LIFT TRUCK SERIES: G35S-2 G40S-2 G45S-2 G40SC-2 G45SC-2 G50SC-2. November 15, 2000 CODE 3150 LT3150-L0 SUBJECT: NEW DRIVE AXLE

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1 LIFT TRUCK SERIES: G35S-2 G40S-2 G45S-2 G40SC-2 G45SC-2 G50SC-2 November 15, 2000 CODE 3150 LT3150-L0 SUBJECT: NEW DRIVE AXLE A new drive axle has been introduced in the above model lift trucks. The purpose of this bulletin is to provide a supplement to the service manual (SB2202E00), which follows. Also, refer to the parts manual, part no. SB1010E01. AFFECTED TRUCKS: Serial numbers CB and up. INTERCHANGEABILITY: The new drive axle assembly is interchangeable with the old drive axle assembly.

2 Differential - Service Manual (SB2202E00) Page 7 7) Torque for bolts kg.m ( lb.ft) 8) Torque for bolts 15-17kg.m ( lb.ft) 9) Torque for bolts 11-13kg.m (80-94lb.ft) 10) Apply Loctite to the surface 1) Pinion gear Inside diameter mm (0.787 in) Wear limit mm (0.797 in) Drive Axle - Service Manual (SB2202E00) Page 16 2) Spider Outside diameter mm (0.787 in) Wear limit mm (0.778 in) 3) Thrust washer Thickness mm ( in) Wear limit. 1.7 mm ( in) 4) Thrust washer Thickness..2.0 mm ( in) Wear limit..1.7 mm ( in) Drive Axle - Service Manual (SB2202E00) Page 8 Carrier Assembly. (2) Drive Shaft. (3) Hub Assembly. (4) Pinion Gear. (5) Ring Gear. (6) Differential Pinion Gears. (7) Spider. (8) Side Gears. (9) Bearings. (10) Plate. (11) Planetary Gears. (12) Planetary Carrier. 1) Torque for bolts.15-17kg.m ( lb.ft) 2) Torque for plug kg.m ( lb.ft) 3) Torque for bolts kg.m ( lb.ft) 4) Torque for bolts.15-17kg.m ( lb.ft) 5) Torque for bolts kg.m (36-54lb.ft) 6) Torque for bolts. 9-16kg.m (65-116lb.ft)

3 Disassembly & Assembly Drive Axle - Service Manual (SB2202E00) Page Disassembly Prior to disassemble clean axle housing carefully. A great help is a bright, spacious working place, free of dirt and chips. The necessary working steps are described and illustrated in the correct sequence. Parts only available as assembly groups will not be stripped any further. Removal and Strip Down of Wheel Hub (4) (3) 1. Loosen oil drain plugs on axle housing and hub and drain oil. 5. Remove snap ring (5) from the planetary carrier. (5) 2. Loosen and remove two cylindrical bolts from brake drum (2). 6. Remove 3 planetary pins (6) with hammer. (6) (2) 3. Remove Brake Drum using cylindrical bolts. 7. Remove needle bearings (7), gears (8) and thrust washers (9). 4. Loosen cylindrical bolts (3) and remove planetary carrier (4) using the bolts. (5) (6) (8) (7) (9)

4 8. Remove axle shaft (10) with sun gear. 13. With the aid of a copper mandrel and a hammer, drive bearings out of the wheel hub. Due to this, the radial shaft seal will be damaged. (10) 9. Remove stop ring (11) and pull off sun gear (12) from the shaft (13). (12) (11) (13) 10. Loosen 8 bolts (14) and remove ring gear & torque plate assembly and shims from axle tube. (14) 11. Remove snap ring from the ring gear and pull torque plate out of the ring gear. 12. Remove wheel hub assembly from the axle tube.

5 Removal and Strip Down of the Axle Housing 6. Loosen and remove the bolts (6) on the (6) 1. Loosen the bolts and remove them. Fasten link bracket to the housing and a hoist. Lift the carrier assembly out of the housing. differential ring gear. 2. Measure rolling resistance of differential assembly and record it for the purpose of reassembly. Remove the locking plates (2). 7. Loosen and remove the bolts (7) on the differential housing. (7) (2) (2) 8. Open differential housing halves. Observe marking prior to opening, as this one must be brought to the same position for reassembly. 3. Prior to remove the differential assembly from the carrier (3), note the mounting position of the caps (4) to the carrier. If not existing, identify mounting position with a mark. (5) (3) (4) 9. Take out thrust washers, side gears, pinion gears and spider and keep them on a clean place. 4. Loosen the 4 hexagon bolts (5). Remove both caps (4). 5. Lift differential assembly out of the carrier.

6 10. Loosen locknut (8). (9) (8) 11. By means of a plastic hammer, drive bevel pinion shaft (9) carefully out of the bearing seat. Note : Take care that bevel pinion shaft is not damaged when driving it out. 12. Remove shims (10) and spacer (11) from the pinion shaft. Pull off the tapered roller bearing inner race from the bevel pinion shaft with the aid of a special bearing puller. (10) (11) 13. With the aid of a copper mandrel and a hammer, drive the tapered roller bearing outer race and shims out of the housing. Do not reuse deformed shims. 14. Tapered roller bearing outer race on the opposite side has to be driven out.

7 Reassembly Clean all parts with a suitable cleaning agent and remove residues of LOCTITE.! WARNING Keep away cleaning agent from your skin, do not drink it or inhale its vapours! Wear safety gloves and goggles! In case of skin contact rinse immediately with a lot of water! If by mistake the cleaning agent was swallowed, call medical aid immediately! Observe regulations for prevention of accidents! Check all parts for wear, damages and cracks, if required replace them. In case of damaged running teeth, the gear set parts have to be replaced per set. Always replace damaged tapered roller bearings (inner and outer race). Do not reuse deformed shim rings and worn thrust washers. Touch up seal faces or smoothen with a fine file. If there is no stamped value, C = 0. Example : Dim. E measured on the housing mm (6.415 in) Dim. B with factory setting to mm (5.244 in) Dim. T measured on the bearing mm (1.152 in) Dim. C stamped on the pinion mm (0.002 in) Then, shim thickness X ; X = = 0.45 mm ( = in) Note : In case of damages on the running teeth, replace bevel gear shaft and bevel gear only per set. Do not reuse or install deformed shims or damaged bearings. 2. Shim ring thickness determined has to be obtained by combining shim rings of variable thickness. Place shim rings into bearing seat. With the aid of a copper mandrel drive bearing outer race into the bearing seat of the housing until contact. Determination of Installation Dimension For Bevel Pinion Shaft 1. The bevel gear set consisting of bevel gear shaft and bevel gear is provided with certain installation dimensions. The correct adjustment of the bevel pinion shaft is required for an exact setting of the contact pattern and the torsional backlash. Shim ring thickness and the correct adjustment of the bevel pinion shaft can be determined according to the following method. 3. Heat bearing inner race up to max. 100 C (212 F) and place onto bevel pinion shaft until contact. Install subsequently until contact after cooling down!! Measure housing dimension E on the housing.! By the equation X = E B T C, it is possible to calculate the thickness of the shim. Which means : B = Installation dimension of bevel pinion shaft is mm (5.244 in) T = Bearing width C = Stamped value on the pinion end face.

8 Measurement Bearing Play of Bevel Pinion Shaft Adjustment of Bearing Preload on Bevel Pinion Shaft 1. Install bearing cup. Put the spacer into the pinion shaft and place shim rings determined on the spacer. With the following method, the dimensions can be used to determine the shim ring (2) thickness. Dim. C = Distance from seat of bearing outer race to spacer surface. Dim. S = Distance from plane face of bearing outer race to plane face of bearing inner race. Calculate shim ring thickness (2) by means of equation Z = S C Example : S = 2.25 mm (0.089 in) measured on bearing C = 1.85 mm (0.073 in) measured on housing Z = = 0.40 mm (Z = = in) 2. Put the pinion shaft into the carrier. Install bearing cone and lock nut. Apply grease into the outer bearing. Apply LOCTITE 271 on pinion thread and tighten locknut to a torque of 45 ~ 51 kg.m (325 ~ 369 lb.ft). Measure rolling resistance of pinion shaft. Adjust shim ring thickness until rolling resistance is 0.20 ~ 0.41 kg.m (1.45 ~ 2.97 lb.ft). Stake locknut into a slot of pinion shaft.

9 Preassembly Differential (2) 5. Place differential assembly into the carrier. Locate bearing cups and screws into the housing halves. It is advantageous to fix the torsional backlash now. This is done by means of the screws. Position dial gauge with magnetic stand right-angled to a tooth flank and measure the torsional backlash rotating the bevel gear. Torsional backlash : 0.18 ~ 0.23 mm (0.007 ~ in) 1. Place thrust washer, side gear, spiders with gears and washers, side gear and thrust washer into one differential housing half. Apply grease onto the bevel gears and thrust washers. 2. Join differential housing halves. NOTE : Observe marking when housing halves are joined! Markings must be in the same position. 3. Connect differential housing halves with bolts. Apply LOCTITE 271 onto threads of bolts. Tighten bolts. Tightening torque : 5 ~ 7.5 kg.m (36 ~ 54 lb.ft) 6. Locate bearing caps. NOTE : Consider same marking on caps to the housing. Fasten bearing caps with hexagon bolts. Tightening torque : 15 ~ 17 kg.m (109 ~ 123 lb.ft) Measure the rolling resistance of the taper roller bearing. Proper rolling resistance of new parts has variety like following table according to the rolling resistance of pinion shaft which was measured in the procedure of Adjustment of Bearing Preload on Bevel Pinion Shaft, Assemble Ring gear with bolts (2). Apply LOCTITE 271 onto threads of bolts. Tightening bolts. Tightening torque : 9 ~ 16 kg.m (65 ~ 116 lb.ft)

10 Rolling Resistance of Bevel Pinion Rolling Resistance of Taper Roller Bearing 0.20 kg.m (1.45 lb.ft) 0.35 ~ 0.41 kg.m (2.53 ~ 2.97 lb.ft) 0.25 kg.m (1.81 lb.ft) 0.40 ~ 0.46 kg.m (2.89 ~ 3.33 lb.ft) 0.30 kg.m (2.17 lb.ft) 0.45 ~ 0.51 kg.m (3.25 ~ 3.69 lb.ft) 0.35 kg.m (2.53 lb.ft) 0.50 ~ 0.56 kg.m (3.62 ~ 4.05 lb.ft) 0.41 kg.m (2.97 lb.ft) 0.56 ~ 0.62 kg.m (4.05 ~ 4.48 lb.ft) Mounting of Brake and Wheel Hub to the Axle Housing 1. Apply LOCTITE 271 onto threads of bolts. Fasten brake plate and axle flange with cylindrical bolts to the axle housing. Tightening torque : 15 ~ 17 kg.m (109 ~ 123 lb.ft) 7. Check if screw fits closely with the bearing. 8. Check torsional backlash once more, as described before. (Bearing caps are tightened) In case of deviations it is possible to correct those over screws. 9. Apply Loctite 271 onto threads of the bearing cap bolts. Tighten the bolts to a torque of 15 ~ 17 kg.m (109 ~ 123 lb.ft). 10. Install locking plates with hexagon bolts. Apply Loctite 271 on threads of the bolts. Tighten the bolts to a torque of 0.8 ~ 1.2 kg.m (5.79 ~ 8.68 lb.ft). 2. Lead brake cable through the provided borehole of the brake carrier and hook it on the pressure rod of brake shoes. Assemble brake shoes, compression springs and tension springs as described in the disassembly Section in reverse order. NOTE : Make the same step on the second side! 11. Apply marking ink onto 3 ~ 4 tooth flanks of the crown gear and have it to get in mesh with the bevel pinion several times. Check contact pattern as described in manual (SB2202E00 page 71) Assembly of Carrier into Axle Housing 3. Drive bearings into the wheel hub until contact. 1. Put gasket on the axle housing face. 2. Install carrier assembly into axle housing. 3. Connect carrier assembly on axle housing with the hexagon bolts. Apply LOCTITE 271 onto threads of the bolts. Tighten bolts. Tightening torque : 11 ~ 13 kg.m (80 ~ 94 lb.ft) NOTE : Then, install the radial shaft seal with the lip of the seal toward the outside of the wheel hub. Apply grease or oil in seal assembly.

11 4. Install preassembled wheel hub onto axle tube flange until contact. Insert bearing cone. (2.2 ~ 3.6 lb.ft) according to the 0.05 mm ( in) thickness change of shim packs. d. If rolling resistance is correct, loosen the bolts (4) and apply LOCTITE 271 onto the threads of bolts. Tighten the bolts to a torque of 15 ~ 17 kg.m (109 ~ 123 lb.ft). 6. Insert sun gear into axle and hold it with stop ring. Insert axle shaft assembly (5) into the axle. Apply grease on the face of shaft which contact bush. Apply grease on the planetary gear teeth. 5. Insert shims and assemble torque plate into ring gear with snap ring and install the ring gear and torque plate assembly onto the axle tube. Apply LOCTITE 271 onto the threads of bolts (2) and tighten the bolts to a torque 15 ~ 17 kg.m (109 ~ 123 lb.ft). Apply grease on the bush. (5) 7. Insert all inner parts into the planetary carrier in the reverse order of removal. (2) When new parts are used, shim thickness (3) should be determined as follows. (3) (4) a. Insert shim rings of 0.5 mm ( in) thickness between torque plate and bearing cone. b. Tighten the bolts (4) to a torque of 15 ~ 17 kg.m (109 ~ 123 lb.ft). c. Rotate the hub several times and measure rolling resistance of the bearings. Adjust shim pack thickness until rolling resistance is 1.5 ~ 3 kg.m (10.9 ~ 21.7 lb.ft). Please add shims if the rolling resistance is less than 1.5 kg.m (10.9 lb.ft) and subtract shims if it is higher than 3 kg.m (21.7 lb.ft). For reference, the rolling resistance varies about 0.3 ~ 0.5 kg.m 8. Install planetary carrier assembly on the wheel hub. Tighten the bolts (6) to a torque of 2.5 ~ 4.0

12 kg.m (18.1 ~ 28.9 lb.ft). (6) 9. Install brake drum and tighten the bolts (7) to a torque of 2.5 ~ 4.0 kg.m (18.1 ~ 28.9 lb.ft). (7) (7)