Steering Axle

8/14/2019 Steering Axle

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STEERING AXLES3.50-5.50XL (S70-120XL) [D004];

S3.50-5.50XM (S70-120XM) [E004, F004];

E3.50-5.50XL (E70-120XL, E70-120XL3) [C098];

H3.50-5.00XL (H70-110XL) [G005];

H6.00-7.00XL (H135-155XL, H135-155XL2) [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


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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 Mainte-

nance 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:

WARNINGIndicates a condition that can cause immediate death or injury!

CAUTION

Indicates a condition that can cause property damage!


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Steering Axle Table of Contents

TABLE OF CONTENTS

General ...............................................................................................................................................................

Description .........................................................................................................................................................

Steering Axle Assembly Repair......................................................................................................................... 6

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), andE3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (D098)................................................................................ 6

Remove....................................................................................................................................................... 6

Install......................................................................................................................................................... 6

Steering Axle H6.00-7.00XL (H135-155XL, H135-155XL2) (F006, G006), H8.00-16.00XL

(H165-360XL) (D019, E007), and H8.00-16.00XM (H170-360HD) (E019, F007, F019, G007).................. 7

Remove.......................................................................................................................................................

Install.........................................................................................................................................................

Wheels and Hubs Repair (All Units) ................................................................................................................ 8

Remove and Disassemble .............................................................................................................................. 8

Clean .............................................................................................................................................................. 8

Inspect ............................................................................................................................................................ 8

Assemble and Install..................................................................................................................................... 8Spindles and Bearings Repair (All Units) ........................................................................................................ 10

Remove ........................................................................................................................................................... 10

Clean .............................................................................................................................................................. 10

Assemble and Install..................................................................................................................................... 10

Tie Rods Repair (All Units) ............................................................................................................................... 1

Remove ........................................................................................................................................................... 1

Clean .............................................................................................................................................................. 1

Install ............................................................................................................................................................. 1

Steering Cylinder Repair................................................................................................................................... 14

Remove and Disassemble .............................................................................................................................. 14

Clean and Inspect .......................................................................................................................................... 14

Assemble and Install..................................................................................................................................... 14

Troubleshooting.................................................................................................................................................. 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


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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.

DescriptionThe 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, E70-120XL3) (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, H135-155XL2) (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 th

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 th

seal are at the center of the piston rod. Oil pressur

on one side of the piston moves the piston in the bore

The piston pushes an equal amount of oil from th

opposite side of the cylinder. The oil returns to th

steering control unit.

When the piston in the steering cylinder reaches th

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 steerin

control unit.

Each spindle turns on two tapered roller bearings in

the axle frame. The preload on the bearings is con

trolled by shims at the lower bearing cap. The ti

rods that connect the spindle arms to the cylinder d

not have an adjustment.

The wheel hubs rotate on two tapered roller bear

ings 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 bearing

from dirt and water. Wear sleeves prevent the seal

from causing wear on the hub.


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Description 1600 SRM 326

1. STEERING AXLE

2. COVER3. CLAMP4. COTTER PIN5. SNAP RING6. TIE ROD AND BUSHING7. NUT8. CAPSCREW9. CAP10. BEARING CONE

11. BEARING CUP

12. SEAL13. WEAR SLEEVE14. SPINDLE (RH)15. SPINDLE (LH)16. O-RING17. SHIM18. BEARING CAP19. LUBE FITTING20. SCREW

21. SEALANT

22. STEER CYLINDER23. OIL SEAL24. CAP (HUB)25. WASHER26. MOUNT27. PLATE28. LOCKWASHER29. WHEEL30. GREASE FITTING

Figure 1. Steering Axle E3.50-5.50XL (E70-120XL, E70-120XL3 ) (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. HUB ASSEMBLY2. STUD3. BEARING CUP4. WEAR SLEEVE5. HUB CAP6. COTTER PIN7. NUT8. WASHER9. LOCKWASHER10. CAPSCREW

11. BEARING CONE12. BEARING CAP13. SHIM14. OIL SEAL15. LUBE FITTING16. PIN17. PLUG18. SPINDLE19. FRAME20. SHAFT

21. TIE ROD22. BUSHING23. ANCHOR24. STEERING CYLINDER25. FITTING26. O-RING27. FLANGE28. LUG NUT29. HANGER CUP

2


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

3


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Description 1600 SRM 326

1. STEERING AXLE2. STEER CYLINDER3. SPINDLE (LH)4. SEAL5. BEARING CONE6. SPINDLE (RH)7. HUB8. BEARING CUP

9. STUD (WHEEL)10. WEAR SLEEVE11. TIE ROD12. CAPSCREW13. NUT (SPINDLE)14. CAP (HUB)15. SHIM16. CAP ASSEMBLY17. PIN

18. SNAP RING19. O-RING20. GREASE FITTING21. COTTER PIN22. MOUNT23. PLATE24. WASHER25. NUT

26. LUG NUT27. PIN28. PLUG AND SEALANT29. CLAMP30. OIL SEAL31. BEARING CAP32. CAPSCREW33. COVER

Figure 3. Steering Axle H3.50-5.00XL (H70-110XL) (G005)

Legend for Figure 4

1. STEERING AXLE

2. SHAFT3. SEAL4. PIN5. SNAP RING6. TIE ROD7. CAPSCREW8. LOCKWASHER9. PLUG

10. BEARING CONE

11. BEARING CUP12. WEAR SLEEVE13. SPINDLE14. O-RING15. SHIM16. SCREW17. OIL SEAL18. HUB

19. STUD

20. WHEEL NUT21. WASHER22. COTTER PIN23. CAP24. GREASE FITTING25. BUSHING26. BEARING CAP27. STEER CYLINDER

4


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Figure 4. Steering Axle H6.00-7.00XL (H135-155XL, H135-155XL2) (F006, G006)

5


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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, E70-120XL3) (C098), AND

E3.50-5.50XL, E4.50XLS (E70-120Z,

E100ZS) (D098)

Remove

WARNING

Put the lift truck on blocks. Follow the proce-

dures for raising the lift truck described in the

Operating Manual for this lift truck. The sur-

face must be solid, even, and level. Make sure

the blocks are solid, one-piece units. Make surethe 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 re-

moved. 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 hy-

draulic 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 brack-

ets under rubber mounts. Remove brackets and

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 Fig-

ure 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 steer-

ing 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 Nm

(53 lbf ft).

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) units. Tighten four bolts to 110 Nm

(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 sys-

tem. Turn steering wheel several times from one

wheel stop to other wheel stop. Check for hy-

draulic leaks.

6


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1600 SRM 326 Steering Axle Assembly Repai

STEERING AXLE H6.00-7.00XL

(H135-155XL, H135-155XL2) (F006,

G006), H8.00-16.00XL (H165-360XL) (D019,

E007), AND H8.00-16.00XM (H170-360HD)

(E019, F007, F019, G007)

Remove

WARNINGPut the lift truck on blocks. Follow the proce-

dures for raising the lift truck described in the

Operating Manual for this lift truck. The sur-

face 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. Dis-

connect hydraulic lines at steering cylinder. In-

stall 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 cap-

screws 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.

Install

WARNINGExcessive play in the pivot bushings will resul

in increased shock loadings to the pivot pin

and increased movement of the axle, and may

affect steering responsiveness. If movement inthe pivot bushings is more than 4 mm (0.16 in.)

or damage to the O-ring seals exists, replac

the bushings, flanges, and O-rings.

1. Install O-ring, spacer, and shims on each pivo

shaft. Lubricate pivot shafts with multipurpos

grease and install fiber bushing. See Figure

and Figure 4.

2. Use a floor jack or another lift truck to put steer

ing axle into position in frame. Make sure fibe

bushings fit into mounts of frame.

3. Install bearing caps.

H6.00-7.00XL (H135-155XL, H135-155XL2(F006, G006) units. Tighten capscrews t

320 Nm (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 t

380 Nm (280 lbf ft). After installation, mak

sure there is zero clearance between shims and

frame. Add or remove shims as necessary to ge

zero clearance.

4. Install dust covers in openings of bearing caps.

5. Remove plugs and caps, and connect hydrauli

lines to steering cylinder. Install wheels if the

were removed.

6. Operate steering system to remove air from sys

tem. Turn steering wheel several times from on

wheel stop to other wheel stop. Check for hy

draulic leaks.

7


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Wheels and Hubs Repair (All Units) 1600 SRM 326

Wheels and Hubs Repair (All Units)

REMOVE AND DISASSEMBLE

WARNINGCompletely 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

WARNINGCleaning solvents can be flammable and toxic

and can cause skin irritation. When using

cleaning solvents, always follow the recom-

mendations of the manufacturer.

Clean all parts with solvent. Make sure bearings are

clean and dry.

INSPECTInspect 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.

1. PRY BAR2. BEARING CUP

3. BEARING CAP4. 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.

CAUTIONDo 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 bearingcone 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.

8


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1600 SRM 326 Wheels and Hubs Repair (All Units

S3.50-5.50XL (S70-120XL) (D004), S3.50-

5.50XM (S70-120XM) (E004, F004), E3.50-

5.50XL (E70-120XL, E70-120XL3 ) (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 Nm

(150 lbf ft) while rotating wheel hub. Loosen cas-

tle nut to less than 27 Nm (20 lbf ft). Tighten

castle nut to 34 Nm (25 lbf ft). Tighten cas-

tle nut until cotter pin can be installed. Install

grease cap.

5. Tighten castle nut to 68 Nm (50 lbf ft). Back

off one quarter turn. Torque castle nut to 3 Nm

(25 lbf in). Insert and bend one prong of cotter

pin.

WARNING Add air to the tires only in a safety cage. In-

spect 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), H6.00-

7.00XL (H135-155XL, H135-155XL2) (F006,

G006) units. Install wheels on the hubs.

H3.50-5.00XL (H70-110XL) (G005) units.

Tighten nuts to 645 Nm (476 lbf ft).

H6.00-7.00XL (H135-155XL, H135-155XL2)

(F006), and H6.00-7.00XL (H135-155XL

(G006) units. Tighten nuts to 610 to 680 Nm

(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:

a. Lubricate studs and nuts as shown in Fig

ure 6. Do not get any oil on outer surface

of wheel or flange of nut.

b. Start with wheel nut at the top and tighten

nuts to 65 to 130 Nm (48 to 96 lbf ft) in

sequence shown. Make sure there is no dirbetween wheel and hub. The wheel must fi

over the pilot surface and be tight against th

hub. Tighten nuts to 640 to 680 Nm (472 t

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.

X. NO LUBRICANT

1. WHEEL RIM2. HUB

3. WHEEL STUD

4. WHEEL NUT5. FLANGE

6. LUBRICATE

Figure 6. Wheels Installation

9


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Spindles and Bearings Repair (All Units) 1600 SRM 326

Spindles and Bearings Repair (All Units)

REMOVE

CAUTIONDo not hit the threads or the nut of the tie rod.

1. Disconnect tie rods as described in Tie Rods Re-

pair (All Units) procedures.

2. Remove grease cap from spindle. Remove cap-

screws from bearing cap and shims. If necessary,

remove bearing cup from bearing cap. See Fig-

ure 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 Fig-

ure 5.

4. Repeat procedure for other spindle.

CLEAN

WARNING

Cleaning solvents can be flammable and toxic




Clean all parts in solvent. Make sure bearings are

clean and dry.


1. Install new seals on spindle. Lubricate seals with

grease. See Figure 1, Figure 2, Figure 3, Fig-

ure 4, Figure 7, and Figure 8.

2. Lubricate bearings with wheel bearing grease.

Make sure bearings are filled with grease. If nec-

essary, press new bearing cups into steering axle

frame and bearing cap. Install wear sleeve in

steering axle frame.

3. Install spindle in steering axle and make the fol-

lowing bearing adjustment:

a. 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, E70-120XL3)

(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 bear-

ing cap. Install bearing cap and cap-

screws. Tighten capscrews to 45 Nm

(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, E70-120XL3)

(C098), and H6.00-7.00XL (H135-155XL,H135-155XL 2) (F006, G006) units and

52 Nm (38 lbf ft) for E3.50-5.50XL,

E4.50XLS (E70-120Z, E100ZS) (D098).

NOTE: Spindle bearings must have no clearance. In-

stall 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 Nm (15 lbf ft). Rotatespindle, then tighten capscrews to 20 Nm

(15 lbf ft) again. Loosen capscrews and

tighten again to 14 Nm (10 lbf ft). Mea-

sure gap. Install correct amount of shims to

equal the gap. Tighten capscrews to 77 Nm

(56.8 lbf ft).

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

sealant between grease cap and steering axle.

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

Units) procedures.

6. Repeat procedure for other spindle.

10


15/22

1600 SRM 326 Tie Rods Repair (All Units

Tie Rods Repair (All Units)

REMOVE

CAUTIONDo not hit the threads or the nut of the tie rod.

1. 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, E70-120XL3) (C098), H6.00-

7.00XL (H135-155XL, H135-155XL2) (F006,

G006), and E3.50-5.50XL, E4.50XLS (E70-

120Z, 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 withanother 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), S3.50-

5.50XM (S70-120XM) (E004, F004), E3.50-

5.50XL (E70-120XL, E70-120XL3) (C098),

and E3.50-5.50XL, E4.50XLS (E70-120Z,

E100ZS) (D098) units. It is necessary toraise 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

WARNINGCleaning solvents can be flammable and toxic


cleaning solvents, always follow the recom


Clean all parts except the ends of the tie rods in sol

vent. Make sure bearings are clean.

INSTALL

1. Use the following procedure to install tie rod t

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, E70-120XL3(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 nu

to 165 Nm (122 lbf ft). For E3.50-5.50XL

E4.50XLS (E70-120Z, E100ZS) (D098

units tighten castle nut to 175 Nm

(129 lbf ft). If the hole in the tie rod en

and the slot in the castle nut do not align

tighten castle nut until cotter pin can b

installed.

b. S3.50-5.50XM (S70-120XM) (E004, F004

units. Install tie rod end into spindle arm

and tighten castle nut to 175 Nm (129 lbf ft)

If the hole in the tie rod end and the slot in

the castle nut do not align, tighten castle nu

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. Instal

seals on tie rod bushings. Use an alignmen

pin to align seals with bushings. Lubricat

pin with an antiseize compound and instal

tie rod pin into the tie rod and cylinder rod or

spindle arm. Grease fittings on tie rod pin

must face downward. Install anchor pin and

capscrew to fasten the pin. Tighten capscrew

in the anchor pin to 44 Nm (32 lbf ft).

NOTE: Tie rods do not have an adjustment.

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Tie Rods Repair (All Units) 1600 SRM 326

1. STEER AXLE2. STEERING CYLINDER3. BOOT4. CLAMP5. CLAMP6. PIN7. SNAP RING8. TIE ROD ASSEMBLY9. CASTLE NUT10. COTTER PIN

11. WASHER12. L.H. SPINDLE13. BEARING CONE

14. BEARING CUP15. SEAL16. WEAR SLEEVE17. R.H. SPINDLE18. CAP19. BEARING CONE20. SEAL21. SEAL22. O-RING23. SHIM(S)

24. CAPSCREW25. LUBE FITTING26. 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, E70-120XL3) (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. AXLE FRAME2. STEERING CYLINDER3. ANCHOR PIN4. CAPSCREW5. PIN, TIE ROD6. TIE ROD7. BEARING CUP8. BEARING CONE9. GREASE CAP10. SEAL

11. WEAR SLEEVE12. SPINDLE

13. WHEEL HUB14. HUB CAP15. NUT16. COTTER PIN17. BEARING ASSEMBLY18. ADHESIVE19. GREASE FITTING20. BEARING CAP21. SHIMS22. BUSHING, TIE ROD

23. 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 pre-

vent oil leaks at the caps, hold caps on shell duringremoval. See Figure 9.

1. Disconnect hydraulic lines at steering cylinder.

Install caps on cylinder fittings and put plugs in

hydraulic lines.

2. Disconnect tie rods as described in the Tie Rods

Repair (All Units) procedures.

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 po-

sition of the mounting place.

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 proce-

dure for other end.

8. Remove one end cap from shell. Carefully pull

rod from shell. Keep rod in center of shell dur-

ing removal. Remove end cap from rod. Re-

move other end cap from shell. Remove all seals,

wipers, and O-rings.

CLEAN AND INSPECT

WARNING

Cleaning solvents can be flammable and toxicand can cause skin irritation. When using



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

away from all personnel. Wear protective gog-

gles or a face shield to prevent injury to the

eyes.

1. Clean all parts in solvent. Use compressed air todry parts.

2. Inspect piston rod for grooves or damage. Re-

move small scratches with fine emery cloth. In-

spect cylinder bore for damage. Inspect mounts

for cracks.


CAUTIONDo not damage the O-rings, seals, or wipers

during installation.

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), S3.50-

5.50XL (S70-120XL) (D004), S3.50-5.50XM

(S70-120XM) (E004, F004), E3.50-5.50XL

(E70-120XL, E70-120XL3) (C098), and

E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS)

(D098) units. Tighten capscrews to 225 Nm

(166 lbf ft).

H6.00-7.00XL (H135-155XL, H135-155XL2)

(F006, G006) units. Tighten capscrews to

245 Nm (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 Nm (320 lbf ft).

4. Install tie rods as described in the Tie Rods Re-

pair (All Units) procedures.

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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

cylinders and system. Turn steering wheel sev

eral times from one wheel stop to the other whee

stop.

1. SHELL2. END CAP

3. PISTON ROD4. PISTON SEAL

5. O-RING6. BACKUP RING

7. ROD SEAL8. WIPER SEAL

Figure 9. Steering Cylinder

Troubleshooting

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

The steering wheels do not

move when the steering

wheel is turned.

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 dam-

aged.

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.

Slow or difficult steering. 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 Trou

bleshooting 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 1600 SRM 326

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

Steering wheel turns the

tires in the wrong direction.

The hydraulic lines are not con-

nected correctly at the steering

cylinder or at the steering control

unit.

Connect lines properly. Remove air

from system.

Steering function contin-

ues after the steering wheel

stops.

The steering control unit was assem-

bled 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 sys-

tem.

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