STEERING AXLE

H1.50-1.75XM (S/H25-35XM)

[C010, D001, D010, E001];

H2.00XMS (S/H40XMS)

[C010, D001, D010, E001]

PART NO. 897545

1600 SRM 532

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:

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 ...............................................................................................................................................................

1

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

1

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

2

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

2

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

2

Wheels and Hubs Repair ...................................................................................................................................

2

Pneumatic Tires, Remove and Disassemble.................................................................................................

2

Cushion Tires, Remove and Disassemble.....................................................................................................

4

Pneumatic Tires, Assemble and Install........................................................................................................

4

Cushion Tires, Assemble and Install............................................................................................................

4

Spindles, Bearings, and Tie Rods Repair .........................................................................................................

5

Pneumatic Tires, Remove..............................................................................................................................

5

Cushion Tires, Remove..................................................................................................................................

5

Pneumatic Tires, Install................................................................................................................................

5

Cushion Tires, Install ....................................................................................................................................

6

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

6

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

6

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

6

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

6

Torque Specifications .........................................................................................................................................

7

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

8

This section is for the following models:

H1.50-1.75XM (S/H25-35XM) [C010, D001, D010, E001];

H2.00XMS (S/H40XMS) [C010, D001, D010, E001]

©2004 HYSTER COMPANY

i

"THE

QUALITY

KEEPERS"

HYSTER

APPROVED

PARTS

1600 SRM 532

Description

General

This section has the description and repair procedures for the steering axle. For additional information on
the parts of the steering system, see the sections Steering Housing and Control Unit 1600 SRM 720 and
Hydraulic System and Gear Pump Assembly 1900 SRM 539.

Description

The steering axle assembly includes an axle frame,
steering cylinder, and two spindle and hub assem-
blies. See Figure 1. The steering axle is connected
to the frame with center pivot mounts. The center
pivot mounts on the axle frame are fastened to the lift
truck frame with rubber mounts. The steering axle
can make an articulated motion, which gives the lift
truck smoother travel over rough surfaces.

There are two plates welded to the steering cylin-
der that allow the cylinder to be mounted to the axle

frame. The oil is kept inside the cylinder by O-rings,
seals, and wipers in the end caps. The piston rod ex-
tends from both ends of the cylinder. A single piston
and seal are at the center of the rod. Oil pressure on
one side of the piston moves the piston in the bore,
pushing an equal amount of oil from the opposite end
of the cylinder. This oil returns to the steering control
unit. When the piston reaches the end of the stroke,
a relief valve controls the oil pressure so the compo-
nents are not damaged.

NOTE: H1.50-1.75XM AND H2.00XMS (H25-35XM AND H40XMS) ARE SHOWN HERE. S25-35XM AND S40XMS
ARE SIMILAR.

1.

SPINDLE AND HUB ASSEMBLY

2.

AXLE FRAME

3.

BRACKET

4.

RUBBER MOUNT

5.

STEERING CYLINDER

6.

CYLINDER MOUNTING CAPSCREW

7.

AXLE MOUNTING CAPSCREW

8.

PIN

9.

LINK

Figure 1. Steering Axle

1

Wheels and Hubs Repair

1600 SRM 532

Links connect the spindle arms to the cylinder. Each
spindle turns on two tapered roller bearings. The
spindle and bearings are held in the axle frame by
a kingpin. A roll pin and lock nut assembly hold
each kingpin in the axle frame. The wheel or hub

rotates on two tapered-roller bearings and is held on
the spindle by a castle nut. The castle nut adjusts
the preload on the bearings. Grease seals in the in-
ner hub and a hub cap protect the bearings from dirt
and water.

Steering Axle Assembly Repair

REMOVE

WARNING

The steering axle assembly without the wheels
weighs approximately 115 kg (253.5 lb).

To

avoid possible injury, use a lifting device if the
steering axle assembly must be lifted.

NOTE: The steering axle can be removed without re-
moving the counterweight.

1.

Make sure the wheels are set for straight travel.
Put the lift truck on blocks so the steering axle
can be removed. See How to Put Lift Truck on
Blocks in the Periodic Maintenance section for
your lift truck. The top of the axle frame must
have clearance under the counterweight so the
steering axle can be removed. See Figure 1.

2.

Disconnect hydraulic lines at steering cylinder.
Install caps on cylinder and put plugs in hy-
draulic lines. The caps will prevent the spindles
from turning when the axle is removed from
under the lift truck.

3.

Slide a floor jack or the forks of another lift truck
under the steering axle. Raise lifting device until

it holds the weight of axle assembly. Remove four
capscrews that fasten two brackets under rubber
mounts. Remove brackets and slowly lower axle
assembly onto wheels. Carefully roll axle assem-
bly from under lift truck.

INSTALL

NOTE: The mounts of the steering axle have TOP
moulded into the rubber. Verify TOP is up when in-
stalling the mounts.

1.

Install rubber mounts onto axle. See Figure 1.

2.

Install bottom brackets.

Tighten four bracket

capscrews and nuts to 41 to 49 N•m (30 to
36 lbf ft).

3.

Remove plugs and caps and connect hydraulic
lines to steering cylinder.

4.

Operate steering system to remove air from sys-
tem. Turn steering wheel several times from one
stop to other stop. Check for hydraulic leaks.

Wheels and Hubs Repair

PNEUMATIC TIRES, REMOVE AND
DISASSEMBLE

WARNING

Completely remove the air from the tires be-
fore removing them from the lift truck.

Air

pressure in the tires can cause the tire and rim
parts to explode which can cause serious injury
or death.

Never loosen the nuts that hold together the
inner and outer wheel halves when there is air
pressure in the tire.

1.

Put axle onto blocks so tires are raised from floor.
Completely remove air from tires.

2.

Remove wheels, grease cap, cotter pin, castle nut,
and outer bearing cone. Slide hub from spindle.
Remove inner bearing cone and seal from spin-
dle. See Figure 2.

3.

If new wheel bearings must be installed, use a
brass drift to remove bearing cups.

4.

Repeat the procedure for the other wheel.

2

1600 SRM 532

Wheels and Hubs Repair

1.

AXLE FRAME

2.

KNUCKLE

3.

KINGPIN

4.

UPPER SLEEVE

5.

LOWER SLEEVE

6.

BEARING

7.

O-RING

8.

GROOVE PIN

9.

OIL SEAL

10. COTTER PIN
11. CASTLE NUT
12. GREASE FITTING
13. LINK
14. PIN

15. BUSHING
16. SCREW
17. LOCK NUT
18. GREASE FITTING
19. STEERING CYLINDER
20. SPACER
21. BOLT
22. WASHER
23. HUB (PNEUMATIC TIRES)
24. BOLT (PNEUMATIC TIRES)
25. WHEEL NUT (PNEUMATIC

TIRES)

26. HUB CAP
27. WASHER

28. BEARING
29. BEARING
30. OIL SEAL
31. FITTING
32. FITTING
33. LOCK NUT
34. RUBBER CUSHION
35. CUSHION COVER
36. WASHER
37. LOCKWASHER
38. BOLT
39. TIRE/WHEEL (CUSHION)

Figure 2. Steering Axle

3

Wheels and Hubs Repair

1600 SRM 532

CUSHION TIRES, REMOVE AND
DISASSEMBLE

WARNING

The steer wheel and tire assembly weighs ap-
proximately 41 kg (90 lb). To avoid possible in-
jury, use a lifting device if the steer wheel and
tire assembly must be lifted.

NOTE: The steer axle does not have to be removed
from the truck to remove the wheel/hub assembly.

1.

Apply a coat of axle grease to bottom surface of
tire. Put axle onto blocks so side of tire with the
grease just touches the floor.

2.

Remove grease cap, cotter pin, castle nut, and
outer bearing cone. Slide wheel/hub assembly
from spindle. Remove inner bearing cone and
seal from spindle. See Figure 2.

3.

If new wheel bearings must be installed, use a
brass drift to remove bearing cups.

4.

Repeat the procedure for the other wheel.

PNEUMATIC TIRES, ASSEMBLE AND
INSTALL

WARNING

Cleaning solvents can be flammable and toxic
and can cause skin irritation.

When using

cleaning solvents, always follow the solvent
manufacturer’s safety procedures.

1.

Clean all parts with solvent. Make sure the bear-
ings are clean.

CAUTION

Do not damage the seals during installation.

2.

If new wheel bearings are installed, use a press
to install new bearing cups in wheel or hub. See
Figure 2. Install grease seal on spindle. Lu-
bricate bearing cones and seal lips with grease.
Make sure bearings are filled with grease. In-
stall bearing cone onto spindle.

3.

Carefully slide hub onto spindle. Install outer
bearing cone.

4.

Install castle nut. Tighten castle nut to 200 N•m
(150 lbf ft) while hub is rotated.

5.

Loosen castle nut to less than 27 N•m (20 lbf ft).
Tighten castle nut to at least 34 N•m (25 lbf ft).

6.

Install cotter pin. If the hole for the cotter pin
is blocked, tighten castle nut until the cotter pin
can be installed.

WARNING

Add air pressure to the tires only in a safety
cage. Inspect the safety cage for damage before
use. When air pressure is added, use a chuck
that fastens onto the valve stem of the inner
tube. Make sure there is enough hose to permit
the operator to stand away from the safety cage
when air pressure is added to the tire. Do not
sit or stand by the safety cage.

7.

Inflate the tire to 698 kPa (101 psi). Mount wheel
and torque wheel nuts to 114 to 136 N•m (84 to
100 lbf ft).

8.

Repeat the procedure for the other wheel.

CUSHION TIRES, ASSEMBLE AND
INSTALL

WARNING

Cleaning solvents can be flammable and toxic
and can cause skin irritation.

When using

cleaning solvents, always follow the solvent
manufacturer’s safety procedures.

1.

Clean all parts with solvent. Make sure the bear-
ings are clean.

WARNING

The steer wheel and tire assembly weighs ap-
proximately 41 kg (90 lb). To avoid possible in-
jury, use a lifting device if the steer wheel and
tire assembly must be lifted.

CAUTION

Do not damage the seals during installation.

2.

If new wheel bearings are installed, use a press
to install new bearing cups in hub. See Figure 2.
Install grease seal on spindle. Lubricate bearing
cones and seal lips with grease. Make sure bear-
ings are filled with grease. Install bearing cone
onto spindle.

4

1600 SRM 532

Spindles, Bearings, and Tie Rods Repair

3.

Apply a coat of axle grease to bottom surface of
tire.

Carefully slide wheel/hub assembly onto

spindle. Install outer bearing cone.

4.

Install castle nut. Tighten castle nut to 200 N•m
(150 lbf ft) while tire and wheel assembly is ro-
tated.

5.

Loosen castle nut to less than 27 N•m (20 lbf ft).
Tighten castle nut to at least 34 N•m (25 lbf ft).

6.

Install cotter pin. If the hole for the cotter pin is
blocked, tighten castle nut until cotter pin can be
installed.

7.

Repeat the procedure for the other wheel.

Spindles, Bearings, and Tie Rods Repair

PNEUMATIC TIRES, REMOVE

WARNING

Completely remove the air from the tires be-
fore removing them from the lift truck.

Air

pressure in the tires can cause the tire and rim
parts to explode, which can cause serious in-
jury or death.

Never loosen the nuts that hold together the
inner and outer wheel halves when there is air
pressure in the tire.

1.

Put the lift truck onto blocks so the tires are
raised from the floor. See How to Put Lift Truck
on Blocks in the Periodic Maintenance section
for your lift truck. Completely remove air from
tires.

2.

Remove wheels.

See the section Wheels and

Hubs Repair for the procedure.

3.

Remove hub from steering axle spindle.

4.

Remove pin to disconnect link from spindle.

5.

Remove kingpin lock nuts. Use a driver to re-
move kingpin.

6.

Use a driver to remove bearings and seals from
axle.

CUSHION TIRES, REMOVE

1.

Put the lift truck onto blocks so the tires are
raised from the floor. See How to Put Lift Truck
on Blocks in the Periodic Maintenance section
for your lift truck.

2.

Remove steer wheel and tire assembly from
steering axle spindle.

See the section Wheels

and Hubs Repair for the procedure.

3.

Remove pin to disconnect link from spindle.

4.

Remove kingpin lock nuts. Use a driver to re-
move kingpin.

5.

Use a driver to remove bearings and seals from
axle.

PNEUMATIC TIRES, INSTALL

1.

If new spindle bearings are installed, use a press
to install new bearing cups into spindle. See Fig-
ure 2. Lubricate bearing cones and seal lips with
grease. Lubricate O-rings with O-ring lubricant.

2.

Install bearings, seals, sleeves, and O-rings into
spindle. If groove pin was removed from kingpin,
install new groove pin. Apply grease to kingpin.
Position spindle in axle and install king pin.

3.

Install first lock nut onto kingpin and tighten
lock nut to 121 N•m (89 lbf ft).

Completely

loosen lock nut, then tighten lock nut to 30 N•m
(22 lbf ft).

4.

Install second lock nut onto kingpin. While hold-
ing first lock nut so it does not turn, tighten sec-
ond lock nut to 81.5 to 98 N•m (60 to 72 lbf ft).

5.

Connect links.

Align setscrews with setscrew

holes in pins. Tighten setscrews and lock nuts.

WARNING

Add air pressure to the tires only in a safety
cage. Inspect the safety cage for damage before
use. When air pressure is added, use a chuck
that fastens onto the valve stem of the inner
tube. Make sure there is enough hose to permit
the operator to stand away from the safety cage
when air pressure is added to the tire. Do not
sit or stand by the safety cage.

6.

Inflate tires to 689 kPa (100 psi). Mount wheels
and tighten wheel nuts to 114 to 136 N•m (84 to
100 lbf ft).

5

Steering Cylinder Repair

1600 SRM 532

CUSHION TIRES, INSTALL

1.

If new spindle bearings are installed, use a press
to install new bearing cups into spindle. See Fig-
ure 2. Lubricate bearing cones and seal lips with
grease. Lubricate O-rings with O-ring lubricant.

2.

Install bearings, seals, sleeves, and O-rings into
spindle. If the groove pin was removed from the
kingpin, install new groove pin. Apply grease
to kingpin. Position spindle in axle and install
kingpin.

3.

Install first lock nut onto kingpin and tighten
lock nut to 121 N•m (89 lbf ft).

Completely

loosen lock nut, then tighten lock nut to 30 N•m
(22 lbf ft).

4.

Install second lock nut onto kingpin. While hold-
ing first lock nut so that it does not turn, tighten
second lock nut to 81.5 to 98 N•m (60 to 72 lbf ft).

5.

Connect links.

Align setscrews with setscrew

holes in pins. Tighten setscrews and lock nuts.

6.

Install steer wheel and tire assembly. See the
section Wheels and Hubs Repair for the proce-
dure.

Steering Cylinder Repair

REMOVE AND DISASSEMBLE

1.

Disconnect hydraulic lines at steering cylinder.
See Figure 3. Mark the locations of the hydraulic
lines to make sure of correct assembly. Install
caps in fittings on cylinders and put caps on hy-
draulic lines.

2.

Remove setscrews from links. Remove pins.

3.

Remove capscrews that fasten cylinder to axle
frame. Remove steering cylinder.

4.

Hold end of steering cylinder over a drain pan.
Remove cap for hydraulic fitting from each end
cap. Push rod toward end of shell that is over
drain pan. Oil will drain from cylinder. Repeat
the procedure for the other end.

5.

Carefully remove one guide assembly from shell.
Carefully pull cylinder rod and piston from shell.
Keep cylinder rod aligned in center of shell dur-
ing removal so the parts are not damaged. Re-
move guide assembly from rod. Remove other
guide assembly 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 solvent
manufacturer’s safety procedures.

1.

Clean all parts in solvent.

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.

ASSEMBLE AND INSTALL

1.

Put dust seals, U-packings, O-rings, and piston
seals into warm hydraulic oil.

CAUTION

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

2.

Lubricate dust seals and U-packings with O-ring
lubricant and install them into guide assemblies.
Lubricate piston seals and install them onto pis-
ton. Install one guide assembly onto cylinder rod.
See Figure 3.

3.

Carefully slide cylinder rod and piston into shell.
Keep cylinder rod aligned in center of shell dur-
ing installation so the parts are not damaged.
Carefully slide guide assembly into shell. Care-
fully install other guide assembly onto rod and
shell. Put caps on hydraulic fittings of end caps.

4.

Install cylinder onto axle frame using capscrews.
Install spacers between cylinder mounts and axle
frame. Tighten capscrews to 294 to 353 N•m
(217 to 260 lbf ft).

5.

Install links between cylinder and spindles. In-
stall pins. Align setscrews with setscrew holes in
pins. Tighten setscrews and lock nuts.

6

1600 SRM 532

Torque Specifications

6.

Remove caps and connect hydraulic lines to
steering cylinder.

Operate steering system to

remove air from cylinder and hydraulic system.

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

1.

ROD ASSEMBLY

2.

GUIDE ASSEMBLY

3.

DUST SEAL

4.

U-PACKING

5.

O-RING

6.

O-RING

7.

PISTON SEAL

8.

SNAP RING

9.

ROD BUSHING

10. PIN BUSHING

Figure 3. Steering Cylinder

Torque Specifications

Steering Axle Mounting Bolts

41 to 49 N•m (30 to 36 lbf ft)

Castle Nut (Initial)

200 N•m (148 lbf ft)

Castle Nut (Final)

34 N•m (25 lbf ft)

Spindle Nut (Initial)

121 N•m (89 lbf ft)

Spindle Nut (Final)

30 N•m (22 lbf ft)

Spindle Lock Nut (Initial)

81 to 98 N•m (60 to 72 lbf ft)

Steering Cylinder Mounting Bolts

294 to 353 N•m (217 to 260 lbf ft)

7

Troubleshooting

1600 SRM 532

Troubleshooting

PROBLEM

POSSIBLE CAUSE

PROCEDURE OR ACTION

Steering wheels do not move
when the steering wheel is
turned.

Oil level is low or there is no oil in
the tank.

Fill tank. Check for leaks.

Steering control unit is damaged.

Repair or install new control unit.

No oil is flowing from the steering
control unit to the steering cylinder.

Repair or install new components.
Check for leaks.

Steering is slow or difficult.

Relief valve for steering system
needs adjustment.

Adjust or install new relief valve.

There is low oil pressure from hy-
draulic pump.

Check for restrictions.

See Trou-

bleshooting Chart in the Hydraulic
System SRM for your lift truck.

A seal in the steering cylinder has a
leak.

Install new seal.

Steering control unit is worn or dam-
aged.

Repair or install new control unit.

Steering wheel turns the
tires in the wrong direction.

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

contin-

ues after the steering wheel
stops.

Steering control unit was assembled
incorrectly or is damaged.

Repair or install new control unit.

There is air in the steering
system.

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.

Hydraulic pump has an air leak at
the inlet.

Repair system. Remove air from sys-
tem.

8

TECHNICAL PUBLICATIONS

1600 SRM 532

10/04 (2/01)(11/94)(8/93) Printed in United Kingdom