 5. Pinion Cone Number Location
4. PINION CONE NUMBERS
NOTE: The pinion cone number is not used when the
Figure 4. Pinion Set Numbers
gear set number is being checked. The pinion cone
NOTE: Always check the gear set for the correct number is used when you adjust the depth of the pin-
marks to make sure the gears are a matched set. ion in the carrier.

3. The location of the pinion and ring gear marks Example: PC+3, PC−3, +3, or −3 equals .003 inch
are shown in Figure 4. The description of the (variation). PC+.03, PC−.03, +.03, or −.03 equals
marks is as follows: .03 mm (variation).

PART NUMBER. The part numbers are the Find the correct thickness of the shim set as fol-
part number of the manufacturer. The part num- lows:
ber for the ring gear is always an even number. 4. Use a micrometer to measure the total thickness
The part number for the pinion is the next odd of the old shim set that was removed from under
number. Check to make sure the pinion and ring
gear are in a sequence. Examples of gear set part

4
1400 SRM 46 Differential Repair

the pinion carrier. Make a note of the measure- 8. Install the universal joint yoke, flange for the
ment for later use. brake rotor or brake drum, or the gear for the
speed reducer. See Figure 7. Install the spacer
5. Check the pinion cone number for the old pinion. and pinion nut. Tighten the pinion nut to the cor-
See Figure 5. If this number is a plus (+) value, rect torque as shown in Table 1.
subtract the value from the value in Step 4. If
the pinion cone number is a minus (−) value, add Differential and Ring Gear, Assemble
the number to the value in Step 4. The number
shown is in 0.00X inch (+2 = +0.002 inch). The
result is the standard thickness for a shim set. CAUTION
Assembly of ring gear on the differential case
NOTE: The value calculated in Step 5 is the thickness must be correct for correct gear adjustment
of the standard shim set, without a variation. and maximum wear.
6. Check the pinion cone number for the new pin- Make sure the ring gear is part of the set of the pinion
ion. Add or subtract this number to the standard and ring gear. See Figure 4.
thickness value of Step 5. Add the number if the
value is a plus (+) value. Subtract the number if
the value is a minus (−) value. The result is the CAUTION
correct thickness for the new shim set. See the Do not install a cold ring gear on the flange
examples. case half. A cold ring gear will damage the
case half because of the close tolerance. Metal
NOTE: The value calculated in Step 6 is the thick- particles between the parts will cause gear
ness of the new shim set that will be installed. See runout that will exceed the specification of
the examples shown in Specifications, Pinion Adjust- 0.2 mm (0.008 in.).
ment.
1. Heat the ring gear in 71 to 82 C (160 to 180 F)
water for approximately ten minutes. Heating
CAUTION
the gear makes it fit easier on the differential
Always use a minimum of three shims for the case.
shim set. Use the thinnest shims on the outside
of the set for a better seal.

7. Install the pinion carrier assembly using the cor-

rect shim set. See Figure 6. Tighten the cap-
screws to the correct value shown in Table 1.

a. If there is a bracket for a disc brake caliper,

install the bracket and tighten the cap-
screws.

b. If there is a speed reducer or drop box, install

it on the pinion carrier assembly. Use John
Crane No. 2® as a sealant. Tighten the nuts
to the correct value shown in Table 1.
1. PINION AND BEARING CARRIER
2. SHIMS
CAUTION 3. DIFFERENTIAL HOUSING
On H7.00-12.50H (H150-275H) trucks, do NOT
use the washer that is on the new pinion. Figure 6. Pinion Carrier Assembly Installation
Use the thicker spacer (Hyster Part Number
125277). The threads can be damaged or the
nut can loosen if the washer is used.

5
Differential Repair 1400 SRM 46

1. BRAKE DISC 3. AIR CHAMBER 5. YOKE 7. SEAL

2. BRAKE CALIPER 4. BRACKET 6. BEARING CARRIER

Figure 7. Units with Air Operated Disc Brakes

6. If RIVETS are used to fasten the ring gear to
WARNING the flange case half, install the rivets cold. Do
Wear protective clothing to prevent injury not heat the rivets. For the correct pressure
when handling the hot ring gear. to press the rivets, see Specifications, Pinion
Preload Pressure. The maximum pressure must
CAUTION be applied for approximately one minute at the
end of the press cycle. Do not use more than the
Never use a press or hammer to install the ring
maximum pressure. Damage to the holes can
gear.
occur. A correctly installed rivet will have a head
2. Take care and lift the ring gear from the water at least 3.18 mm (0.125 in.) larger than the hole
using a lifting tool. diameter. Install the rivets in pairs opposite
each other (A-A, B-B), from the case half side of
3. Install the ring gear on the flange case half im- the assembly. See Figure 9.
mediately after the gear is heated. If the ring
gear does not fit easily on the case half, heat the 7. Use a thickness gauge that has a thickness of
gear again. 0.08 mm (0.003 in.) to check for correct instal-
lation. Put the gauge between the ring gear and
4. Align fastener holes of the ring gear and flange the case at four points that are separated by 90 .
case half. Rotate the ring gear as needed. The gauge cannot go in more than half the dis-
tance between the flange outer diameter and the
5. If SPECIAL CAPSCREWS are used to fasten the pilot diameter for the gear. If the gauge goes
ring gear to the flange case half, install the cap- more than half the distance, the ring gear must
screws, washers, and nuts as shown in Figure 8. be removed and installed again. See Figure 10.
The capscrew heads MUST be against the ring
gear. Use pairs of capscrews opposite each other
to tighten the case and ring gear together. For
capscrew torque specifications, see Table 1.

6
1400 SRM 46 Differential Repair

10. Put the flange case half on a bench with the ring
gear teeth toward the top.

1. FLANGE CASE HALF

2. RING GEAR
3. BOLT HEAD AGAINST GEAR

Figure 8. Installation with Capscrews

1. CHECK FOR CLEARANCE FOUR PLACES WITH

0.08 mm (0.003 in.) GAUGE

Figure 10. Gear and Case Half Installation

Check

Differential Pinion and Side Gear

Assembly, Assemble
1. Install one thrust washer and side gear in the
case. Put the pinion gears and thrust washers
on the spider. Install the spider assembly in
the case. Install the other side gear and thrust
washer.
1. RING GEAR 2. CASE HALF
2. Align the marks and assemble the two halves of
Figure 9. Installation with Rivets the differential case. See Figure 11.

8. Install the bearing cones on both of the case 3. Use Loctite No. 272® on the threads of the cap-
halves. Use a press and a sleeve of the correct screws. Install four of the capscrews, washers
size. and nuts into the case halves in a cross pattern.
The distance between the fasteners MUST be
9. Apply axle lubricant to the inside surfaces of both equal. Tighten the fasteners to the correct torque
case halves, spider (cross), thrust washers, side value in a pattern opposite each other. See Fig-
gears, and differential pinions. ure 12. Also see Table 1.

7
Differential Repair 1400 SRM 46

1. APPROXIMATELY 305 mm (12 in.)

2. WELD NUT TO END OF SHAFT

Figure 13. Tool to Check Differential Gears

1. THRUST WASHER 4. CASE HALF 2. Install the tool into the differential until the
2. SIDE GEAR 5. ALIGNMENT
3. SPIDER GEARS MARKS splines of the tool engage one side of the gear.

Figure 11. Differential Pinion and Side Gears 3. Attach a torque wrench to the nut on the tool
and rotate the differential gears. Read the value
indicated on the torque wrench as the differen-
tial gears rotate. See Figure 14. The maximum
torque applied to one side gear must not exceed
68 N•m (50 lbf ft). If the torque value exceeds
this specification, disassemble the differential
gears from the case halves.

Figure 12. Fasteners Tightening Sequence

4. Install the other fasteners into the case halves.

Tighten the fasteners to the correct torque value.

5. Check that the differential gears can freely ro-

tate in the case. 1. TOOL 2. READ TORQUE
VALUE
Differential Gears Rotating Torque, Check
Figure 14. Rotating Torque Check
NOTE: Make a tool for checking the rotating torque
of the differential gears. The tool can be made from 4. Check the case halves, spider, gears, and thrust
an axle shaft that has the same spline size of the washers for the problem that caused the incor-
differential side gear. See Figure 13. rect torque value. Repair or replace parts as nec-
essary. Assemble the parts after repair and re-
1. Put the differential and ring gear assembly in a peat Step 1 through Step 3.
vise. Be sure to install soft metal covers for the
jaws of the vise to protect the ring gear.

8
1400 SRM 46 Differential Repair

Differential and Ring Gear Assembly, cups MUST be flat against the bores between the
Install carrier legs. See Figure 15. Make sure that the
ring gear does not touch the pinion.
1. Clean the oil and dirt from the outer diameters of
the bearing cups and bearing bores in the carrier 6. Install both of the bearing adjusting rings into
and bearing caps. There is no special cleaning position between the carrier legs. Turn each ad-
required. justing ring until hand tight against the bearing
cups. See Figure 16.
2. Apply axle lubricant to the bearing cones and the
inner diameters of the bearing cups of the main
differential. Do NOT get oil on the outer diame-
ter of the bearing cup, and Do NOT permit oil to
drop onto bearing bores.

NOTE: Adhesives normally become hard (dry) in ap-

proximately two hours. Be sure to complete the as-
sembly process within this time period. If two hours
have passed since application of the adhesive, clean
the parts again and apply new adhesive.

3. Apply a continuous bead of adhesive to the bear-

ing bores in the carrier and bearing caps. Ap-
ply the adhesive completely around the smooth,
ground surfaces ONLY. DO NOT put adhesive on
threaded areas.

4. Install the bearing cups over the bearing cones

that are assembled on the case halves. See Fig- 1. BEARING CAP
2. BEARING BORE
ure 15. 3. ADJUSTMENT RING
4. ALIGNMENT MARKS

Figure 16. Bearing Caps Installation

7. Install the bearing caps over the bearings and ad-

justment rings in the correct location as marked
before removal.

WARNING
Wear eye protection. Do not hit steel parts with
a steel hammer. Parts can break and cause in-
jury.

8. Use a light leather, plastic, or rubber hammer

and seat each bearing cap to move it into position.
The caps MUST fit easily against the bearings,
adjustment rings, and carrier. DO NOT FORCE
THE BEARING CAP INTO POSITION.
1. BEARING CUP 3. BEARING BORE
2. CARRIER 4. PUT ADHESIVE 9. Install the capscrews and washers that hold
HERE
bearing caps to the carrier. Tighten the cap-
Figure 15. Differential Assembly Installation screws by hand four to six turns, then tighten
the capscrews to the correct torque value. See
5. Use a lifting device that has the capacity to lift Table 1.
the weight of the differential assembly and in-
stall the assembly into the carrier. The bearing

9
Differential Repair 1400 SRM 46

spanner type wrench can be used for this pur-

CAUTION pose. Be sure the wrench fits correctly so that
If bearing caps are not installed in the correct the lugs will not be damaged.
original locations, the bores and threads in
caps will not match the carrier. Assembling 3. Push the differential assembly left and right to
mismatched caps into the carrier can result in see that axial movement shows on the dial in-
carrier damage after reassembly to axle and dicator. Use two pry bars, one between the dif-
during vehicle operation. Do not force the ferential case and carrier, and one between ring
bearing caps into unmatched bore locations in gear side and the carrier. For the method used,
the carrier. see Figure 18.

10. If the bearing caps do not correctly fit into po- 4. Tighten the bearing adjustment ring that was
sition, check the alignment marks between the just loosened so that there is no movement of the
caps and the carrier. Remove the caps and re- differential assembly. Now, tighten each adjust-
peat Step 5. ment ring one notch to obtain the preload. The
maximum axial movement permitted is 0.15 to
NOTE: Do not install the cotter keys, pins, or lock 0.33 mm (0.006 to 0.013 in.) (see NOTE that
plates (as furnished on axle model) that hold the follows). The maximum torque required to turn
bearing adjusting rings in position. First, adjust the the differential bearings is 1.7 to 3.9 N•m (15 to
preload of the differential bearings, adjust the gear 35 lbf in).
clearance, and check the tooth contact pattern.
NOTE: Use 0.08 to 0.22 mm (0.003 to 0.009 in.) on
Differential Bearings, Preload Adjust Rockwell RS-140 and RS-145 axles.

1. Make sure the ring gear is not touching the pin- 5. Continue assembly and check the runout of the
ion. Install a dial indicator as shown in Fig- ring gear.
ure 17. Adjust the dial indicator so that the
plunger or pointer is against the back surface of
the ring gear.

1. DIAL INDICATOR
1. BAR MUST NOT TOUCH BEARINGS
Figure 17. Bearing Preload Adjustment
Figure 18. Gear Movement Check
2. Loosen the bearing adjustment ring that is on the
same side as the dial indicator. Ring Gear, Runout Check
1. Attach a dial indicator to the mounting flange of
CAUTION the carrier as shown in Figure 17. Adjust the
Always use a tool that engages two or more op- dial indicator so that the plunger or pointer is
posite notches in the adjustment ring. A T-bar against the back surface of the ring gear. Set the
indicator to zero.

10
1400 SRM 46 Differential Repair

2. Rotate the ring gear and check the dial indi- NOTE: If the original gear set is installed, adjust the
cator for the maximum needle movement. The clearance to the original value recorded in Step 1 of
maximum movement permitted is 0.20 mm Disassemble. If a new gear set is installed, adjust the
(0.008 in.). If the movement exceeds the maxi- adjustment rings for 0.25 mm (0.010 in.).
mum limit, remove the differential and ring gear
assembly from the carrier and find the reason NOTE: If the unit has a thrust block, tighten the
for the movement. adjustment screw. The thrust block must be tight
against the ring gear. Turn the adjustment screw
3. Install the differential and ring gear into the 90 counterclockwise and tighten the jam nut. The
carrier after the parts are repaired or replaced. clearance between the thrust block and ring gear
Use the procedure in the section Differential and will be 0.25 to 0.38 mm (0.010 to 0.015 in.). On
Ring Gear Assembly, Install. Repeat the preload H6.00-7.00XL (H135-155XL) units, set the clearance
adjustment of the differential bearings. by turning the thrust screw counterclockwise 180 .
Tighten the jam nut to the specification shown in
Gear Clearance, Adjust Table 1. The correct clearance between the thrust
screw and the ring gear is 0.635 to 0.889 mm (0.025
1. Install a dial indicator as shown in Figure 19. Be to 0.035 in.). Refer to Figure 20.
sure the plunger or pointer touches the tooth sur-
face. Make sure the preload adjustment of the Install into Axle Housing
differential bearing is complete before the clear-
ance is adjusted. NOTE: For correct torque values for the fasteners
used in this installation, see Table 1. For general lo-
2. The gear clearance adjustment is done by loosen- cation of the fasteners, see Figure 21.
ing one bearing adjustment ring and tightening
the other adjustment ring the same amount. 1. Use Loctite Sealant No. 504 or silicone RTV
sealant on the flange of the differential assem-
bly housing. Install the differential assembly in
the axle housing. Tighten the nuts or capscrews.
Do the following as required:

a. ON UNITS WITH AIR OPERATED DISC

BRAKES, install mounting brackets for
slack adjusters. Install the air chamber
rod pins and the cotter pin in the splined
coupling.

b. ON UNITS WITH HYDRAULIC DISC

BRAKES, install the parts of the brake as
described in the brake section for your unit.
Connect the drive shaft and tighten the
capscrews at the yoke to 120 N•m (90 lbf ft).

c. On H7.00-12.50H (H150-257H) units, assem-

ble the axle. Install the axle in the lift truck
if it was removed. Connect the drive shaft.
Make sure to use a 11 mm (0.4375 in.) spacer
between the speed reducer gear and the pin-
Figure 19. Gear Clearance Check ion nut. Tighten the nut to 1342 to 1790 N•m
(990 to 1320 lbf ft) without lubricant. Always
Gear Set, Tooth Contact Pattern Check use a new nut.

NOTE: The gear clearance can be changed within

the limits of 0.13 to 0.38 mm (0.005 to 0.015 in.) for
better tooth contact.

11
Differential Repair 1400 SRM 46

Figure 20. Ring Gear and Pinion Tooth Contact Adjustment (Generoid Gears)

12
1400 SRM 46 Differential Repair

d. On STRADDLE TRUCKS, install the bear- correct position on the input shaft. The nut
ing and seal in the bearing retainer. Install can require torque up to 271 N•m (200 lbf ft)
the universal joint yoke in the bearing re- to install the yoke correctly.
tainer. Install the snap ring to hold the yoke.
Install the stub shaft in the differential. Use
CAUTION
a new gasket and install the yoke and bear-
ing retainer. Install the capscrews for the Make sure the seal is not damaged as the yoke
bearing retainer. Install the yoke capscrew. passes through the seal.
Tighten the capscrews.
f. Remove the nut, collar, and pilot shaft. In-
2. Do the following for H26.00-32.00C (H550-700C) stall the assembly nut for the yoke on the end
and H36.00-48.00C (H800-1050C) units with a of the input shaft. Tighten the assembly nut
drum brake installed on the differential: to 1627 N•m (1200 lbf ft).

NOTE: Special tools (a pilot shaft, a collar, and an g. Install the brake drum and fasten with the
installation nut) are required to install the yoke cor- eight capscrews.
rectly. See Figure 21.
h. Attach the linkage to the brake adjuster arm.
a. Apply axle lubricant on the yoke seal. Connect the drive shaft from the yoke flange
on the brake drum.
b. Check all surfaces of the yoke hub for dam-
age. If necessary, polish the yoke hub with
emery cloth or crocus cloth.

c. Install the pilot shaft on the input shaft of

the differential. See Figure 21.

CAUTION
Do not use a hammer or mallet to install the
yoke onto the shaft. A hammer or mallet can
damage the yoke.

d. Slide the yoke over the pilot shaft. Align the

yoke splines with the shaft splines. Slide the
collar onto the pilot shaft and against the
yoke. See Figure 21.
1. INPUT SHAFT 5. COLLAR*
CAUTION 2. YOKE 6. PILOT SHAFT*
3. BRAKE DRUM 7. DIFFERENTIAL
Do not use the yoke assembly nut for the instal- 4. NUT* HOUSING
lation procedure. Use a similar nut for the pro-
cedure described in Figure 21. *SPECIAL TOOL

e. Install the nut on the pilot shaft. Tighten the Figure 21. Yoke Installation
nut against the collar until the yoke is in the

13
Specifications 1400 SRM 46

Specifications
GENERAL SPECIFICATIONS PINION ADJUSTMENT
Item Specification mm in
Pinion Rotating Torque 0.11 to 1.70 N•m Example 1
(0.08 to 1.3 lbf ft)
Thickness of old shim set 0.76 0.030
Ring Gear Movement 0.20 mm (0.008 in.) Oil pinion cone number (PC+2) −0.05 −0.002
(Clearance)
Standard thickness of shim set 0.71 0.028
Ring Gear Clearance 0.13 to 0.38 mm New pinion cone number (PC+5) +0.13 +0.005
(0.005 to 0.015 in.)
Correct thickness for new shim 0.84 0.033
set
RIVET INSTALLATION PRESSURE
Example 2
Pressure for Correct Installation Thickness of old shim set 0.76 0.030
Kg/Metric Inch (mm) Pounds/Tons Old pinion cone number (PC+2) −0.05 +0.002
Tons Standard thickness of shim set 0.81 0.032
19958/20 7/16 (11.13) 44,000/22 New pinion cone number (PC+5) +0.13 +0.005

27216/27.2 1/2 (12.7) 60,000/30 Correct thickness for new shim 0.94 0.037
set
32659/32.7 9/16 (14.3) 72,000/36
Example 3
40824/40.8 5/8 (15.88) 90,000/45
Thickness of old shim set 0.76 0.030
Old pinion cone number (PC+2) −0.05 −0.002
PINION PRELOAD PRESSURE
Standard thickness of shim set 0.71 0.028
Pressure for Correct Preload New pinion cone number (PC−5) −0.13 −0.005
Pinion Nut Kg/Metric Pounds/Tons Correct thickness for new shim 0.58 0.023
Thread Size Tons set
7/8" - 20 9979/10 22,000/11 Example 4
1" - 20 13608/13.6 30,000/15 Thickness of old shim set 0.76 0.030
1-1/4" - 12 24494/24.5 54,000/27 Old pinion cone number (PC−2) +0.05 +0.002

1-1/4" - 18 24494/24.5 54,000/27 Standard thickness of shim set 0.81 0.032

New pinion cone number (PC−5) −0.13 −0.005
1-1/2" - 12 24494/24.5 54,000/27
Correct thickness for new shim 0.68 0.027
1-1/2" - 18 24494/24.5 54,000/27 set
1-3/4" - 12 22680/22.7 50,000/25
NOTE: Item Numbers in Table 1 correspond to num-
2" - 12 22680/22.7 50,000/25 bered callouts on Figure 22.

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1400 SRM 46 Specifications

NOTE: SEE TABLE 1 FOR TORQUE VALUES.

Figure 22. Fasteners Location (Typical Differential Assembly)

Table 1. Torque Specifications

Item Location Size N•m* lbf ft*

No.
1 Bearing Cap Capscrews 9/16" - 12 156 to 190 115 to 140
5/8" - 11 217 to 258 160 to 190
3/4" - 10 393 to 475 290 to 350
7/8" - 14 504 to 590 372 to 435
7/8" - 9 637 to 746 470 to 550
2 Differential Case Capscrews ** 3/8" - 16 41 to 68 30 to 50
7/16" - 14 81 to 102 60 to 75
1/2" - 13 122 to 163 90 to 120
1/2" - 20 142 to 183 105 to 135
5/8" - 11 251 to 319 185 to 235
5/8" - 18 285 to 366 210 to 270
3 Ring Gear to Case Capscrews 1/2" - 13 122 to 163 90 to 120
5/8" - 11 203 to 258 150 to 190
5/8" - 18 258 to 285 190 to 210
See Figure 22 for Item Nos.
*Torque values are for threads lubricated with machine oil unless Loctite is used.
**Use Loctite No. 272 on the capscrews.

15
Specifications 1400 SRM 46

Table 1. Torque Specifications (Continued)

Item Location Size N•m* lbf ft*

No.
4 Thrust Screw Jam Nut 3/4" - 16 197 to 258 145 to 190
7/8" - 14 197 to 258 145 to 190
5 Pinion Carrier to Housing Capscrews 3/8" - 16 41 to 54 30 to 40
7/16" - 14 68 to 88 50 to 65
1/2" - 13 108 to 142 80 to 105
5/8" - 11 176 to 230 130 to 170
6 Pinion Nut 7/8" - 20 271 to 373 200 to 275
1" - 20 407 to 542 300 to 400
1-1/4" - 12 949 to 1220 700 to 900
1-1/4" - 18 949 to 1220 700 to 900
1-1/2" - 12 1085 to 1492 800 to 1100
1-1/2" - 18 1085 to 1492 800 to 1100
1-3/4" - 12 1220 to 1627 900 to 1200
2" - 12 1627 to 2034 1200 to 1500
See Figure 22 for Item Nos.
*Torque values are for threads lubricated with machine oil unless Loctite is used.
**Use Loctite No. 272 on the capscrews.

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1400 SRM 46 Troubleshooting

Troubleshooting

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

The lift truck will not move. Ring and pinion gears are damaged. Repair the damaged gears.

Axle shaft(s) is damaged. Replace axle shaft(s).

The differential makes noise. The gears or shafts in the differential Repair the damaged gears.
are damaged.

There is no oil in the axle housing. Fill the axle with the correct oil.

Parts of the brake assembly are dam- Repair the parts of the brakes.
aged.

The mounting bolts for the differen- Tighten the capscrews.

tial housing are loose.

The ring and pinion are not adjusted Check and adjust the gears.
correctly.

The nut for the input yoke is loose. Tighten the nut.

The thrust screw is not adjusted cor- Adjust and tighten the screw and jam
rectly. nut.

The differential has leaks. There is no sealant between the dif- Assemble the parts with the correct
ferential and drive axle housing. sealant.

There are capscrews missing from Install the missing capscrews.

the differential assembly.

There are plug(s) missing from the Install the missing plug(s).
differential housing.

The seal for the yoke is damaged. Install a new seal.

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