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7

Chapter 7 FRONT AXLE AND REDUCTION DIFFERENTIAL

1. Specifications.......................................................................................... 7-12. Structure .................................................................................................. 7-2

2.1 Standard Model (with Drum Brake) .........................................................................7-22.2 Option Model (with Wet Disc Brake)........................................................................7-3

3. Removal and Installation........................................................................ 7-43.1 Front Wheels (Common to Standard and Option Truck) .........................................7-43.2 Shoe and Lining (Standard Truck)...........................................................................7-73.3 Wet Disc Brake Assembly (Option Truck) ...............................................................7-83.4 Front Axle Assembly (Standard Truck)....................................................................7-93.5 Front Axle Assembly (Option Truck)...................................................................... 7-133.6 Removal and Installation of Each Assembly (Standard Truck) ............................. 7-173.7 Removal and Installation of Each Assembly (Option Truck) ................................. 7-20

4. Disassembly and Reassembly............................................................. 7-214.1 Tube Assembly and Final Reduction (Standard Truck)......................................... 7-214.2 Tube Assembly and Final Reduction (Option Truck)............................................. 7-314.3 Wear Gauge for Wet Disc Brakes ......................................................................... 7-454.4 Reduction Differential (Common to Standard and Option Truck) .......................... 7-46

5. Troubleshooting (Common to Standard and Option Truck) ............. 7-616. Service Data........................................................................................... 7-62

7-1

FRONT AXLE AND REDUCTION DIFFERENTIAL

Chapter 7 FRONT AXLE AND REDUCTION DIFFERENTIAL

1. Specifications

ItemTruck model

P8000 P9000 P10000 P11000 P12000PD8000 PD9000 PD10000 PD11000 PD12000

Power transmission device

Reduction gearsGear type Hypoid gear

Reduction gear ratio 5.667

Final reduction gears

Gear type Planet gear

Reduction gear ratio 4.125

Differential gears

Case type Banjo type

Gear type and number

Large Straight bevel gear x 2

Small Straight bevel pinion x 2

Traveling deviceFront axle type Full-floating axle tube

Suspension sys-tem Front wheel Built-in frame

7-2


2. Structure2.1 Standard Model (with Drum Brake)

The front axle assembly is bolted to the frame at theframe supports.The reduction differential is double-reduction gearwhich is composed of an input flange and reductionpinion, reduction pinion and reduction gear.Transmission power generated from the center shaft,reduces power at the final reduction, and the powergoes out to the axle shaft.

The axle shaft relays this power to the wheel hubs,which causes the wheels to rotate, and the lift truck tomove.The wheel brake, which is connected to the axle tubevia the frame support, produces braking force by gen-erating friction between the shoe and drum.

1 Frame support2 Universal joint3 Input flange4 Drive gear5 Driven gear6 Reduction pinion

7 Reduction gear8 Differential pinion9 Differential gear

10 Center shaft11 Planet carrier12 Planet gear

13 Ring gear14 Axle shaft15 Wheel hub16 Wheel brake drum17 Wheel Brakes

Wheel hub and brake

Final reduction

Reduction differential

116 1715

2

3

4

56

7810

12

1311

149

215693

7-3


2.2 Option Model (with Wet Disc Brake)

1 Frame support2 Universal joint3 Input flange4 Drive gear5 Driven gear6 Reduction pinion

7 Reduction gear8 Differential pinion9 Differential gear

10 Center shaft11 Planet carrier12 Planet gear

13 Ring gear14 Axle shaft15 Wheel hub16 Wet disc brake assembly

Wheel hub and brake

Final reduction

Reduction differential

11615

2

3

4

56

7810

12

1311

149

215693

7-4


3. Removal and Installation3.1 Front Wheels (Common to Standard and Option Truck)3.1.1 Preparation(1) Block the rear wheels.

(2) Loosen the wheel nuts by two full turns.

(3) Raise the front wheels off the ground by eithermethod below.

(4) Stop the engine.

Raising the front wheels(a) Method using a crane

Hitch slings to the eye-bolts at both ends of thetop cross member on the outer mast, and thenlift the front end of the lift truck with a hoist.

(b) Using hydraulic systemFirstly, tilt the mast all the way back and placewood blocks under the mast. Then, tilt the mastforward to raise the front wheels.

213685

215907

After the front wheels are raised by either method, be sure to place jack stands under the frame to support it.

215908

7-5


3.1.2 RemovalRemoval sequence (single tires)

Removal sequence (double tires)

Suggestions for removal

In the case of double wheels, remove the outer wheelnuts and outer wheel. Then, remove the inner wheelnuts and the inner wheel.

1 Wheel nuts2 Front wheels

1

2

215694

1 Extension valves2 Wheel nuts (outer)3 Front wheels (outer)4 Wheel nuts (inner)5 Front wheels (inner)

1

2

3

5

4

216935

216936

Inner wheel nuts

Outer wheel nuts

7-6


3.1.3 InstallationFor installation, follow the removal sequence inreverse by referring to the following instructions below.(1) Wheel nuts

(a) Thoroughly clean the fitting surfaces of thewheel bolts and nuts using a metal cleaningsolvent. Make sure all of the oil is cleaned offthe fitting.

(b) Evenly tighten the wheel nuts with a torquewrench to the specified torque so that thewheels do not wobble during operation. Use atorque wrench.

(2) Retighten wheel nuts

(a) After installation, perform a test drive for 10minutes to check for proper performance of for-ward/reverse drive and the braking system.

(b) Retighten all the wheel nuts with a torquewrench to the specified torque.

(3) Do not forget to tighten the inner wheel nuts whenretightening the outer wheel nuts of the doubletires.

Unit: N·m (kgf·m) [lbf·ft]

Tightening torquesingle tires double tires

600 (61.2) [442.8]

Follow the proper tightening order by referring to the illustration on the right. Tighten the wheel nuts with a torque wrench.

16

4

2 5

3

215695

216989

Loosen the outer nut

Tighten the inner nut

Tighten the outer nut

Tightening sequence of double tires

7-7


3.2 Shoe and Lining (Standard Truck)Note: Removal and installation of brake shoes and

linings can be done by removing the wheelbrake drum (the work can be done without re-moving the axle shaft and wheel hub.) This sec-tion describes the removal and installationprocedure of the shoes and linings. Refer to "9BRAKE SYSTEM" for more details.

3.2.1 PreparationRemove the front wheels. For removing front wheels,refer to the previous section.

3.2.2 Removal(1) Brake drums

Evenly tighten the two jack bolts into place asshown in the illustration, and remove the brakedrum.

(2) Brake shoeUse the notch in the wheel hub to remove shoeand lining. Refer to "9 BRAKE SYSTEM" for moredetails.

3.2.3 Inspection and AdjustmentBrake drums

(a) Thoroughly clean and remove any dirt on thefriction surface with a clean rag.

(b) If oil or grease adheres to the lining or drum,use a brake cleaner.

3.2.4 InstallationBrake drumsEvenly tap the wheel fitting surface to secure the brakedrum in place.

Unit: mm (in.)

Jack bolt M14 x 1.5 Nominal length:50 (1.97)

215696

Return springinstallingpoint

Hold down spring215909

Concaved pointof wheel hub

7-8


3.3 Wet Disc Brake Assembly (Option Truck)3.3.1 PreparationRemove the front wheels. For removing front wheels,refer to "3.1 Front Wheels (Common to Standard andOption truck)".

3.3.2 RemovalFor removing the wet disc brake assembly, refer to "9.BRAKE SYSTEM".

3.3.3 Inspection and AdjustmentFor inspection and adjustment of wet disc brakeassembly, refer to "9. BRAKE SYSTEM".

3.3.4 InstallationFor installing the wet disc brake assembly, refer to "9.BRAKE SYSTEM".

7-9


3.4 Front Axle Assembly (Standard Truck)3.4.1 Preparation(1) Block the rear wheels.

(2) Remove the mast assembly. For removing mastassembly, refer to "12 MAST AND FORKS."

(3) Place a proper-sized container under the fronthousing to collect oil. Drain the oil from the frontaxle by removing the oil filler plug and the drainplug from the front housing.

(4) Remove the front wheels. For removing frontwheels, refer to "3.1 Front Wheels."

(5) Place jack stands under the frame to support it.For raising the front wheels, refer to "3.1 FrontWheels."

(6) Support the front axle housing with a mission jack.

Unit: liter (cu.in.)

Oil capacity 7.9 (482.1)

215698

Unit: kg (lb)

Item

Truck modelP8000, P9000 P10000, P11000, P12000

PD8000, PD9000

PD10000, PD11000, PD12000

Front axle weight

Approximately 440 (970)

Approximately 460 (1014)

Be sure to support the front axle housing securely to prevent it from falling because the differential is not located in the center of the front axle.

215989

Mission jack

7-10


3.4.2 Removal

215699

1

2

3

Removal sequence1 Brake pipe 2 Universal joint 3 Front axle assembly

7-11


Suggestions for Removal

(1) Brake pipeAfter removing the brake pipe, close the brakepipe connector with tape to prevent dust or foreignsubstances from entering.

(2) Universal joint

(a) Using a rope, hold the universal joint to thetransmission.

(b) Separate the universal joint from the inputflange side of the reduction differential.

(3) Front axle assembly

(a) Place jack stands under the transmission toprevent it from falling.

(b) Remove the connecting bolts between thetransmission and the front axle.

(c) Remove mounting nuts from each side of theaxle support, then remove the front axleassembly.

Note: The two bolts (shown in the right illustration) onthe left support contact to the brake hose andconnector. Displace or remove the brake hoseand connector to remove the bolts.

Transmission oil will drain if the universal joint sepa-rates from the transmission.

Input flange side ofreduction differential

Remove the bolt on theinput flange side

Universal joint

215700

Front axle

Transmission

Connecting bolts

Place jack stand 215701

215910

Mounting nut

217317

The bolt contacts

Connector

Bolt

Brake hoseConnector

Bolt

Brake hose

Top view

7-12


3.4.3 InstallationFor installation, follow the removal sequence inreverse.

Suggestions for Installation

Bleeding the air out of the brake oil circuit Bleed the air out of the brake oil circuit before install-ing the mast assembly. For bleeding air, refer to "9 BRAKE SYSTEM."

Tightening torque for main partsUnit: N·m (kgf·m) [lbf·ft]

Item All truck model

Mounting bolts on input flange side

54.0 to 63.8(5.5 to 6.5)

[39.9 to 47.1]Apply LOCTITE 242.

Connecting bolts between the transmission and the front axle

59.8 ± 5.98(6.1 ± 0.6)[44.1 ± 4.4]

Axle support mounting nuts94 ± 69

(70.8 ± 7.0)[512.2 ± 50.9]

7-13


3.5 Front Axle Assembly (Option Truck)3.5.1 Preparation(1) Block the rear wheels.

(2) Remove the mast assembly. For removing mastassembly, refer to "12 MAST AND FORKS."

(3) Place a proper-sized container under the fronthousing to collect oil. Drain the oil from the frontaxle by removing the oil filler plug and the drainplug from the front housing.

(4) Remove the front wheels. For removing frontwheels, refer to "3.1 Front Wheels."

(5) Place jack stands under the frame to support it.For raising the front wheels, refer to "3.1 FrontWheels."

(6) Remove the drain plug that installed on the backof right and left wet disc brake assemblies. Then,drain brake oil.

(7) Support the front axle housing with a mission jack.

Unit: liter (cu.in.)

Oil capacity 7.9 (482.1)

215698

217163

Unit: kg (lb)


Front axle weight Approximately438 (965.8)

Be sure to support the front axle housing securely to prevent it from falling because the differential is not located in the center of the front axle.

215989

Mission jack

7-14


3.5.2 Removal

215699

12

4

3

Removal sequence1 Brake pipe2 Universal joint

3 Cooling return horse4 Front axle assembly

7-15



(1) Brake pipeAfter removing the brake pipe, close the brakepipe connector with tape to prevent dust or foreignsubstances from entering.

(2) Cooling return horseAfter removing the cooling return horse, close thecooling return horse connector with tape to pre-vent dust or foreign substances from entering.

(3) Universal joint

(a) Using a rope, hold the universal joint to thetransmission.

(b) Separate the universal joint from the inputflange side of the reduction differential.

(4) Front axle assembly

(a) Place jack stands under the transmission toprevent it from falling.

(b) Remove the connecting bolts between thetransmission and the front axle.

(c) Remove mounting nuts from each side of theaxle support, then remove the front axleassembly.

Note: The two bolts (shown in the right illustration) onthe left support contact to the brake hose andconnector. Displace or remove the brake hoseand connector to remove the bolts.

Transmission oil will drain if the universal joint sepa-rates from the transmission.

Input flange side ofreduction differential

Remove the bolt on theinput flange side

Universal joint

215700

Front axle

Transmission

Connecting bolts

Place jack stand 215701

215910

Mounting nut

217317

The bolt contacts

Connector

Bolt

Brake hoseConnector

Bolt

Brake hose

Top view

7-16


3.5.3 InstallationFor installation, follow the removal sequence inreverse.

Suggestions for Installation

Bleeding the air out of the brake oil circuit Bleed the air out of the brake oil circuit before install-ing the mast assembly. For bleeding air, refer to "9 BRAKE SYSTEM."

Tightening torque for main partsUnit: N·m (kgf·m) [lbf·ft]


Mounting bolts on input flange side

54.0 to 63.8(5.5 to 6.5)

[39.9 to 47.1]Apply LOCTITE 242.

Connecting bolts between the transmission and the front axle

59.8 ± 5.98(6.1 ± 0.6)[44.1 ± 4.4]

Axle support mounting nuts94 ± 69

(70.8 ± 7.0)[512.2 ± 50.9]

7-17


3.6 Removal and Installation of Each Assembly (Standard Truck)3.6.1 Preparation(1) Remove the front axle assembly. For removing

the front axle assembly, refer to "Preparation" of"Front Axle Assembly (Standard Truck)".

3.6.2 Removal

215702

The numbers indicate the removal sequence.

5

4

1

2

3

1 Axle shaft2 Tube assembly and final reduction3 Center shaft

4 Reduction differential assembly5 Axle housing

7-18



(1) Tube assembly and final reduction

(a) Set a wire rope between the support and thebrake part, and lift the wire rope taut with ahoist.

(b) Remove mounting bolts, and remove the chainassembly while lifting. Then, the center shaftwill be simultaneously disengaged.

Note: Pay attention to the axle housing as the final re-duction ring gear may remain attached to theaxle housing.

(2) Reduction differential assembly

(a) Place the front axle housing with the differentialside facing upward.

(b) Install two eye bolts at the positions indicatedby the "a" in the illustration, attach wire ropesto the eye bolts, and lift the wire ropes taut witha hoist.

(c) Remove the mounting bolts, and install the twojack bolts at the positions indicated by the "b"in the illustration, and evenly tighten the twobolts until the reduction differential assembly isremoved.

Unit: kg (lb)

Item

Truck modelP8000,P9000 P10000,P11000,P12000

PD8000, PD9000

PD10000,PD11000, PD12000

Tube Assembly weight

Approximately147 (324)

Approximately161 (355)

215703

Ring gear

215911

Threaded hole for the eye bolt M12 x 1.25

Unit: mm (in.)

Jack bolt M12 x 1.25Approximate nominal length: 30 (1.18)

a b

a

b215704

Mounting bolt

7-19


(d) Lift the reduction differential assembly using ahoist, and remove the assembly from the frontaxle housing.

3.6.3 InstallationTo install, follow the removal sequence in reverse. Suggestions for Installation

(1) Reduction differential assembly(a) Thoroughly clean the mounting surface, and

apply a liquid gasket onto the surface.

(b) Tighten the mounting bolts to the specifiedtorque.

(2) Tube assembly

(a) Tighten the mounting bolts to the specifiedtorque.

Unit: kg (lb)

Reduction DifferentialAssembly weight 88 (194)

215705

Liquid gasket ThreeBond #1104or equivalent


Tightening torque108 ± 9.8

(11.0 ± 0.1)[79.7 ± 7.2]

215706


Tightening torque 300 (30.6) [221.4]

215912

Tube assembly

7-20


3.7 Removal and Installation of Each Assembly (Option Truck)3.7.1 Preparation(1) Remove the front axle assembly. For removing

the front axle assembly, refer to "Preparation" of"Front Axle Assembly (Option Truck)".

3.7.2 Removal


The removing procedure is same as for a standardtruck.

3.7.3 InstallationThe installing procedure is same as for a standardtruck.

215702

The numbers indicate the removal sequence.

4

2

1

3

5

1 Axle shaft2 Tube assembly and final reduction3 Center shaft

4 Reduction differential assembly5 Axle housing

Unit: kg (lb)

Item All truck modelTube Assembly weight 150 (330.8)

7-21


4. Disassembly and Reassembly4.1 Tube Assembly and Final Reduction (Standard Truck)4.1.1 Disassembly

215707

910

3

5

67

23

4

2 1

2

14

13

1516 17

18

20 21

2219

25

24

81012

11

Disassembly sequence1 Ring gear2 O-ring3 Plug4 Set screw5 Planet carrier 6 Snap ring7 Ball bearing8 Spring pin9 Planet pin

10 Thrust washer11 Planet gear12 Needle bearing13 Brake drums14 Lock ring15 Lock nut16 Wheel hub17 Tapered roller bearing18 Oil seal

19 Oil seal20 Seal retainer 21 O-ring22 Tapered roller bearing23 Wheel Brakes24 Axle support 25 Axle tube

7-22


Disassembly Suggestions on Final Reduction (1) Ring gear

(a) Tap the ring gear along the periphery with acopper hammer so that the ring gear is stag-gered from the mating face with axle tube.

(b) Remove the ring gear by hammering it from thebottom.

(2) Planet carrier

(a) Remove the plug.

(b) Remove the set screw located deep inside.

(c) Remove the planet carrier assembly.

(3) Ball bearingRemove the snap ring, and then remove the ballbearing.

(4) Planet gear

(a) Install the spring pin into the planet pin hole.

Tap to stagger

Hit and Remove

215708

Unit: mm (in.)

Width across flats ofhexagon socket 5 (0.2)

Unit: mm (in.)

Width across flats ofhexagon socket 3 (0.12) 215709

Plug

Set screwPlanet carrier assembly

215710

Install

Planet pinSpring pin

215913

Into the planet pin hole

7-23


(b) After removing the planet pin, remove theplanet gear, thrust washer, and needle bearingat the same time.

Disassembly Suggestions on Tube Assembly

(1) Lock nut

(a) Remove the lock ring, and remove the lock nutusing a lock nut wrench.

(2) Front wheel hub

(a) Remove the front wheel hub using a wheel hubpuller.

(b) Remove the oil seal from the front wheel hub.

Planet pin

Planet carrierPlanet gear

Needle bearings

Thrust washer

Thrust washer

215711

Special toolLock nut wrench 03703-49000

215712

Special tool

Special tool

Wheel hub puller Commercially available hub puller

Unit: kg (lb)

Weight of front wheel hub Approximately23.5 (805.7)

215914

Special tool

Oil seal

215915

Front wheel hub

7-24


(3) Tapered roller bearing

(a) Remove the tapered roller bearing and the oilseal retainer together using a bearing retainer.

(b) Remove the O-ring from the oil seal retainer.

(4) Wheel Brake assembly

(a) Remove the mounting bolts and remove thewheel brake assembly.

(b) Remove the mounting bolts and remove theaxle support.

215916

Oil seal retainer

O-ring

215917

Wheel brake

215918

Axle support

215919

7-25


4.1.2 Inspection and Repair(1) Axle shaft

(a) Spline backlash Install the planet carrier of the final reduction tothe splined end of the axle shaft, and measurethe shaft rotation backlash with a dial gauge.

(b) Axle shaft deflectionMeasure deflection with a dial gauge posi-tioned on the center of the axle shaft whilerotating the shaft.

(c) Face runout of axle shaft flangeMeasure face runout with a dial gauge posi-tioned against the axle shaft flange while rotat-ing the shaft.

(2) Axle tube

(a) Check the axle tube for distortion, dents, orcracks.

(b) Check the mast bearing sliding area for dam-age.

(3) Oil seal and Oil seal retainer

(a) Check both the outer and inner oil seals forwear or damage.

(b) Check the periphery of the oil seal retainer forwear or damage.

Unit: mm (in.)

Axle shaftSpline backlash

A 0.07 to 0.17(0.0028 to 0.0067)

B 0.5 (0.02)

A: Standard value B: Repair or service limit215941

V block

Dial gauge

Unit: mm (in.)

Axle shaft deflection (1/2 of gauge reading)

A 1.0 (0.04) maximum

B 2.0 (0.08)

A: Standard value B: Repair or service limit

Unit: mm (in.)

Face runout of axle shaft flange

A 0.04 (0.0016)

B 0.5 (0.0197)


215714

Face runout of axle shaft flange

Axle shaft deflection

215715

Mast bearing sliding area on the axle

Deformation, dents or cracks

7-26


(4) Brake drums

(a) If minor scratches or wear are found on thebrake drum surfaces, grind them smooth.

(b) Measure inside diameter of the brake drum. Ifthe measured value reaches or exceeds theservice limit, replace the brake drum with anew one.

Unit: mm (in.)

Brake drums inside diameter B 318.5 (12.54)

B :Service limit

Measure inside diameterUneven wear and damage

Brake drum 215920

7-27


4.1.3 ReassemblyTo reassemble, follow the disassembly sequence inreverse.

(1) Axle support

(a) Apply liquid gasket to the mating surfacesbetween the axle tube and the brake drum.

(b) Tighten the mounting bolts to the specifiedtorque.

(2) Wheel Brake assemblyThoroughly wash the mounting bolt threads, andapply sealing compound to the threads beforetightening the bolts to the specified torque.


215717Brake drum side Axle tube side



Axle support

215919

Sealing compound LOCTITE #271or equivalent


Item

Truck modelP8000,P9000 P10000,P11000,

P12000

PD8000,PD9000 PD10000,PD11000,PD12000

Tightening torque 214(21.8)[157.9] 295(30.1)[217.7]

Wheel brake

215918

7-28


(3) Tapered roller bearing

(a) Fit a steel pipe of approximately 105 mm (4.13in.) in inside diameter and 150 mm (5.91 in.) inlength over the tapered roller bearing, and thenhammer the steel pipe to install the taperedroller bearing together with the oil seal retainerinto the axle tube.

(b) Fill the roller cage of tapered roller bearing withthe specified grease. Palm press the grease sothat it is thoroughly applied inside the rollercage.

(4) Wheel hub

(a) Fill the inside of the wheel hub with grease asshown in the illustration. For the correct greasebrand.

(b) Apply grease to the oil seal lip.

(5) Tapered roller bearing preload adjustment

(a) Lightly tighten the lock nut using a socketwrench (special tool).

(b) Tap the periphery of the wheel hub with a cop-per hammer while rotating the hub so that thebearing fits snuggly.

(c) Hook a spring balance to the wheel bolt, andmeasure the tangential force.

(d) Adjust the tightening force of lock nut so thatthe tangential force falls within the above spec-ified range.

(e) After the specified tangential force is obtained,place the lock ring on the wheel hub andsecure the lock ring with the lock bolt.

(f) Measure tangential force again to make surethat it is within the specified range.

Grease Auto Rex A

Use extreme care to prevent surplus grease from spilling on the brake portion.

215921

Steel pipe

After the wheel hub is installed, be sure to wipe off excessive grease from the hub.

215719

Special toolSocket wrench 03703-49000

Unit: N (kgf) [lbf]

Tangential force onwheel bolt

22.5 to 40.2(2.3 to 4.1)[5.1 to 9.0]

215720

7-29


(6) Brake drums

(a) Thoroughly clean the brake friction surfaceswith a clean cloth.

(b) If a friction surface is spotted with oil or grease,wash them away with a brake cleaner.

(7) Planet carrier

(a) Apply gear oil to the rolling contact surfaces ofthe needle bearings before installation.

(b) Install the planet pin with its alignment markfacing outward.

(c) Install the spring pin with its cut line oriented ina rotational direction.

(d) Install the planet carrier assembly to the tubeassembly, and then look through the set screwhole to make sure that the groove of the bear-ing is at the center.

Remove contaminants such as oil, grease

Brake drum 215922

Rolling contact surface

Needle bearing215923

215722

Planet pin Spring pin

216028

Planet carrier assembly Groove of bearing

7-30


(e) Apply sealing compound to the thread of theset screw before tightening it.

(f) Tighten the plug.

(8) Axle shaft

(a) Apply liquid gasket to the mating surfacesbetween the wheel hub and the axle shaft.

(b) Tighten the mounting bolt to the specifiedtorque.

Sealing compound LOCTITE #271

216029

Plug

Set screw



Tightening torque 219 (22.3) [161.6]215721

7-31


4.2 Tube Assembly and Final Reduction (Option Truck)4.2.1 Disassembly

215707

1817

1920

2122

24

2325

15

1614

13

2

2

1

5

810

12

11

12

109

7630

4 3

29

28 27

24

26

Disassembly sequence1 Ring gear2 O-ring3 Plug4 Set screw5 Planet carrier 6 Snap ring7 Ball bearing8 Spring pin9 Planet pin

10 Thrust washer

11 Planet gear12 Needle bearing13 Lock ring14 Lock nut15 Wheel hub16 Tapered roller bearing17 Oil seal retainer18 O-ring19 Oil seal20 Spacer plate

21 Tapered roller bearing22 Oil seal23 Floating seal retainer24 Floating seal 25 O-ring26 Seal washer27 Wet disc brake assembly28 O-ring29 Axle support30 Axle tube

7-32


Disassembly Suggestions on Final Reduction

The disassembling procedure is same as a standardtruck. Disassembly Suggestions on Tube Assembly

(1) Remove the lock ring.

(2) Using the lock nut wrench (special tool), removethe lock nut.

(3) Using a special tool, remove the front wheel hub.

(4) Remove the floating seal retainer, oil seal, spacerplate, and tapered roller bearing from the frontwheel hub.

Special toolLock nut wrench 03703-59001

215712

Special tool

Special toolWheel hub guide 91K67-03300

Adjusting plate 91K67-03400

Adjusting bolt 91K67-03600

Unit: kg (lb)

Weight of front wheel hub 35 (77.2)

217214

Special tool

217215

Front wheel hub

Front wheel hub

Floating seal retainer

Floating seal

Oil seal

O-ringOil seal

Spacer plate

Tapered roller bearing (Inner race)

Tapered roller bearing (Outer race)

Tapered roller bearing (Outer race)

7-33


(5) Remove the oil seal retainer from the tube assem-bly.

(6) Remove the O-ring from the oil seal retainer.

(7) Remove the installing bolt, and then remove thewet disc brake assembly.

(8) Remove the floating seal from the wet disc brakeassembly.

(9) Remove the brake cover and O-ring from the wetdisc brake assembly.

(10)Remove the mating plate, friction plate and endplate.

Note: Check the sequence of the removed matingplates, friction plates and end plate.

(11)Remove the brake housing.

(12)Remove the O-ring.

217164

O-ring O-ring

Oil seal retainer

Wet disc brake assembly

Axle support

Front axle tube

217165

Floating seal

O-ring

Brake cover


Mating plate 5

Friction plate 5

End plate 1

217166

Mating plateFriction plate

End plate

F

217167

Brake housing

Piston housing

O-ring

O-ring

7-34


(13)Remove the snap ring and plain washer that fixedthe return plate, and then remove the return plate.

(14)Remove the gauge plug, gauge rod and O-ringfrom the piston housing.

(15)Remove the plug, O-ring, spring guide and returnspring from the piston housing.

(16)Remove the drain plug, O-ring and breeder screwfrom the piston housing.

(17)Remove the brake piston, piston seal, piston ring,ring seal and O-ring from the piston housing.

(18)Remove the axle support from the front axle tube.

217168

Snap ringPlain washer

Return plate

217169

Drain plug

Plug

Breeder screw

Piston housing

Gauge plugO-ring

O-ring

O-ringSpring guide

Return springGauge rod

217170

Brake piston

Piston seal

Piston ring

Piston housing

O-ring

O-ring

Ring seal

217171

Axle supportFront axle tube

7-35


4.2.2 Inspection and RepairRefer to "Inspection and Repair" of standard truck forthe following (1) to (3).

(1) Axle

(2) Axle shaft deflection

(3) Oil seal and oil seal retainer

(4) Wet disc brake assembly

Piston

Check the sliding areas for any wear or damage. If there is any surface flaw, grind the surface, then wash the surface.

Brake housing and hub

Check the tooth faces for any wear or damage.

Piston housing

Check the sliding areas of the piston for any wear or damage.

Friction plate and mating plate

(c) Check for any burn, trace of uneven contact,deformation or damage.

(d) Check the mating plate for any heat spots.

(e) Check the inner teeth and outer teeth surfacesfor any wear or damage.

(f) Measure the thickness of each plate.

Note: A complete replacement is required with newones if any of the above checks reveal a prob-lem. Upon replacement, perform flushing.

215622

A: Standard value B: Service limit

Unit: mm (in.)

Mating Plate A 2.00 ± 0.08(0.078 ± 0.003)

Friction plateA 3.7 ± 0.1

(0.145 ± 0.004)

B 3.3 (0.13)

End Plate A 3.2 ± 0.1(0.126 ± 0.004)

7-36


(g) Return springMeasure the free length of return spring.

(h) Floating sealCheck the floating seal lip surface for any dam-age, and replace the lip if damaged.

A: Standard value

Unit: mm (in.)

Free length of return spring A 24 (0.94)

214807

7-37


4.2.3 Reassembly(1) Clean the installing bolt for the axle support fully,

apply the sealing compound/

(2) Install the axle support to the axle tube to thespecified torque.

(3) Reassemble the wet disc brake assembly.

(a) Assemble the piston seal, piston ring, O-ring,ring seal to the brake piston as shown in theright illustration.

Note: Apply oil (SAE 10W-30 Engine oil CD) to thebrake piston, piston seal, piston ring, O-ring,ring seal and sliding surface.

(b) Install the brake piston and O-ring to the pistonhousing.

(c) Insert the return spring and spring guide fromthe piston housing, and install the return plate,plain washer and snap spring.

(d) Install the O-ring to the piston housing.

Note: Be sure to install the multiple O-rings.

Sealing compound LOCTITE #271 or equivalent



217171

Axle supportFront axle tube

217172

Brake piston

Piston seal

Piston ring

O-ring

Ring seal

217173

Brake piston assembly

Piston housing

O-ring

217174

Snap ring Plain washer

Piston housing

Return plate

Return spring

O-ring

O-ring

Spring guide

7-38


(e) Install the stud bolt to the brake housing asshown in the right illustration.

(f) Install the brake housing to the piston housing,and tighten the flange nut and bolt to the speci-fied torque.

(g) Using a special tool, install the end plate, fric-tion plate, and mating plate in the same orderas they were removed.

Note: Align the 5 friction plates spline recesses.

(h) Install the O-ring to the wet disc brake assem-bly.

217175

L.H R.H

Stud bolt


Tightening torque of bolt137.3 ± 27.5(14.0 ± 2.8)

[101.3 ± 20.3]

Tightening torque of flange nut

73.5 ± 7.4(7.5 ± 0.8)[54.2 ± 5.5]

217176

End plate 1

Friction plate 5

Mating plate 5

Special tool

Friction plate holder 91K67-03200

217177

O-ring

Mating plateFriction plate

End plate Special tool

216027

7-39


(i) Install the brake cover and O-ring to the wetdisc brake assembly to the specified torque.

(j) Install the spacer, plug, and O-ring as shown inthe illustration to fix the friction plate. Then,temporary tighten them to the wet disc brakeassembly.

(k) Install the spacer to the gauge rod, and tempo-rary tighten it to the wet disc brake.

(l) Tighten the air breeder screw and drain plugplug to the wet disc brake assembly to thespecified torque.

(m)Install the taper plug to the wet disc brakeassembly.

(n) Remove the friction plate holder from the wetdisc brake assembly.

(o) Use the special tool to install the floating sealto the wet disc brake assembly.

(p) Install the O-ring to the wet disc brake assem-bly.


Tightening torque of hexa-gon socket bolt

60.7 ± 12.1(6.2 ± 1.2)[44.8 ± 8.9]

217178

Hexagon socket bolt

Brake cover


Special tool

Spacer 91K33-17900

Spacer 91K33-17900


Tightening torque of air breeder screw

6.86 to 11.78(0.7 to 1.2)

[5.06 to 8.69]

Tightening torque of drain plug

19.6 ± 2.0(2.0 ± 0.2)[14.5 ± 1.5]

217179L.H R.H

Inserting positions for spacerAir breeder screw Air breeder screw

Drain plug

217180

SpacerSpacer

Taper plug Special tool

Special tool

Floating seal inserter 91K67-03700

Guide inserter 91K67-03800

217181

Special tool Floating seal

O-ringWet disc brake assembly

7-40


(4) Assemble the front wheel hub.

(a) Use the special tool to install the floating sealto the floating seal retainer.

(b) Install the O-ring to the front wheel hub.

(c) Tighten the floating seal retainer to the frontwheel hub to the specified torque.

(d) Use the special tool installer to tap the oil sealand tapered roller bearing (outer race) into thefront wheel hub.

(e) Insert the tapered roller bearing (inner race) tothe front wheel hub. Then, using the specialtool, install the spacer plate and oil seal.

(f) Apply grease on the inside of front wheel hub.(shaded area in the right illustration)

(5) Install the wet disc brake assembly to the axletube to the specified torque.

Note: 1. Only one bolt is shorter than other bolts. Becareful not to make a mistake when installing.

2. Clean the mounting bolts completely. Then,install the seal washer, and apply sealingcompound.

Special tool

Floating seal inserter 91K67-03700

Guide inserter 91K67-03800

Guide plate 91K67-03900

217182

Floating sealSpecial tool



Tightening torque of hexagon socket bolt

38.1 ± 7.6(3.9 ± 0.8)[28.1 ± 5.6]

217183

Hexagon socket bolt

O-ring

Oil seal

Tapered roller bearing (outer race)

Tapered roller bearing (outer race)

Grease Auto Rex A

217184

Tapered roller bearing (inner race) Oil seal

Apply grease

Spacer plate



Unit: mm (in.)

Short bolt 40 (1.6)

Long bolt 92 (3.6)

Sealing compound LOCTITE #271 or equivalent 217185

L.H R.H

Positions for short bolts

7-41


(6) Install the O-ring to the oil seal retainer, andassemble it to the axle tube.

(7) Using a special tool, insert the front wheel hubwith careful not to displace the friction plate.

Note: a) The clearance between the floating seal re-tainer and brake cover must be approx. 3 mm (0.12 in.) when the front wheel hub contacts end fully.If the clearance deviates from the specified value, check for the damage or scratch, and reinsert the front wheel hub again.

b) If the special tool is removed, the clearancebetween the floating seal retainer and brakecover will be changed with a reactive force.Check if the nominal size is approx. 3 mm(0.12 in.), and write down the checked clear-ance size.

(8) Insert the tapered roller bearing (inner race) to thefront wheel hub.

(9) Using the lock nut wrench (special tool), lightlytighten the lock nut of front wheel hub.

217186

Oil seal retainer

O-ring

Special tool

Wheel hub guide 91K67-03300

Adjusting plate 91K67-03400

Adjusting bolt 91K67-03500

Wheel nut MC810632

217191

Approx. 3 mm (0.12 in.)

Special tool

Wheel nut

Special tool

Special tool

Lock nut wrench 03703-59001

217190

Lock nut

Special tool

Tapered roller bearing ( inner race)

7-42


(10)Remove the spacer that fixed the friction plate.Install the plug and gauge rod to the specifiedtorque.

(11)Rotate the front wheel hub and tap its peripherywith a softhead mallet.

(12)Adjust the tightening force of lock nut so that thepreload of tapered roller bearing falls within theservice limit.

Note: a) To check the preload, hook a spring balancer on the wheel nut, then pull it to measure the tangential force.

b) Adjust the preload, and then adjust the clear-ance between the floating seal retainer andbrake cover to be 3 mm (0.12 in.). Too largeclearance causes for looseness of bearing.

(13)After the specified tangential force is obtained,install the lock ring to the lock nut.

(14)Fix the lock ring with the lock bolt that is appliedsealant.

(15)Measure tangential force again to make sure thatit is within the specified range.

Spacer 91K33-17900


Tightening torque of plug34.3±3.4

(3.5±0.35)[25.3±2.5]

Tightening torque of gauge rod

39.2±3.9(4.0±0.4)[29.0±2.9] 217187L.H R.H

Gauge rod

Plug

Unit: N (kgf) [lbf]

Tangential force of wheel bolt

22.5 to 40.2(2.3 to 4.1)[5.1 to 9.0]

Add the tangential force before tightening.Example: the tangential force before tightening is 20 (2.0) [4.5]20 + 22.5 to 40.2 = 42.5 to 60.2 (4.3 to 6.1) [9.6 to 13.5]

217188

217314

Approx. 3 mm (0.12 in.)


Brake cover

Specified sealant LOCTITE #271

217189

Lock ring

Bolt

7-43


(16)Planet carrier

(g) Apply gear oil to the rolling contact surfaces ofthe needle bearings before installation.

(h) Install the planet pin with its alignment markfacing outward.

(i) Install the spring pin with its cut line oriented ina rotational direction.

(j) Install the planet carrier assembly to the tubeassembly, and then look through the set screwhole to make sure that the groove of the bear-ing is at the center.

(k) Apply sealing compound to the thread of theset screw before tightening it.

(l) Tighten the plug.

Rolling contact surface

Needle bearing215923

215722

Planet pin Spring pin

216028

Planet carrier assembly Groove of bearing

Sealing compound LOCTITE #271

216029

Plug

Set screw

7-44


(17)Axle shaft

(a) Apply liquid gasket to the mating surfacesbetween the wheel hub and the axle shaft.

(b) Tighten the mounting bolt to the specifiedtorque.

Liquid gasket ThreeBond #1194 or equiv-alent


Tightening torque 219 (22.3) [161.6]215721

7-45


4.3 Wear Gauge for Wet Disc BrakesStandard for replacing the plate of a wet disc brake

217198

Replace the plate when the gauge rod has been driven in up to the groove after pushing the gauge rod.

7-46


4.4 Reduction Differential (Common to Standard and Option Truck)4.4.1 Disassembly

Remove 4 through 9 as an assembly.

213699

2

42

4 8

21

16

19

20

15

1

17

7

9

6

5

6

3

3

12

17

1410

11

10

18

13

Disassembly sequence1 Lock plate2 Adjusting screw3 Bearing cap4 Tapered roller bearing5 Spring pin, Pinion shaft 6 Differential pinion, Thrust washer 7 Differential gear, Thrust washer 8 Differential case 9 Reduction gear

10 Cover, O-ring11 Lock nut, Shims

12 Reduction pinion, Tapered roller bearing (inner),Shims

13 Carrier cover14 Tapered roller bearing15 Driven gear16 Plate17 Drive gear, Ball bearing18 Input flange19 Ball bearing20 Oil seal21 Differential carrier

7-47


Suggestions for Disassembly

Note: 1. Before disassembling the reduction differen-tial, be sure to measure and record gearbacklash so that it will be used as a referenceduring reassembly, except when replacingthe reduction gear set.

2. Put alignment marks across the bearing cap,adjusting screw, and the carrier for correct re-fitting.

(1) Removing tapered roller bearing from differentialcase, use a bearing puller to remove the bearinginner race.

(2) Removing shimsAfter removing lock nut 11 and shims, measureand record the total thickness of the shims. Tie allof the shims to the locknut with a string to preventlosing them.

Unit: mm (in.)

Reduction gear-to-reduction pinion backlash

0.20 to 0.26(0.008 to 0.010)

213700

215924

213702

Lock nut

Shims

215925

7-48


(3) Removing tapered roller bearingDo not need to remove the tapered roller bearing(inner) from the reduction pinion 12 unless adefect is found.

(4) Removing carrier coverScrew the two jack bolts into the jack bolt holes (atthe positions marked with *) and remove the car-rier cover while tapping near the dowel pins (2places) with a plastic hammer.

(5) Checking oil sealDo not remove the oil seal 20 from the carriercover 13 unless it is found to be defective.

Tapered roller bearing (inner)

Reduction pinion

Ware, damage,and burns

215926

Unit: mm (in.)

Jack bolt M10×1.25 Nominal length of 50 (1.97) or above

215942

#

#

7-49


4.4.2 Inspection and Repair(1) Reduction bevel gear and reduction pinion

(a) Check both the gear and pinion for uneventooth contact, wear, pitting, flaking, and chip-ping.

(b) Minor flaws on the tooth surfaces can beremoved by grinding with an oil stone or sand-paper.

(c) If the gear and/or pinion is badly damaged,replace them as a set.

(2) Differential

(a) Check the seat surfaces between the differen-tial case and the tapered roller bearing innerrace for flaking.

(b) Check the differential case for cracks. Also,check the sliding contact surfaces of the thrustwasher and the differential gears for wear anddamage.

(c) Check the teeth of the differential pinions andgears for wear, damage, and flaking. Also,check the thrust washer contact area for wearor damage.

(d) Check the inner surface of the differential pin-ions and the outer surface of the pinion shaftsfor wear.

(e) Check the differential gears and axle shaftsplines for wear and free play (looseness).

(3) Drive gear and driven gear

(a) Check both gears for uneven tooth contact,wear, pitting, flaking, and chipping.

(b) Replace both drive and driven gears as a seteven if one of them is defective.

Reduction gear

Reduction pinion

215927

Unit: mm (in.)

Clearance betweenpinions and shafts

A 0.02 to 0.085(0.0008 to 0.0033)

B 0.35 (0.014)


Unit: mm (in.)

Free play (looseness) of differential gear and axle shaft splines

A 0.09 to 0.28(0.0035 to 0.0110)

A: Standard value

Differential case

Differential gearThrust washer

Differential pinionThrust washer

215928

A

A

Flaking

Pinion shaft

7-50


Note: 1. The combination of drive and driven gearsvaries depending on the model of lift truck.

2. Each gear can be identified by the letter (A, B,C, D, E, or F) stamped on its side face.

3. Before replacing gears, be sure to check thestamped letter marks to make sure of the cor-rect combination.

Driven gear

Drive gear

215929

7-51


4.4.3 Reassembly

215723

56

4 7

8

18

19

13 2

4

11222120121413

15

16

17

10

23

9

Reassembly sequence1 Differential case 2 Reduction gear3 Bolt4 Differential gear, Thrust washer 5 Differential pinion, Thrust washer 6 Pinion shaft, Spring pin 7 Tapered roller bearing8 Differential carrier9 Bearing cap

10 Adjusting screw11 Carrier cover12 Oil seal

13 Ball bearing14 Input flange15 Drive gear16 Ball bearing17 Plate18 Reduction pinion, Shims, Tapered roller bearing (inner)19 Driven gear20 Tapered roller bearing21 Shim22 Lock nut, O-ring, Cover23 Lock plate

7-52


Suggestions for Reassembling Differential

(1) Reassembling differential case assembly

(a) Assemble the thrust washer to the differentialgear, and then install the differential gearassembly to the differential case.

(b) Assemble the thrust washer to the differentialpinion, and then install the differential pinionassembly to the differential case.

(c) Secure the spring pin to the differential caseassembly.

Note: Install the spring pin to the differential assemblyso that its cutting line positions at a right angleto the pinion shaft. (See the illustration.)

(2) Differential case assembly operational check

(a) Install the center shaft to the differential gear,and check for smooth rotation. If rotation is notsmooth, replace the thrust washer of differen-tial gear with a new one. (Check both sides ofthe differential gear assembly.)

(b) Install the center shafts into the differential gearassembly from both sides. Rotate one of thetwo center shaft while clamping the other shaft,and check for smooth differential rotation.

Differential case

Differential gearThrust washer

Differential pinion

Thrust washer

215930

A

A

Pinion shaft

Spring pin

Cutting line

215943

Center shaft

V blockRotate

Differential case assembly

215944

Center shaft

Center shaft

V blockRotate

Differential case assembly

215945

Clamped

7-53


(3) Installing reduction gear

(a) Apply sealing compound to the mounting boltsand tighten them to the specified torque.

(4) Installing differential case assembly

(a) Install the tapered roller bearing to the differen-tial case.

(b) Install the differential case assembly and thebearing cap onto the differential carrier, andloosely tighten the cap bolts in place.

Note: The bearing caps and the differential carrier aremachined together. Pay attention to the align-ment marks so that they are positioned thesame side as they were before disassembly.

(5) Installing adjusting screw When turning the adjusting screws, turn theadjusting screws, right and left, by the sameamount in the same direction in order not to affectthe bearing preload.

Sealing compound LOCTITE No. 271


Tightening torque226 ± 9.8(23 ± 1)[167 ± 7]

Reduction gear Differential case

Apply sealing compound

215931

Bearing cap

Differential caseassembly

Tapered roller bearing

Differential carrier

215932

215924

Adjusting screw

215933

7-54


(6) Adjusting bearing preload

(a) Tap the reduction gear on the back with a cop-per hammer while rotating it for a snug fitting.

(b) Hook a spring balance to the reduction gearmounting bolt head.

(c) Pull the spring balance, and measure tangen-tial force just as the reduction gear starts tomove.

(d) If the tangential force falls out of the specifiedrange, adjust the force by changing the tighten-ing force of the adjusting screws.

Note: When turning the adjusting screws, turn the ad-justing screws, right and left, by the sameamount in the same direction in order not to af-fect the bearing preload.

(7) Removing differential case assemblyAfter confirming the differential case preload,remove the differential case from the differentialcarrier.

Note: Put alignment marks across the adjusting screwand the bearing cap.

Unit: N (kgf) [lbf]

Tangential force 14.7 to 29.4(1.5 to 3.0)[3.3 to 6.6]

215934

Tangential forceDecrease

Increase

Tangential force

DecreaseIncrease

215935


Bearing cap

Adjusting screw

215936

7-55


Suggestions for Reassembling Reduction Assembly

(1) Adjusting reduction pinion shims (front side) When reduction gears and pinions are replaced,add or remove shims according to the machiningerror so that total shim thickness meets the stan-dard value (0.8 mm [0.03 in.]).

(a) Check the machining error value marked onthe end face of the reduction pinion.

(b) Calculate shim thickness using the followingformula: Total shim thickness = standard value -(machining error value)

(c) Select appropriate shims from the table belowto match a calculated value.

(2) Installing oil seal

(a) Using a special tool, install the oil seal into thecarrier cover.

Note: Pay attention to the orientation of the oil sealwhen installing.

(b) Apply grease to the oil seal lip.

(3) Applying liquid gasketApply liquid gasket to the joint surfaces when fit-ting the carrier cover to the differential carrier.

Example: If machining error is 0.10 mm (0.004 in.)Total shim thickness = 0.8 mm - (-0.1 mm)

= 0.8 mm + 0.1 mm

= 0.9 mm (0.035 in.)

213708

Shims

Shim thickness Part number

0.10 mm (0.004 in.) 91331-01200

0.20 mm (0.008 in.) 91331-01300

0.50 mm (0.02 in.) 91331-01400

Special toolInstaller 91263-05400

Grease LG2213709

Oil seal

Liquid gasket ThreeBond #1104

213710

7-56


(4) Adjusting reduction pinion shims (rear side)

(a) Drive the tapered roller bearing into the differ-ential carrier cover.

(b) Measure clearance between the end faces ofboth the differential carrier cover and taperedroller bearing.

(c) Measured clearance can be used as a refer-ence when determining shim thickness. Stan-dard value for shim thickness is 1.25 mm(0.049 in.)

(d) Select appropriate shims from the table belowto match the measured value.

(e) Tighten the lock nut to the specified torque.

(f) After assembling the reduction assembly, hookthe spring balance to the input flange.

(g) Pull the spring balance in the tangential direc-tion, and measure tangential force just as theinput flange starts to move.

(h) If the tangential force falls out of the specifiedrange, adjust the force by adjusting shim thick-ness.

213711

Shim thickness Part number

0.05 mm (0.002 in.) 97E27-01400

0.10 mm (0.004 in.) 97E24-00800

0.20 mm (0.008 in.) 97E24-00900

0.50 mm (0.02 in.) 97E27-01100

1.00 mm (0.04 in.) 97E27-01200

Lock nut

Shims

215925


Tightening torque294 ± 19.6

(29.98 ± 2.00)[216.97 ± 14.46]

Unit: N (kgf) [lbf]

Tangential force 53.94 to 83.36

(5.5 to 8.5)[12.1 to 18.7]

213712

7-57


Reassembling Suggestions for Reduction Differ-ential Assembly

(1) Adjusting backlash

(a) Turn over the differential carrier, and place thereduction differential assembly facing upward.

(b) Paying attention to the match mark made onthe bearing cap and adjusting screw, reinstallthe differential case to the differential carrier.

(c) Tentatively tighten the bearing cap mountingbolts.

(d) Set a dial gauge on the reduction differentialassembly with its probe positioned at a rightangle to the tooth face of the reduction gear.

(e) Turn the gear back and forth, and read deflec-tion on the dial gauge (backlash).

(f) If the backlash value falls out of the specifiedrange, adjust backlash value by turning theadjusting screw.

Note: When turning the adjusting screws, turn the ad-justing screws, right and left, by the sameamount in the same direction in order not to af-fect the bearing preload.

(2) Checking and adjusting reduction gear tooth con-tact.Check the reduction gear for uneven tooth con-tact, and adjust it, if necessary, by referring to"4.2.4 Adjustment."

(3) Tightening bearing capsAfter checking the tooth contact, tighten the bear-ing cap bolts to the specified torque, and bend thelock plate to clinch the bearing cap.


Bearing cap

Adjusting screw

215936

Unit: mm (in.)

Backlash 0.20 to 0.26(0.008 to 0.010)

213700

213714

Backlash

Backlash

Decrease

Decrease

Increase

IncreaseIncreaseDecrease


Bearing cap tightening torque

235 ± 6.8(23.96 ± 0.69)[173.45 ± 5.02]

Tighten to thespecific torque

Lock plate

215937

7-58


(4) Securing lock nut

(a) Lay the reduction differential assembly on itsside.

(b) Secure the reduction pinion lock nut by caulk-ing its head.

(5) Installing cover

(a) Install O-ring to the cover.

(b) Install the cover, and tighten the mounting boltsto the specified torque.

215938

Caulking


Tightening torque39.2 ± 3.9

(4.00 ± 0.40)[28.93 ± 2.88]

O-ring

Cover

Tighten to thespecific torque

215939

7-59


4.4.4 AdjustmentAdjusting Reduction Gear Tooth Contact

(1) Apply a thin and even coat of colorant to a fewreduction gear teeth, on both drive and coastsides.

(2) Rotate the reduction gear back and forth by handuntil a contact pattern is located on both sides ofthe gear teeth. (For adjustment, refer to theinstructions on the next page.)

Note: "Toe" or "Heel" contact is determined by checking the contact pattern on the outside (convex side) of the re-duction gear tooth. For "Face" or "Flank" contact, repeat the above adjusting procedure until the correct toothcontact is obtained.

213715

Adjusting reduction gear tooth contactTooth contact condition Adjusting procedure

1

Extends from toe to middle portion, covering 50% or more of tooth length.

Good

2

Strong contact at toe of tooth(Toe)

1. Move gear away from pinion.

2. Move pinion toward gear for correct back-lash by increasing shim thickness.

3

Short contact at heel of tooth(Heel)

1. Move gear toward pinion.

2. Move pinion away from gear for correct backlash by decreasing shim thickness.

4

Strong contact on face or top half (addendum) of tooth (Face)

1. Move pinion toward gear by increasing shim thickness.

2. Move gear away from pinion for correct backlash.

5

Heavy contact on bottom half (dedendum) of tooth (Flank)

1. Move pinion away from gear by decreasing shim thickness.

2. Move gear toward pinion for correct back-lash.

213716

213717 213721

2

1

213718 213722

2

1

213719 213723

1

2

213720 213724

1

2

7-60


Reduction Gear Adjustment

Turn the adjusting screws, right and left, by the sameamount in the same direction to adjust distance fromthe center.

Reduction Pinion Adjustment

Disassemble the reduction assembly, and add orremove pinion shims (front side) as needed.

215940Distance from center

Distance from center

Distance from center

Near

Near

Far

Far

Near Far

213708

Shims

7-61


5. Troubleshooting (Common to Standard and Option Truck)

Condition Possible cause Action

Continuous gear noise during travel

Reduction bevel gear teeth are badly worn or chipped. Replace

Bearing preload too much or too little, or bearings worn excessively Adjust or replace

Hub bearings are damaged. Replace

Uneven teeth contact between reduction pinion and reduction gear Adjust

Irregular noises dur-ing traveling

Reduction of taper roller bearings and/or hub bearings are damaged. Replace

Differential gear teeth are broken, or thrust washers are worn. Replace gears or washers

Foreign substance in axle housing Clean and change oil

Bolts that secure the axle shaft or differential carrier are loosened. Retighten

Abnormal noises when turning a cor-ner

Fit of differential gears in differential case out of specifi-cation due to wear Replace worn parts

Differential gear teeth (pinion gear teeth) are broken, worn, or damaged by piston. Replace defective parts

Overheated reduc-tion case after trav-eling

Bearing is damaged due to excessive preload. Replace bearings and readjust preload.

Backlash between reduction pinion of output shaft and reduction gear may be too small. Adjust teeth contact and backlash

7-62


6. Service DataUnit: mm (in.)



Thickness 1 of mating plate A 2.00 ± 0.08 (0.078 ± 0.003)

Thickness 2 of friction plateA 3.7 ± 0.1 (0.145 ± 0.004)

B 3.3 (0.13)

Thickness 3 of end plate A 3.2 ± 0.1 (0.126 ± 0.004)

Free length 4 of return spring A 24 (0.94)

A: Standard value B: Service limit217216

1

2

4

3

Section A-A

Section B-B

B

A

A

B

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