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• 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.
• Always use YALE 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.
• 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 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 background.
The CAUTION symbol and word are on yellow background.
Drive Axle and Differential Assembly Repair Table of Contents
TABLE OF CONTENTS
General................................................................................................................................................................ 1
Drive Axle Repair................................................................................................................................................. 1
Remove and Disassemble .............................................................................................................................. 1
Clean and Inspect ........................................................................................................................................... 4
Assemble and Install ....................................................................................................................................... 4
Differential Repair................................................................................................................................................ 6
Remove ........................................................................................................................................................... 6
Support Differential Assembly From Differential Housing Assembly .......................................................... 6
Differential Assembly From Differential Assembly Support......................................................................... 8
Differential Assembly Support from Drop Box ............................................................................................ 11
Drive Pinion and Pinion Gear, From Differential Assembly Support ........................................................... 13
Disassemble.................................................................................................................................................... 14
Differential Assembly .................................................................................................................................. 14
Drop Box Housing....................................................................................................................................... 16
Differential Assembly Support..................................................................................................................... 17
Differential Housing..................................................................................................................................... 18
Clean and Inspect ........................................................................................................................................... 19
Assemble ........................................................................................................................................................ 19
Differential Housing..................................................................................................................................... 19
Differential Assembly Support..................................................................................................................... 20
Drop Box Housing....................................................................................................................................... 21
Differential Assembly .................................................................................................................................. 22
Install............................................................................................................................................................... 26
Pinion Inner Shim Set, Adjust Thickness (Depth of Pinion) ........................................................................ 26
Drive Pinion and Pinion Gear Into Differential Assembly Support .............................................................. 28
Differential Assembly Into Differential Assembly Support ........................................................................... 30
Ring Gear Backlash, Adjust ........................................................................................................................ 33
Gear Set, Tooth Contact Pattern Check...................................................................................................... 34
Differential Assembly Support Into Differential Housing ............................................................................. 37
Torque Specifications .......................................................................................................................................... 38
General
This section has the repair procedures for the drive axle and differential assembly.
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Drive Axle Repair 1400 YRM 1245
2
1400 YRM 1245 Drive Axle Repair
24. Remove pin retaining the thrust washer, planetary 27. Remove the thrust washer from the inside of plan-
gear, spacer, and needle bearings. See Figure 4. etary gear assembly. Repeat Step 19 through
Step 27 for the opposite side. See Figure 5.
25. Remove planetary gear, thrust washers, and nee-
dle bearings from housing.
3
Drive Axle Repair 1400 YRM 1245
4
1400 YRM 1245 Drive Axle Repair
14. Connect slings and lifting device to drive axle. Figure 7. Transmission to Differential Housing
Assembly Mounting Bolts
NOTE: When installing the drive axle, ensure the drive
axle is held with the upper surface of the drive axle 19. Remove blocks from under the transmission.
against the frame. This will prevent any gap between
20. Install parking brake cable. Make sure the brake ca-
the frame and the drive axle mount, and will ensure
ble is routed properly and has no interference. Ver-
even weight distribution.
ify that the parking brake operates properly. Refer
15. Position the drive axle in the lift truck. to the section Brake System 1800 YRM 1247.
NOTE: It is recommended to use a torque multiplier to 21. Connect the brake line connecting the master cylin-
achieve the torque specification in Step 16. der to the brake manifold located on top of the dif-
ferential housing assembly.
16. Install the four mounting capscrews and washers.
Tighten the capscrews to 820 to 902 N•m (605 to NOTE: When tightening the wheel nuts, DO NOT use
665 lbf ft). any lubricant on the studs or nuts.
17. Place the drive shaft in position and install the re- 22. Install the wheel and nuts and tighten the nuts to
taining capscrews. Tighten the drive shaft cap- 610 to 680 N•m (450 to 502 lbf ft).
screws to 50 to 66 N•m (37 to 49 lbf ft).
23. Apply multipurpose grease to new O-ring and install
18. Install the transmission isolator mounting bolt lo- O-ring on the drain plug.
cated on top of the assembly. Tighten the bolt to
24. Install the O-ring and drain plug, and tighten to 14
225 to 250 N•m (166 to 184 lbf ft). See Figure 7.
to 27 N•m (10 to 20 lbf ft).
5
Differential Repair 1400 YRM 1245
25. Fill the drive axle to the proper level with 7.5 to
8.0 liter (7.9 to 8.4 qt) of SAE 80W-90 gear oil
through the fill hole as shown in Figure 8.
32. Operate the lift truck and check for proper operation
and leaks.
Differential Repair
REMOVE 5. Remove brake manifold bracket.
For the following repair procedures, the drive axle must 6. Remove capscrews and lockwashers retaining
be removed and disassembled. Refer to the section the differential assembly support to the differential
Drive Axle Repair. housing.
Support Differential Assembly From Using two of the M8 × 1.25 × 40 capscrews re-
Differential Housing Assembly moved from the differential assembly support, push
the differential assembly support from the differen-
1. Remove input shaft (yoke). tial housing. If the capscrews do not have enough
threaded length, use a pry bar to finish removing
2. Remove the dust cover. the differential assembly support.
3. Remove the oil seal. See Figure 9. 7. Remove differential assembly support from the dif-
ferential housing assembly. See Figure 10.
4. Remove capscrew and lockwasher retaining brake
manifold bracket to the differential assembly sup-
port. See Figure 10.
6
1400 YRM 1245 Differential Repair
7
Differential Repair 1400 YRM 1245
NOTE: If the lift truck was manufactured prior to October 2006 and the retaining rings have not been replaced, go
to STEP 1. If the lift truck was manufactured after October 2006 or the retaining rings have been replaced in a lift
truck manufactured prior to October 2006, go to STEP 2.
STEP 1.
Remove differential assembly retainer ring cotter pins.
Using a retainer ring special tool, Yale P/N 580055253,
loosen the retainer rings. If necessary, loosen the
bearing cap capscrews to allow the retainer rings to
turn freely.
1. COTTER PIN
2. RETAINER RING
8
1400 YRM 1245 Differential Repair
STEP 2.
Remove differential assembly retainer ring cotter pins.
Using a retainer ring special tool, Yale P/N 580083667,
loosen the retainer rings. If necessary, loosen the
bearing cap capscrews to allow the retainer rings to
turn freely.
1. COTTER PIN
2. RETAINER RING
9
Differential Repair 1400 YRM 1245
STEP 3.
Remove the retainer rings.
STEP 4.
Mark one differential carrier leg and bearing cap to cor-
rectly match the parts when assembling differential as-
sembly support. Mark the part using a center punch
and hammer. Remove the capscrews and washers re-
taining the bearing caps. Remove the bearing caps.
10
1400 YRM 1245 Differential Repair
STEP 5.
Remove the differential assembly from the differential
assembly support.
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Differential Repair 1400 YRM 1245
CAUTION
When removing the pinion nut, make sure the staked areas do not touch the pinion threads. The staked
areas can cause damage to the pinion threads, making the pinion unserviceable.
STEP 2.
Use a small, flat chisel to unstake the pinion nut.
STEP 3.
Remove the capscrews, washers, and clamp retaining
the drop box housing.
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1400 YRM 1245 Differential Repair
STEP 1.
Carefully remove pinion assembly from the differential
assembly support. Using a press and a bearing puller,
remove the shims and inner bearing from the pinion.
STEP 2.
Remove drive gear and driven gear.
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Differential Repair 1400 YRM 1245
DISASSEMBLE
Differential Assembly
STEP 1.
Remove the bearing cups. Using a suitable bearing
puller, remove the bearings from the differential assem-
bly.
1. BEARING CUP
2. TAPERED ROLLER BEARING
3. DIFFERENTIAL ASSEMBLY
STEP 2.
Remove the capscrews retaining the ring gear to the dif-
ferential assembly. Remove the ring gear.
1. RING GEAR
2. DIFFERENTIAL ASSEMBLY
3. CAPSCREW
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1400 YRM 1245 Differential Repair
NOTE: Mark each side of the case halves before separating to ensure alignment at reassembly.
STEP 3.
Remove the capscrews retaining the case halves to-
gether and separate the case halves.
1. CAPSCREWS
2. CASE HALF
3. SPIDER ASSEMBLY
4. CASE HALF
STEP 4.
Remove the side gears and thrust washers from the
case halves.
1. CASE HALF
2. THRUST WASHER
3. SIDE GEAR
4. SPIDER ASSEMBLY
5. CASE HALF
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Differential Repair 1400 YRM 1245
STEP 5.
Remove the spherical washers and spider gears from
the cross.
1. SPHERICAL WASHER
2. SPIDER GEAR
3. CROSS
1. OUTER BEARING
2. DROP BOX HOUSING
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1400 YRM 1245 Differential Repair
STEP 2.
Using a suitable soft drift, remove the bearing cup.
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Differential Repair 1400 YRM 1245
STEP 2.
Using a bearing puller, remove inner bearing from the
differential assembly support.
Differential Housing
NOTE: Only remove the breather cap if damaged.
STEP 1.
Remove breather cap from differential housing.
1. DIFFERENTIAL HOUSING
2. BREATHER CAP
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1400 YRM 1245 Differential Repair
CLEAN AND INSPECT • Tapered roller bearings- Inspect the cup, cone,
rollers, and cage of all tapered roller bearings in the
WARNING assembly. If bearings show signs of wear, cracks, or
damage, replace with new bearing.
Cleaning solvents can be flammable and toxic and
• Pinion and gears- Inspect the pinion and gears for
can cause skin irritation. When using cleaning sol-
wear or damage. Gears that are worn or damaged
vents, always follow the recommendations of the
must be replaced.
manufacturer.
• Main differential assembly- Inspect all parts of the
main differential assembly for corrosion, wear, or
WARNING damage. Parts that are damaged must be replaced.
Compressed air can move particles so that they • Differential Assembly Support- Inspect all parts of
cause injury to the user or to other personnel. the differential assembly support for corrosion, wear,
Make sure that the path of the compressed air is or damage. Parts that are damaged must be re-
away from all personnel. Wear protective goggles placed.
or a face shield to prevent injury to the eyes. • Drop box housing- Inspect all parts of the drop box
housing for corrosion, wear, or damage. Parts that
Clean and inspect the following parts of the differential: are damaged must be replaced.
• Drive axle- Clean the parts of the axle with solvent • Alignment pins- Inspect all alignment pins for corro-
and dry with compressed air. Inspect all machined sion, wear, or damage. Parts that are damaged must
surfaces and bearings for wear and damage. be replaced.
ASSEMBLE
Differential Housing
STEP 1.
Wrap the breather cap threads with approximately 1.5
turns of Teflon tape. Install the breather cap.
1. DIFFERENTIAL HOUSING
2. BREATHER CAP
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Differential Repair 1400 YRM 1245
STEP 2.
Using a press, press the pinion inner bearing cup into
the differential assembly support.
20
1400 YRM 1245 Differential Repair
1. OUTER BEARING
2. DROP BOX HOUSING
STEP 2.
Using a press, press the inner cup until it seats on the
bottom of the bore.
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Differential Repair 1400 YRM 1245
Differential Assembly
STEP 1.
Lubricate both sides of the spherical washers with 80W
- 90 gear lube. Install the spider gears and spherical
washers onto the cross.
1. SPHERICAL WASHER
2. SPIDER GEAR
3. CROSS
STEP 2.
Lubricate both sides of the thrust washers with 80W -
90 gear lube. Install the side gears and thrust washers
into the differential halves.
1. CASE HALF
2. THRUST WASHER
3. SIDE GEAR
4. SPIDER ASSEMBLY
5. CASE HALF
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1400 YRM 1245 Differential Repair
STEP 3.
Place spider assembly into the case halves and assem-
ble the case halves. Apply Loctite® 242 to the threads
of the capscrews and install the capscrews. Tighten the
capscrews in the sequence shown to 125 to 145 N•m
(92 to 107 lbf ft).
1. CAPSCREWS
2. CASE HALF
3. SPIDER ASSEMBLY
4. CASE HALF
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Differential Repair 1400 YRM 1245
STEP 4.
Place the ring gear in position on the differential assem-
bly and install the capscrews. Tighten the capscrews
in the sequence shown to 152 to 167 N•m (112 to
123 lbf ft).
1. RING GEAR
2. DIFFERENTIAL ASSEMBLY
3. CAPSCREW
24
1400 YRM 1245 Differential Repair
CAUTION
Do not damage the bearing rollers or cage when pressing the bearing cones onto the differential assembly.
Press on the inner raceway of the cone.
STEP 5.
Press the bearing cones onto the differential assembly.
Install the bearing cups onto the bearing cones.
1. BEARING CUP
2. TAPERED ROLLER BEARING
3. DIFFERENTIAL ASSEMBLY
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Differential Repair 1400 YRM 1245
26
1400 YRM 1245 Differential Repair
Examples in. mm
NOTE: The Pinion Variation Number is on the end of the pinion. See Figure 12.
1. Original Shim Set Thickness 0.030 0.76
Original Pinion Variation Number = +2 in. (+0.05 mm) 0.002 0.05
Standard Shim Set Thickness 0.028 0.71
New Pinion Variation Number = +5 in. (+0.13 mm) +0.005 +0.13
New Shim Set Thickness = 0.033 0.84
2. Original Shim Set Thickness 0.030 0.76
Original Pinion Variation Number = 2 in. ( 0.05 mm) +0.002 +0.05
Standard Shim Set Thickness 0.032 0.81
New Pinion Variation Number = +5 in. (+0.13 mm) +0.005 +0.13
New Shim Set Thickness = 0.037 0.94
3. Original Shim Set Thickness 0.030 0.76
Original Pinion Variation Number = +2 in. (+0.05 mm) 0.002 0.05
Standard Shim Set Thickness 0.028 0.71
New Pinion Variation Number = 5 in. ( 0.13 mm) 0.005 0.13
New Shim Set Thickness = 0.023 0.58
4. Original Shim Set Thickness 0.030 0.76
Original Pinion Variation Number = 2 in. ( 0.05 mm) +0.002 +0.05
Standard Shim Set Thickness 0.032 0.81
New Pinion Variation Number = 5 in. ( 0.13 mm) 0.005 0.13
New Shim Set Thickness = 0.027 0.68
27
Differential Repair 1400 YRM 1245
STEP 2.
Install mounting distance (inner) shims, determined in
Pinion Inner Shim Set, Adjust Thickness (Depth of Pin-
ion), onto the pinion.
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1400 YRM 1245 Differential Repair
STEP 3.
Apply Loctite 515 sealant to the mating surface of the
drop box housing.
NOTE: Ensure the bearing being installed is lubricated with SAE 80W-90 gear oil.
STEP 4.
Install the preload (outer) shims and outer bearing. In-
stall the washer and new pinion nut.
29
Differential Repair 1400 YRM 1245
STEP 2.
Place the retainer rings in position in the differential as-
sembly support. Carefully place the bearing caps in the
same location as removed.
30
1400 YRM 1245 Differential Repair
NOTE: If the lift truck was manufactured prior to October 2006 and the retaining rings have not been replaced, go
to STEP 3. If the lift truck was manufactured after October 2006 or the retaining rings have been replaced in a lift
truck manufactured prior to October 2006, go to STEP 4.
STEP 3.
Using a retainer ring special tool, Yale P/N 580055253,
adjust the retainer rings in equal rotations so the back-
lash of the ring gear is 0.15 to 0.20 mm (0.006 to
0.008 in.). See Ring Gear Backlash, Adjust.
Verify that the rotating torque at the pinion shaft has in-
creased 0.5 to 0.7 N•m (4.4 to 6.2 lbf in). Check the
pinion and ring gear tooth contact pattern. See Gear
Set, Tooth Contact Pattern Check.
1. COTTER PIN
2. RETAINER RING
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Differential Repair 1400 YRM 1245
STEP 4.
Using a retainer ring special tool, Yale P/N 580083667,
adjust the retainer rings in equal rotations so the back-
lash of the ring gear is 0.20 to 0.28 mm (0.008 to
0.011 in.). See Ring Gear Backlash, Adjust.
Verify that the rotating torque at the pinion shaft has in-
creased 0.5 to 0.7 N•m (4.4 to 6.2 lbf in). check the
pinion and ring gear tooth contact pattern. See Gear
Set, Tooth Contact Pattern Check.
1. COTTER PIN
2. RETAINER RING
STEP 5.
Stake the pinion nut with 8 mm spherical punch until a 1 to 2 mm (0.039 to 0.079 in.) gap is between the nut and
pinion shaft at two places. Retighten the drop box capscrews to 19 to 23 N•m (14 to 17 lbf ft).
32
1400 YRM 1245 Differential Repair
STEP 6.
Apply RTV High Performance sealant, Yale P/N
580057351 or equivalent, to the mating surface of
the pinion cover plate.
Ring Gear Backlash, Adjust 7. If the backlash reading is not within specifications,
adjust backlash using retainer rings. Continue onto
If the old gear set is installed, adjust the backlash to Step 8 through Step 11.
the setting that was measured before the differential as-
sembly was disassembled. 8. Verify that the bearing cap capscrews are only fin-
ger tight.
If a new gear set will be installed, adjust the backlash
to 0.15 to 0.20 mm (0.006 to 0.008 in.).
33
Differential Repair 1400 YRM 1245
34
1400 YRM 1245 Differential Repair
The contact area is the center between the top and NOTE: Normal pattern during adjustment shown.
bottom of the tooth. The contact area is toward the
inner circumference of the ring gear.
The contact area is the center between the top and the NOTE: Wear pattern from operation shown.
bottom of the tooth. The contact area will be almost
the full length of the tooth.
35
Differential Repair 1400 YRM 1245
The pinion is too far away from the center of the gear.
Add shims to move pinion toward ring gear. Check that
the clearance is correct. Some movement of ring gear
away from pinion may be necessary.
36
1400 YRM 1245 Differential Repair
1. DIFFERENTIAL HOUSING
2. DIFFERENTIAL ASSEMBLY SUPPORT
3. BRAKE MANIFOLD BRACKET
4. WASHERS
5. CAPSCREWS
6. CAPSCREWS
7. WASHERS
STEP 2.
Using a press on the outer diameter of the input shaft
oil seal, press the input shaft oil seal into the drop box
until the seal is flush with the housing. After installing
the oil seal, apply grease to the lip of the oil seal.
37
Torque Specifications 1400 YRM 1245
Torque Specifications
Axle Shaft Capscrews Drop Box Housing Capscrews
90 to 99 N•m (66 to 73 lbf ft) 19 to 23 N•m (14 to 17 lbf ft)
38
Yale Europe Materials Handling Limited
Flagship House, Reading Road North, Fleet, Hampshire GU138 HR United Kingdom