Steering Axle

STEERING AXLE S3.50-5.50XL (S70-120XL) [D004]; S3.50-5.50XM (S70-120XM) [E004, F004]; E3.50-5.50XL (E70-120XL, E70-120XL 3) [C098]; H3.50-5.00XL (H70-110XL) [G005]; H6.00-7.00XL (H135-155XL, H135-155XL 2) [F006, G006]; H8.00-16.00XL (H165-360XL) [D019, E007]; H8.00-16.00XM (H170-360HD) [E019, F007, F019, G007]; E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) [D098]

PART NO. 897108

1600 SRM 326

SAFETY PRECAUTIONS MAINTENANCE AND REPAIR • When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and that the load being lifted is balanced. Make sure the crane, cables, and chains have the capacity to support the weight of the load. • Do not lift heavy parts by hand, use a lifting mechanism. • Wear safety glasses. • DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift trucks. Disconnect the battery ground cable on internal combustion lift trucks. • Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance section. • Keep the unit clean and the working area clean and orderly. • Use the correct tools for the job. • Keep the tools clean and in good condition. • Always use HYSTER APPROVED parts when making repairs. Replacement parts must meet or 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. • Be sure to follow the WARNING and CAUTION notes in the instructions. • Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are 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 condition that can cause immediate death or injury!

CAUTION Indicates a condition that can cause property damage!

Steering Axle

Table of Contents

TABLE OF CONTENTS General ............................................................................................................................................................... Description ......................................................................................................................................................... Steering Axle Assembly Repair......................................................................................................................... Steering Axle H3.50-5.00XL (H70-110XL) (G005), S3.50-5.50XL (S70-120XL) (D004), S3.50-5.50XM (S70-120XM) (E004, F004), E3.50-5.50XL (E70-120XL, E70-120XL 3) (C098), and E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (D098) ................................................................................ Remove....................................................................................................................................................... Install ......................................................................................................................................................... Steering Axle H6.00-7.00XL (H135-155XL, H135-155XL 2) (F006, G006), H8.00-16.00XL (H165-360XL) (D019, E007), and H8.00-16.00XM (H170-360HD) (E019, F007, F019, G007).................. Remove....................................................................................................................................................... Install ......................................................................................................................................................... Wheels and Hubs Repair (All Units) ................................................................................................................ Remove and Disassemble .............................................................................................................................. Clean .............................................................................................................................................................. Inspect ............................................................................................................................................................ Assemble and Install ..................................................................................................................................... Spindles and Bearings Repair (All Units) ........................................................................................................ Remove ........................................................................................................................................................... Clean .............................................................................................................................................................. Assemble and Install ..................................................................................................................................... Tie Rods Repair (All Units) ............................................................................................................................... Remove ........................................................................................................................................................... Clean .............................................................................................................................................................. Install ............................................................................................................................................................. Steering Cylinder Repair................................................................................................................................... Remove and Disassemble .............................................................................................................................. Clean and Inspect .......................................................................................................................................... Assemble and Install ..................................................................................................................................... Troubleshooting..................................................................................................................................................

1 1 6

6 6 6 7 7 7 8 8 8 8 8 10 10 10 10 11 11 11 11 14 14 14 14 15

This section is for the following models: S3.50-5.50XL (S70-120XL) [D004]; S3.50-5.50XM (S70-120XM) [E004, F004]; E3.50-5.50XL (E70-120XL, E70-120XL 3) [C098]; H3.50-5.00XL (H70-110XL) [G005]; H6.00-7.00XL (H135-155XL, H135-155XL 2) [F006, G006]; H8.00-16.00XL (H165-360XL) [D019, E007]; H8.00-16.00XM (H170-360HD) [E019, F007, F019, G007]; E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) [D098]

©2005 HYSTER COMPANY

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"THE QUALITY KEEPERS" HYSTER APPROVED PARTS

1600 SRM 326

Description

General This section has the description and repair procedures for the steering axle. For information on the steering control unit, see the section Steering Control Unit.

Description The steering axle assembly includes an axle frame, steering cylinder, tie rods, and two spindle and hub assemblies. The steering axle is articulated and is connected to the frame with center pivot mounts. The center pivot mounts permit the steering axle to move in the frame mount when the lift truck travels over rough surfaces. See Figure 1, Figure 2, Figure 3, and Figure 4. The center pivots for the axle are installed in rubber mounts on the following units: H3.50-5.50XL (H70-110XL) (D004) S3.50-5.50XL (S70-120XL) (G005) S3.50-5.50XM (S70-120XM) (E004, F004) E3.50-5.50XL (E70-120XL, E70-120XL 3) (C098) E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (D098) The center pivots for the axle are installed in the frame of the lift truck and rotate in fiber bushings on the following units: H6.00-7.00XL (H135-155XL, H135-155XL 2) (F006, G006) H8.00-16.00XL (H165-360XL) (D019, E007) H8.00-16.00XM (H170-360HD) (E019, F007, F019, G007)

The end caps of the steering cylinder are also the mounts for the cylinder and are held to the axle by capscrews. The ends of the piston rod extend from both ends of the cylinder. A single piston and the seal are at the center of the piston rod. Oil pressure on one side of the piston moves the piston in the bore. The piston pushes an equal amount of oil from the opposite side of the cylinder. The oil returns to the steering control unit. When the piston in the steering cylinder reaches the end of the stroke, a relief valve controls the oil pressure. The relief valve for the steering system is in the manifold block that is installed on the steering control unit. Each spindle turns on two tapered roller bearings in the axle frame. The preload on the bearings is controlled by shims at the lower bearing cap. The tie rods that connect the spindle arms to the cylinder do not have an adjustment. The wheel hubs rotate on two tapered roller bearings and are held on the spindles by a castle nut. The bearing preload of the wheel hubs is adjusted by the castle nut. The grease seals protect the bearings from dirt and water. Wear sleeves prevent the seals from causing wear on the hub.

1

Description

1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

STEERING AXLE COVER CLAMP COTTER PIN SNAP RING TIE ROD AND BUSHING NUT CAPSCREW CAP BEARING CONE

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11. 12. 13. 14. 15. 16. 17. 18. 19. 20.

BEARING CUP SEAL WEAR SLEEVE SPINDLE (RH) SPINDLE (LH) O-RING SHIM BEARING CAP LUBE FITTING SCREW

21. 22. 23. 24. 25. 26. 27. 28. 29. 30.

SEALANT STEER CYLINDER OIL SEAL CAP (HUB) WASHER MOUNT PLATE LOCKWASHER WHEEL GREASE FITTING

Figure 1. Steering Axle E3.50-5.50XL (E70-120XL, E70-120XL 3) (C098), S3.50-5.50XL (S70-120XL) (D004), S3.50-5.50XM (S70-120XM) (E004, F004) and E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (D098) Legend for Figure 2 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

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HUB ASSEMBLY STUD BEARING CUP WEAR SLEEVE HUB CAP COTTER PIN NUT WASHER LOCKWASHER CAPSCREW

11. 12. 13. 14. 15. 16. 17. 18. 19. 20.

BEARING CONE BEARING CAP SHIM OIL SEAL LUBE FITTING PIN PLUG SPINDLE FRAME SHAFT

21. 22. 23. 24. 25. 26. 27. 28. 29.

TIE ROD BUSHING ANCHOR STEERING CYLINDER FITTING O-RING FLANGE LUG NUT HANGER CUP

1600 SRM 326

Description

Figure 2. Steering Axle H8.00-16.00XL (H165-360XL) (D019, E007) and H8.00-16XM (H170-360HD) (E019, F007, F019, G007)

3

Description

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17.

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18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33.

STEERING AXLE STEER CYLINDER SPINDLE (LH) SEAL BEARING CONE SPINDLE (RH) HUB BEARING CUP STUD (WHEEL) WEAR SLEEVE TIE ROD CAPSCREW NUT (SPINDLE) CAP (HUB) SHIM CAP ASSEMBLY PIN

SNAP RING O-RING GREASE FITTING COTTER PIN MOUNT PLATE WASHER NUT LUG NUT PIN PLUG AND SEALANT CLAMP OIL SEAL BEARING CAP CAPSCREW COVER

Figure 3. Steering Axle H3.50-5.00XL (H70-110XL) (G005) Legend for Figure 4 1. 2. 3. 4. 5. 6. 7. 8. 9.

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STEERING AXLE SHAFT SEAL PIN SNAP RING TIE ROD CAPSCREW LOCKWASHER PLUG

10. 11. 12. 13. 14. 15. 16. 17. 18.

BEARING CONE BEARING CUP WEAR SLEEVE SPINDLE O-RING SHIM SCREW OIL SEAL HUB

19. 20. 21. 22. 23. 24. 25. 26. 27.

STUD WHEEL NUT WASHER COTTER PIN CAP GREASE FITTING BUSHING BEARING CAP STEER CYLINDER

1600 SRM 326

Description

Figure 4. Steering Axle H6.00-7.00XL (H135-155XL, H135-155XL 2) (F006, G006)

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Steering Axle Assembly Repair

1600 SRM 326

Steering Axle Assembly Repair STEERING AXLE H3.50-5.00XL (H70-110XL) (G005), S3.50-5.50XL (S70-120XL) (D004), S3.50-5.50XM (S70-120XM) (E004, F004), E3.50-5.50XL (E70-120XL, E70-120XL 3) (C098), AND E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (D098) Remove WARNING Put the lift truck on blocks. Follow the procedures for raising the lift truck described in the Operating Manual for this lift truck. The surface must be solid, even, and level. Make sure the blocks are solid, one-piece units. Make sure the lifting devices used during repairs can lift the weight of the parts. The steering axle can be removed without removing the counterweight. 1. Make sure wheels are set for straight travel. Put blocks under frame in front of steer wheels and under counterweight so steering axle can be removed. The top of the axle frame must have clearance under the counterweight so that the steering axle can be removed. 2. It is not required, but it can make removal of the axle easier if wheels are removed. See Wheels and Hubs Repair (All Units) for wheel removal. Disconnect hydraulic lines at steering cylinder. Install caps on cylinder and put plugs in hydraulic lines. Caps will prevent spindles from turning when axle is removed from the lift truck. 3. Slide a floor jack or forks of another lift truck under steering axle. Raise lifting device until it holds the weight of the axle assembly. Remove four capscrews and nuts that fasten two brackets under rubber mounts. Remove brackets and

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slowly lower axle assembly. Carefully remove axle assembly from under lift truck.

Install 1. Install rubber mounts on axle. Make sure part number is away from axle frame and tapered edge of rubber mount is at the top. See Figure 1and Figure 3. 2. Apply a lubricant that is approved for use with rubber (tire lubricant) to the rubber mounts. Lubricant is used where rubber mount fits into frame brackets. 3. Use a floor jack or another lift truck to put steering axle into position in the frame. Make sure rubber mounts fit inside frame brackets for the mounts. If necessary, lower weight of the lift truck onto axle to make sure rubber mounts fit completely in frame brackets. 4. Install bottom brackets for rubber mounts. H3.50-5.00XL (H70-110XL) (G005) units. Tighten four bolts for brackets to 72 N•m (53 lbf ft). S3.50-5.50XL (S70-120XL) (D004), S3.505.50XM (S70-120XM) (E004, F004), E3.505.50XL (E70-120XL, E70-120XL 3) (C098), and E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (D098) units. Tighten four bolts to 110 N•m (81 lbf ft). 5. Remove plugs and caps and connect hydraulic lines to steering cylinder. Install wheels if they were removed. 6. Operate steering system to remove air from system. Turn steering wheel several times from one wheel stop to other wheel stop. Check for hydraulic leaks.

1600 SRM 326

STEERING AXLE H6.00-7.00XL (H135-155XL, H135-155XL 2) (F006, G006), H8.00-16.00XL (H165-360XL) (D019, E007), AND H8.00-16.00XM (H170-360HD) (E019, F007, F019, G007) Remove WARNING Put the lift truck on blocks. Follow the procedures for raising the lift truck described in the Operating Manual for this lift truck. The surface must be solid, even, and level. Make sure the blocks are solid, one-piece units. Make sure the lifting devices used during repairs can lift the weight of the parts. The steering axle can be removed without removing the counterweight. 1. Make sure wheels are set for straight travel. Put blocks under frame in front of steer wheels, so steering axle can be removed. Top of axle frame must have clearance under counterweight so steering axle can be removed. 2. It is not required, but it can make removal of the axle easier if the wheels are removed. Disconnect hydraulic lines at steering cylinder. Install caps on cylinder and put plugs in hydraulic lines. Caps will prevent spindles from turning when axle is removed from under the lift truck. 3. Remove two dust covers from openings of bearing caps. 4. Slide a floor jack or forks of another lift truck under steering axle. Raise lifting device until it holds weight of axle assembly. Remove four capscrews and washers that fasten two bearing caps to frame. Remove bearing caps and slowly lower axle assembly. Carefully remove axle assembly from under lift truck.

Steering Axle Assembly Repair

Install WARNING Excessive play in the pivot bushings will result in increased shock loadings to the pivot pins and increased movement of the axle, and may affect steering responsiveness. If movement in the pivot bushings is more than 4 mm (0.16 in.), or damage to the O-ring seals exists, replace the bushings, flanges, and O-rings. 1. Install O-ring, spacer, and shims on each pivot shaft. Lubricate pivot shafts with multipurpose grease and install fiber bushing. See Figure 2 and Figure 4. 2. Use a floor jack or another lift truck to put steering axle into position in frame. Make sure fiber bushings fit into mounts of frame. 3. Install bearing caps. H6.00-7.00XL (H135-155XL, H135-155XL 2) (F006, G006) units. Tighten capscrews to 320 N•m (236 lbf ft). H8.00-16.00XL (H165-360XL) (D019, E007), and H8.00-16.00XM (H170-360HD) (E019, F007, F019, G007) units. Tighten capscrews to 380 N•m (280 lbf ft). After installation, make sure there is zero clearance between shims and frame. Add or remove shims as necessary to get zero clearance. 4. Install dust covers in openings of bearing caps. 5. Remove plugs and caps, and connect hydraulic lines to steering cylinder. Install wheels if they were removed. 6. Operate steering system to remove air from system. Turn steering wheel several times from one wheel stop to other wheel stop. Check for hydraulic leaks.

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Wheels and Hubs Repair (All Units)

1600 SRM 326

Wheels and Hubs Repair (All Units) REMOVE AND DISASSEMBLE WARNING Completely remove the air from the tire before removing the tire and wheel from lift truck. Air pressure in the tires can cause the tire and wheel parts to explode, causing serious injury or death. 1. Raise axle to remove weight from tires, but have tires still touching the floor. Loosen wheel nuts just enough so they can be easily removed. Raise axle so tires can be removed. Use a tire jack to remove tires and wheels. 2. If a tire jack is not available, raise axle only enough so tires are just touching the floor. Slide tires from axle while they are still on the floor. 3. Remove wheels. Remove grease cap. Remove cotter pin and castle nut. Remove bearing cone. Slide hub from spindle. Remove inner bearing cone and seal from spindle. 4. If wheel bearings must be replaced, use pry bars to remove bearing cups and the wear sleeve. See Figure 5. 5. Remove grease seal from spindle. 6. Repeat procedure for other hub.

CLEAN WARNING Cleaning solvents can be flammable and toxic and can cause skin irritation. When using cleaning solvents, always follow the recommendations of the manufacturer. Clean all parts with solvent. Make sure bearings are clean and dry.

INSPECT Inspect spindle to ensure it does not have any rough or sharp areas that would prevent the bearings from being correctly installed. If necessary, smooth any rough or sharp areas before installing the bearings.

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1. PRY BAR 2. BEARING CUP

3. BEARING CAP 4. O-RING

Figure 5. Bearing Cup Removal

ASSEMBLE AND INSTALL 1. If bearings in hubs must be replaced, use a press to install new bearing cups in hub. Install a new wear sleeve in wheel hub.

CAUTION Do not damage the seals during installation. 2. Install grease seal on spindle. Lubricate bearing cones and seal surfaces with grease. Make sure bearings are filled with grease. Install bearing cone on spindle. 3. Carefully slide hub onto spindle. On some units, the hub weighs enough to require a lifting device during installation. Install outer bearing cone.

1600 SRM 326

Wheels and Hubs Repair (All Units)

S3.50-5.50XL (S70-120XL) (D004), S3.505.50XM (S70-120XM) (E004, F004), E3.505.50XL (E70-120XL, E70-120XL 3 ) (C098), and E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (D098) units. Install solid wheel and hub assembly onto spindle and install outer bearing cone. NOTE: For newer E3.50-5.50XL (E70-120XL, E70-120XL 3) (C098) lift truck models and E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (D098) lift truck models, go to Step 5. 4. Install castle nut. Tighten castle nut to 203 N•m (150 lbf ft) while rotating wheel hub. Loosen castle nut to less than 27 N•m (20 lbf ft). Tighten castle nut to 34 N•m (25 lbf ft). Tighten castle nut until cotter pin can be installed. Install grease cap. 5. Tighten castle nut to 68 N•m (50 lbf ft). Back off one quarter turn. Torque castle nut to 3 N•m (25 lbf in). Insert and bend one prong of cotter pin.

a. Lubricate studs and nuts as shown in Figure 6. Do not get any oil on outer surfaces of wheel or flange of nut. b. Start with wheel nut at the top and tighten nuts to 65 to 130 N•m (48 to 96 lbf ft) in sequence shown. Make sure there is no dirt between wheel and hub. The wheel must fit over the pilot surface and be tight against the hub. Tighten nuts to 640 to 680 N•m (472 to 502 lbf ft).

WARNING When the wheels have been installed, check all wheel nuts after 2 to 5 hours of operation. Tighten the nuts to the correct torque. When the nuts stay tight after an 8-hour check, the interval for checking can be extended to time specified in the Periodic Maintenance section. 8. Repeat procedure for other wheel.

WARNING Add air to the tires only in a safety cage. Inspect safety cage for damage before use. When adding air, use a clip on chuck with enough hose to let the operator stand clear of the cage. 6. Install wheel on hub. Be careful not to damage threads on studs. 7. H3.50-5.00XL (H70-110XL) (G005), H6.007.00XL (H135-155XL, H135-155XL 2) (F006, G006) units. Install wheels on the hubs. H3.50-5.00XL (H70-110XL) (G005) Tighten nuts to 645 N•m (476 lbf ft).

units.

H6.00-7.00XL (H135-155XL, H135-155XL 2) (F006), and H6.00-7.00XL (H135-155XL (G006) units. Tighten nuts to 610 to 680 N•m (450 to 502 lbf ft). H8.00-16.00XL (H165-360XL) (D019, E007), and H8.00-16.00XM (H170-360HD) (E019, F007, F019, G007) units. Use the following procedure to install wheels on the hub:

X. NO LUBRICANT 1. WHEEL RIM 2. HUB 3. WHEEL STUD

4. WHEEL NUT 5. FLANGE 6. LUBRICATE

Figure 6. Wheels Installation

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Spindles and Bearings Repair (All Units)

1600 SRM 326

Spindles and Bearings Repair (All Units) REMOVE CAUTION Do not hit the threads or the nut of the tie rod. 1. Disconnect tie rods as described in Tie Rods Repair (All Units) procedures. 2. Remove grease cap from spindle. Remove capscrews from bearing cap and shims. If necessary, remove bearing cup from bearing cap. See Figure 5. 3. Tilt spindle and lift spindle from axle. If bearing must be replaced, remove bearing and seals from spindle. If wear sleeve and bearing cup must be replaced, remove them from axle frame. See Figure 5. 4. Repeat procedure for other spindle.

CLEAN WARNING Cleaning solvents can be flammable and toxic and can cause skin irritation. When using cleaning solvents, always follow the recommendations of the manufacturer. Clean all parts in solvent. Make sure bearings are clean and dry.

ASSEMBLE AND INSTALL 1. Install new seals on spindle. Lubricate seals with grease. See Figure 1, Figure 2, Figure 3, Figure 4, Figure 7, and Figure 8.

S3.50-5.50XM (S70-120XM) (E004, F004), E3.50-5.50XL (E70-120XL, E70-120XL 3) (C098), H6.00-7.00XL (H135-155XL, H135-155XL 2) (F006, G006), and E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (D098) units. Install bearing cap without O-ring. Measure clearance between bearing cap and axle. Remove bearing cap and install enough shims to give a preload 0.00 to 0.127 mm (0.000 to 0.005 in.). Install O-ring on bearing cap. Install bearing cap and capscrews. Tighten capscrews to 45 N•m (33 lbf ft) for H3.50-5.00XL (H70-110XL) (G005), S3.50-5.50XL (S70-120XL) (D004), S3.50-5.50XM (S70-120XM) (E004, F004), E3.50-5.50XL (E70-120XL, E70-120XL 3) (C098), and H6.00-7.00XL (H135-155XL, H135-155XL 2) (F006, G006) units and 52 N•m (38 lbf ft) for E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (D098). NOTE: Spindle bearings must have no clearance. Install shims 0.00 to 0.13 mm (0.000 to 0.005 in.) less than measured clearance. b. H8.00-16.00XL (H165-360XL) (D019, E007), and H8.00-16.00XM (H170-360HD) (E019, F007, F019, G007) units. Install bearing cap without shims. Tighten three capscrews to 20 N•m (15 lbf ft). Rotate spindle, then tighten capscrews to 20 N•m (15 lbf ft) again. Loosen capscrews and tighten again to 14 N•m (10 lbf ft). Measure gap. Install correct amount of shims to equal the gap. Tighten capscrews to 77 N•m (56.8 lbf ft).

2. Lubricate bearings with wheel bearing grease. Make sure bearings are filled with grease. If necessary, press new bearing cups into steering axle frame and bearing cap. Install wear sleeve in steering axle frame.

4. Install grease cap on top of steering axle. Use a sealant between grease cap and steering axle.

3. Install spindle in steering axle and make the following bearing adjustment:

6. Repeat procedure for other spindle.

a. H3.50-5.00XL S3.50-5.50XL

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(H70-110XL) (S70-120XL)

(G005), (D004),

5. Install tie rod as described in Tie Rods Repair (All Units) procedures.

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Tie Rods Repair (All Units)

Tie Rods Repair (All Units) REMOVE CAUTION Do not hit the threads or the nut of the tie rod. 1. H3.50-5.00XL (H70-110XL) (G005), S3.505.50XL (S70-120XL) (D004), S3.50-5.50XM (S70-120XM) (E004, F004), E3.50-5.50XL (E70-120XL, E70-120XL 3) (C098), H6.007.00XL (H135-155XL, H135-155XL 2) (F006, G006), and E3.50-5.50XL, E4.50XLS (E70120Z, E100ZS) (D098) units. Use the following procedure to remove tie rods on these lift trucks (see Figure 1, Figure 3, Figure 4): a. Remove cotter pin and castle nut. To loosen stud, hold a large hammer behind spindle arm of spindle. Hit side of spindle arm with another large hammer. The shock of the hammer from hitting the spindle arm will normally loosen tapered stud. b. Spindle and tie rod can be removed as a unit. Disconnect tie rod at retaining pin inside dust cover. S3.50-5.50XL (S70-120XL) (D004), S3.505.50XM (S70-120XM) (E004, F004), E3.505.50XL (E70-120XL, E70-120XL 3) (C098), and E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (D098) units. It is necessary to raise steer wheels 8 to 15 cm (3 to 6 in.) from the floor. Remove lower snap ring, and use a hammer and a drift to push pins for tie rods upward. See Figure 7. 2. H8.00-16.00XL (H165-360XL) (D019, E007), and H8.00-16.00XM (H165-360HD) (E019, F007, F019, G007) units. Remove capscrew, anchor pin, and tie rod pin from each end of the tie rod. See Figure 8.

CLEAN WARNING Cleaning solvents can be flammable and toxic and can cause skin irritation. When using

cleaning solvents, always follow the recommendations of the manufacturer. Clean all parts except the ends of the tie rods in solvent. Make sure bearings are clean.

INSTALL 1. Use the following procedure to install tie rod to spindle arm or steering cylinder (see Figure 1, Figure 3, Figure 4, Figure 7, and Figure 8): a. H3.50-5.00XL (H70-110XL) (G005), S3.50-5.50XL (S70-120XL) (D004), E3.50-5.50XL (E70-120XL, E70-120XL 3) (C098), H6.00-7.00XL (H135-155XL, H135-155XL 2) (F006, G006), and E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (D098) units. Install tie rod end into spindle arm and tighten castle nut to 165 N•m (122 lbf ft). For E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (D098) units tighten castle nut to 175 N•m (129 lbf ft). If the hole in the tie rod end and the slot in the castle nut do not align, tighten castle nut until cotter pin can be installed. b. S3.50-5.50XM (S70-120XM) (E004, F004) units. Install tie rod end into spindle arm and tighten castle nut to 175 N•m (129 lbf ft). If the hole in the tie rod end and the slot in the castle nut do not align, tighten castle nut until cotter pin can be installed. c. H8.00-16.00XL (H165-360XL) (D019, E007) and H8.00-16.00XM (H170-360HD) (E019, F007, F019, G007) units. Install seals on tie rod bushings. Use an alignment pin to align seals with bushings. Lubricate pin with an antiseize compound and install tie rod pin into the tie rod and cylinder rod or spindle arm. Grease fittings on tie rod pins must face downward. Install anchor pin and capscrew to fasten the pin. Tighten capscrew in the anchor pin to 44 N•m (32 lbf ft). NOTE: Tie rods do not have an adjustment.

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Tie Rods Repair (All Units)

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.

STEER AXLE STEERING CYLINDER BOOT CLAMP CLAMP PIN SNAP RING TIE ROD ASSEMBLY CASTLE NUT COTTER PIN WASHER L.H. SPINDLE BEARING CONE

1600 SRM 326

14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26.

BEARING CUP SEAL WEAR SLEEVE R.H. SPINDLE CAP BEARING CONE SEAL SEAL O-RING SHIM(S) CAPSCREW LUBE FITTING BEARING CAP

Figure 7. Steering Axle S3.50-5.50XL (S70-120XL) (D004), S3.50-5.50XM (S70-120XM) (E004, F004), E3.50-5.50XL (E70-120XL, E70-120XL 3) (C098), and E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (D098)

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1600 SRM 326

Tie Rods Repair (All Units)

A. H8.00-12.00XL (H165-280XL) (D019) AND H8.00-12.00XM (H170-280HD) (E019, F019) B. H13.00-16.00XL (H300-360XL) (E007) AND H13.00-16.00XM (H300-360HD) (F007, G007) 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.

AXLE FRAME STEERING CYLINDER ANCHOR PIN CAPSCREW PIN, TIE ROD TIE ROD BEARING CUP BEARING CONE GREASE CAP SEAL WEAR SLEEVE SPINDLE

13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23.

WHEEL HUB HUB CAP NUT COTTER PIN BEARING ASSEMBLY ADHESIVE GREASE FITTING BEARING CAP SHIMS BUSHING, TIE ROD PILOT SURFACE

Figure 8. Steering Axle H8.00-16.00XL (H165-360XL) (D019, E007) and H8.00-16.00XM (H170-360HD) (E019, F007, F019, G007)

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Steering Cylinder Repair

1600 SRM 326

Steering Cylinder Repair REMOVE AND DISASSEMBLE NOTE: End caps of the steering cylinder are held in the shell by the cylinder mount capscrews. To prevent oil leaks at the caps, hold caps on shell during removal. See Figure 9. 1. Disconnect hydraulic lines at steering cylinder. Install caps on cylinder fittings and put plugs in hydraulic lines.

away from all personnel. Wear protective goggles or a face shield to prevent injury to the eyes. 1. Clean all parts in solvent. Use compressed air to dry parts. 2. Inspect piston rod for grooves or damage. Remove small scratches with fine emery cloth. Inspect cylinder bore for damage. Inspect mounts for cracks.

2. Disconnect tie rods as described in the Tie Rods Repair (All Units) procedures.

ASSEMBLE AND INSTALL

3. Loosen the capscrews that hold the cylinder to the axle frame (do not remove capscrews) enough to move the end caps to the maximum outer position of the mounting place.

Do not damage the O-rings, seals, or wipers during installation.

4. Move the shell to one side of the assembly, to cap one side of the shell. 5. Measure the distance from the shell to the end gap and install shims to fit. 6. Remove capscrews and washers that fasten cylinder to axle frame. Hold end caps on shell and remove steering cylinder. 7. Hold end of steering cylinder over a drain pan. Remove hydraulic fitting cap from each end cap. Push rod toward end of shell that is over drain pan. Oil will drain from cylinder. Repeat procedure for other end. 8. Remove one end cap from shell. Carefully pull rod from shell. Keep rod in center of shell during removal. Remove end cap from rod. Remove other end cap from shell. Remove all seals, wipers, and O-rings.

CLEAN AND INSPECT WARNING Cleaning solvents can be flammable and toxic and can cause skin irritation. When using cleaning solvents, always follow the recommendations of the manufacturer. Compressed air can move particles so they cause injury to the user or to other personnel. Make sure the path of the compressed air is

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CAUTION

1. Lubricate O-rings, seals, and wipers with O-ring lubricant. Install O-rings, seals, and wipers. See Figure 9. 2. Carefully slide rod into shell. Keep rod in center of shell during installation. Slide end cap into shell. Install other end cap on rod and shell. Put caps on hydraulic fittings of end caps. 3. Hold end caps and install cylinder on axle frame using capscrews and washers. Make sure end caps are fully engaged with shell. H3.50-5.00XL (H70-110XL) (G005), S3.505.50XL (S70-120XL) (D004), S3.50-5.50XM (S70-120XM) (E004, F004), E3.50-5.50XL (E70-120XL, E70-120XL 3) (C098), and E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (D098) units. Tighten capscrews to 225 N•m (166 lbf ft). H6.00-7.00XL (H135-155XL, H135-155XL 2) (F006, G006) units. Tighten capscrews to 245 N•m (181 lbf ft). H8.00-16.00XL (H165-360XL) (D019, E007), and H8.00-16.00XM (H170-360HD) (E019, F007, F019, G007) units. Tighten capscrews to 435 N•m (320 lbf ft). 4. Install tie rods as described in the Tie Rods Repair (All Units) procedures.

1600 SRM 326

Troubleshooting

5. Remove plugs and caps, and connect hydraulic lines to steering cylinder. Start engine, and operate steering system to remove air from

1. 2. 3. 4.

SHELL END CAP PISTON ROD PISTON SEAL

cylinders and system. Turn steering wheel several times from one wheel stop to the other wheel stop.

5. 6. 7. 8.

O-RING BACKUP RING ROD SEAL WIPER SEAL

Figure 9. Steering Cylinder

Troubleshooting PROBLEM The steering wheels do not move when the steering wheel is turned.

Slow or difficult steering.

POSSIBLE CAUSE

PROCEDURE OR ACTION

The hydraulic oil level is low or there is no hydraulic oil in the tank.

Fill tank. Check for leaks.

The steering control unit is damaged.

Repair or install new control unit.

No oil flow from the steering control unit to the steering cylinder.

Repair or install new components. Check for leaks.

Relief valve for the steering system needs adjustment.

Adjust or install new relief valve.

Low oil pressure from the hydraulic pump.

Check for restrictions. See Troubleshooting Chart in the Hydraulic System SRM for your lift truck.

Seal in the steering cylinder has a leak.

Install new seal.

Steering control unit is worn or has damage.

Repair or install new control unit.

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Troubleshooting

PROBLEM

1600 SRM 326

POSSIBLE CAUSE

PROCEDURE OR ACTION

Steering wheel turns the tires in the wrong direction.

The hydraulic lines are not connected correctly at the steering cylinder or at the steering control unit.

Connect lines properly. Remove air from system.

Steering function continues after the steering wheel stops.

The steering control unit was assembled wrong or has damage.

Repair or install new control unit.

There is air in the steering system.

The oil level in the tank is low.

Add hydraulic oil as necessary. Check for leaks.

Air was not removed after repair to the hydraulic or steering system.

Remove air from system.

The hydraulic pump has an air leak at the inlet.

Repair system. Remove air from system.

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TECHNICAL PUBLICATIONS 1600 SRM 326

3/05 (10/03)(9/03)(11/01)(8/01)(8/00)(6/94)(7/89)(5/88)(5/86) Printed in U.S.A.