STEERING AXLE

E/J1.25-1.75XL (E/J25-35XL) [C114];

J2.00-3.00XL (J40-60XL) [B168];

H2.00-3.20XM (H40-65XM) [D177];

J2.00-3.20XM (J40-60XM, J40-60XM

) [A216];

J2.00-3.20XM (J40-65Z) [A416];

H2.00-3.20XM (H45-65XM) [H177]

PART NO. 897097

1600 SRM 316

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

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

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

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

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

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

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

Clean ..............................................................................................................................................................

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

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

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

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

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

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

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

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

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

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

This section is for the following models:

E/J1.25-1.75XL (E/J25-35XL) [C114];

J2.00-3.00XL (J40-60XL) [B168];

H2.00-3.20XM (H40-65XM) [D177];

J2.00-3.20XM (J40-60XM, J40-60XM

) [A216];

J2.00-3.20XM (J40-65Z) [A416];

H2.00-3.20XM (H45-65XM) [H177]

"THE

QUALITY

KEEPERS"

HYSTER

APPROVED

PARTS

1600 SRM 316

Description

General

This section has the description and repair procedures for the steering axle. See the following sections for addi-
tional information on the parts of the steering system: Steering Housing and Control Unit and Hydraulic
System.

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 and gives the
lift truck a smoother travel over rough surfaces.

The end caps of the steering cylinder are also the
mounts for the cylinder and are held to the shell by
the mount capscrews.

O-rings, seals, and wipers

in the end caps are used to keep the oil inside the

steering cylinder. 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 rod. Oil pressure
on one side of the piston moves the piston in the
bore. When the piston moves in the bore, it pushes
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 components are
not damaged. Tie rods connect the spindle arms to
the cylinder.

SPINDLE AND HUB ASSEMBLY

AXLE FRAME

BRACKET

RUBBER MOUNT

STEERING CYLINDER

NUT AND BOLT

Figure 1. Steering Axle

Steering Axle Assembly Repair

1600 SRM 316

Each spindle turns on two tapered roller bearings.
The spindle and bearings are held in the axle frame
by a kingpin. The preload on the bearings is con-
trolled by a threaded nut on the bottom of the king-
pin.

The wheel or hub rotates on two tapered roller bear-
ings and is held on the spindle by a castle nut. The
preload on the bearings in the hub is adjusted by the
castle nut. A grease seal in the inner hub and a hub
cap protect the bearings from dirt and water. A wear
sleeve in the inner hub protects the hub from wear
by the seal.

Steering Axle Assembly Repair

REMOVE

WARNING

PUTTING THE LIFT TRUCK ON BLOCKS

The lift truck must be put on blocks for some
types of maintenance and repair. The removal
of the following assemblies will cause large
changes in the center of gravity: drive axle,
battery, or counterweight. When the lift truck
is put on blocks, put additional blocks in the
following positions:
1.

If the mast and drive axle are removed, put
blocks under the counterweight so the lift
truck cannot fall backward.

If the battery (electric lift trucks) or coun-
terweight is removed, put blocks under the
mast so the lift truck cannot fall forward.

Put the lift truck on blocks on a solid, even, and
level surface. Make sure the blocks of stands
have enough capacity to hold the lift truck. Use
additional blocks next to the tires as necessary
to prevent movement of the lift truck. Make
sure the lifting devices used during repairs can
lift the weight of the parts and assemblies.

NOTE: The steering axle assembly without the
wheels weighs approximately 115 kg (250 lb).

The steering axle can be removed without remov-
ing the counterweight. If necessary, remove counter-
weight as described in the Frame section.

Make sure wheels are set for straight travel. Put
lift truck on blocks so steering axle can be re-
moved.

The top of the axle frame must have

clearance under the counterweight so the steer-
ing axle can be removed. See Figure 1.

Disconnect hydraulic lines at steering cylinder.
Install caps on cylinder and put plugs in hy-
draulic lines.

The caps will prevent spindles

from turning when axle is removed from under
lift truck.

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 onto wheels. Care-
fully roll axle assembly from under lift truck.

INSTALL

Install rubber mounts on axle as follows (see Fig-
ure 1):

a. E1.25-1.75XL

(E25-35XL),

J2.00-3.00XL

(J40-60XL),

H2.00-3.20XM

(H40-65XM),

J2.00-3.20XM

(J40-60XM,

J40-60XM

)

(A216), and J2.00-3.20XM (J40-65Z) (A416):
Make sure PART NO. on the mounts is right
side up and facing away from axle frame.

b. J1.25-1.75XL (Europe only):

Make sure

PART NO. on mounts is upside down and
facing away from axle frame.

Apply a lubricant that is approved for use with
rubber to rubber mount. The lubricant is used
where the rubber mount fits into the frame
brackets.

Use a floor jack or another lift truck to put steer-
ing axle into position in frame. Make sure rubber
mounts fit inside frame brackets for mounts.

Install bottom brackets.

Tighten four bracket

capscrews and nuts to 88 N•m (65 lbf ft).

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

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

1600 SRM 316

Wheels and Hubs Repair

REMOVE AND DISASSEMBLE

WARNING

PUTTING THE LIFT TRUCK ON BLOCKS

If the mast and drive axle are removed, put
blocks under the counterweight so the lift
truck cannot fall backward.

If the battery (electric lift trucks) or coun-
terweight is removed, put blocks under the
mast so that the lift truck cannot fall for-
ward.

WARNING

Completely deflate the tires before removing
them from the lift truck. Air pressure in the
tires can cause the tire and rim parts to ex-
plode, causing serious injury or death.

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

Put axle on blocks so tires are raised from floor.
Remove grease cap. Remove cotter pin and castle
nut. Remove outer bearing cone. Slide wheel
from spindle. Remove inner bearing cone and
seal from spindle. See Figure 2.

If the wheel bearings must be replaced, use a
brass drift to remove bearing cups and wear
sleeve.

Repeat procedure for other wheel.

CLEAN

WARNING

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

When using

cleaning solvents, always follow the solvent
manufacturer’s recommended safety proce-
dures.

Clean all parts with solvent. Make sure bearings are
clean.

ASSEMBLE AND INSTALL

CAUTION

Do not damage the seals during installation.

If wheel bearings must be replaced, use a press
to install new bearing cups in wheel or hub. See
Figure 2. Install new wear sleeve in wheel or
hub. Install grease seal on spindle. Lubricate
bearing cones with grease. Make sure bearings
are filled with grease. Install bearing cone on
spindle.

Carefully slide wheel or hub onto spindle. Install
outer bearing cone.

Install castle nut. Tighten castle nut to 200 N•m
(150 lbf ft) while wheel is rotated. Loosen nut
to less than 27 N•m (20 lbf ft). Tighten nut to
34 N•m (25 lbf ft). If cotter pin cannot be in-
stalled with nut tightened to 34 N•m (25 lbf ft),
tighten castle nut until cotter pin can be in-
stalled. Install cotter pin.

Repeat procedure for other wheel.

Wheels and Hubs Repair

1600 SRM 316

NOTE: H2.00-3.20XM (H40-65XM) SHOWN, OTHERS SIMILAR.

AXLE FRAME

WASHER

BOLT

BELLEVILLE WASHER

RUBBER MOUNT

BRACKET

NUT

STEERING CYLINDER

10. SNAP RING
11. BUSHING
12. TIE ROD
13. GREASE FITTING
14. CASTLE NUT
15. SLEEVE

16. SEAL
17. BEARING CONE
18. BEARING CUP
19. SPINDLE
20. SPACER
21. O-RING
22. KINGPIN
23. GROOVE PIN
24. WEAR SLEEVE
25. HUB*
26. STUD*
27. WHEEL NUT*
28. COTTER PIN
29. GREASE CAP

*PNEUMATIC TIRES ONLY

Figure 2. Steering Axle

1600 SRM 316

Spindles, Bearings, and Tie Rods Repair

REMOVE

WARNING

PUTTING THE LIFT TRUCK ON BLOCKS

If the mast and drive axle are removed, put
blocks under the counterweight so the lift
truck cannot fall backward.

If the battery (electric lift trucks) or coun-
terweight is removed, put blocks under the
mast so the lift truck cannot fall forward.

Put the lift truck on blocks on a solid, even, and
level surface. Verify the blocks of stands have
enough capacity to hold the lift truck. Use ad-
ditional blocks next to the tires as necessary to
prevent movement of the lift truck. Verify the
lifting devices used during repairs can lift the
weight of the parts and assemblies.

NOTE: Dirt and corrosion can make the spacer diffi-
cult to remove from the steering axle frame. A ma-
chined space is made in the top of the spacer so that
the spacer can be removed with a bearing puller.

Remove wheel or hub from steering axle spindle. See
Figure 3. Remove pin to disconnect tie rod from spin-
dle. Remove cotter pin and castle nut from bottom of
kingpin. Use a driver to remove kingpin. Remove
sleeve and then spindle from axle. Use a driver to
remove bearings and seals from spindle.

INSTALL

Use new bearings and seals. See Figure 2 and
Figure 3. Apply grease to bearings and kingpin
as they are installed in axle. Install bearings in
spindle. Install seals in correct position. Align
spindle in axle and install kingpin. Make sure
new O-ring is installed at top of kingpin. Install
sleeve on bottom of kingpin. Install castle nut
and tighten it to 90 N•m (66 lbf ft). Loosen cas-
tle nut to less than 34 N•m (25 lbf ft). Tighten
nut to 34 N•m (25 lbf ft).

If cotter pin can-

not be installed with nut tightened to 34 N•m

(25 lbf ft), tighten castle nut until cotter pin can
be installed. Install cotter pin.

O-RING

KINGPIN

GROOVE PIN

SPACER

SEAL

BEARING CONE

BEARING CUP

SPINDLE

SEAL

10. WEAR SLEEVE
11. CASTLE NUT
12. COTTER PIN
13. GREASE CAP
14. SLEEVE

Figure 3. Spindle Assembly

Connect tie rods. Verify belleville washers are
installed on both sides of bushings.

Install wheels or hubs.

See the section

Wheels and Hubs Repair for proper installa-
tion procedure. On H2.00-3.20XM (H40-65XM),
J2.00-3.20XM (J40-60XM, J40-60XM

) (A216),

J2.00-3.20XM (J40-65Z) (A416) tighten wheel
nuts to 237 to 305 N•m (175 to 225 lbf ft).
On J1.25-1.75XL (J25-35XL) and J2.00-3.00XL
(J40-60XL), tighten wheel nuts to 155 N•m
(115 lbf ft).

Steering Cylinder Repair

1600 SRM 316

Steering Cylinder Repair

REMOVE AND DISASSEMBLE

WARNING

PUTTING THE LIFT TRUCK ON BLOCKS

If the mast and drive axle are removed, put
blocks under the counterweight so the lift
truck cannot fall backward.

If the battery (electric lift trucks) or coun-
terweight is removed, put blocks under the
mast so the lift truck cannot fall forward.

Put the lift truck on blocks on a solid, even, and
level surface. Make sure the blocks of stands

have enough capacity to hold the lift truck. Use
additional blocks next to the tires as necessary
to prevent movement of the lift truck. Make
sure the lifting devices used during repairs can
lift the weight of the parts and assemblies.

NOTE: The 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 during
removal.

Disconnect hydraulic lines at steering cylinder.
See Figure 4. Install caps in fittings on cylinders
and put caps on hydraulic lines.

Remove snap rings from pins in tie rods. Remove
pins.

Remove capscrews or nuts and bolts that fasten
cylinder to axle frame. Hold end caps on shell
and remove steering cylinder.

ROD

WIPER

END CAP

O-RING

BACKUP RING

SHELL

PISTON SEAL

ROD SEAL

QUADRANT RING

Figure 4. Steering Cylinder

1600 SRM 316

Torque Specifications

Hold end of steering cylinder over drain pan. Re-
move 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 proce-
dure for other end.

Carefully slide one end cap from shell. Carefully
pull cylinder rod and piston from shell. Keep
cylinder rod aligned in center of shell during re-
moval so parts are not damaged. Remove end cap
from rod. Remove other end cap from shell. Re-
move 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 recommended safety proce-
dures.

Clean all parts in solvent.

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

Put seals and wipers in warm hydraulic oil. In-
stall quadrant ring and piston seal as shown in
Figure 4.

CAUTION

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

Lubricate O-rings, seals, and wipers with O-ring
lubricant and install them in end caps. Install
one end cap on cylinder rod.

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

NOTE: On J2.00-3.00XL (J40-60XL) units, the nuts
are against the end caps.

Hold end caps and install cylinder on axle
frame using capscrews or nuts and capscrews.
On H2.00-3.20XM (H40-65XM), J2.00-3.20XM
(J40-60XM, J40-60XM

) (A216), J2.00-3.20XM

(J40-60Z) (A416), tighten capscrews to 225 N•m
(166 lbf ft).

On E/J1.25-1.75XL (E/J25-35XL)

and J2.00-3.00XL (J40-60XL), tighten capscrews
and nuts to 165 N•m (122 lbf ft).

Install tie rods between cylinder and spindles.
Make sure belleville washers are on each side
of the bushings in the tie rods. Install pins and
snap rings.

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.

Torque Specifications

Steer Axle Mount Bracket Hardware

88 N•m (65 lbf ft)

Wheel/Hub Nut

Initial Torque 200 N•m (150 lbf ft)
Final Torque 34 N•m (25 lbf ft)

Kingpin Nut

Initial Torque 90 N•m (66 lbf ft)
Final Torque 34 N•m (25 lbf ft)

Wheel Nuts

H2.00-3.20XM (H40-65XM), J2.00-3.20XM
(J40-60XM J40-60XM2) (A216), J2.00-3.20XM
(J40-65Z) (A416) 237 to 305 N•m (175 to 225 lbf ft)
J1.25-1.75XL (J25-35XL) 155 N•m (116 lbf ft)
J2.00-3.00XL (J40-60XL) 155 N•m (116 lbf ft)

Steer Cylinder Mount Hardware

H2.00-3.20XM (H40-65XM), J2.00-3.20XM
(J40-60XM J40-60XM2) (A216), J2.00-3.20XM
(J40-65Z) (A416) 225 N•m (166 lbf ft)
E/J1.25-1.75XL (E/J25-35XL) 165 N•m (122 lbf ft)
J2.00-3.00XL (J40-60XL) 165 N•m (122 lbf ft)

Troubleshooting

1600 SRM 316

Troubleshooting

PROBLEM

POSSIBLE CAUSE

PROCEDURE OR ACTION

There is no action when the
steering wheel is turned.

There is no oil or not enough oil in
the hydraulic tank.

Fill tank to correct level.

The lines are loose at the control unit
or manifold block.

Tighten fittings.

The sleeve and spool in the control
unit will not move.

Repair steering control unit.

Steering cylinder leaks.

Repair steering cylinder.

Spacer for center pin is not installed.

Assemble steering control unit cor-
rectly.

The lift truck steers slowly.
The steering wheel is hard
to turn.

The oil level is low. There is no oil in
the tank.

Fill tank to correct level.

The lines to the control unit are dam-
aged.

Repair oil lines.

The sleeve and spool in the control
unit are worn.

Repair steering control unit.

The parts of the metering section are
worn.

Repair steering control unit.

The check valve in the control unit
does not open.

Clean or repair steering control unit.

The check valve or relief valve in the
manifold block is damaged or is not
adjusted correctly.

Clean or replace manifold block.

Priority valve is not operating cor-
rectly.

Clean or repair priority valve.

Steering relief pressure is too low.

Adjust relief pressure.

Engine idle speed is too low.

Adjust idle speed to specifications.

The steering wheel turns the
tires in the wrong direction.

The lines at the control unit are not
correctly connected.

Connect lines correctly.

1600 SRM 316

Troubleshooting

PROBLEM

POSSIBLE CAUSE

PROCEDURE OR ACTION

The tires continue to turn af-
ter the steering wheel stops.

The neutral position springs are bro-
ken.

Repair steering control unit.

The sleeve or spool has damage.

Repair steering control unit.

Steering wheel kicks back in
both directions.

Center shaft is not correctly aligned
with metering section.

Correctly assemble steering control
unit.

NOTES

____________________________________________________________

TECHNICAL PUBLICATIONS

1600 SRM 316

4/05 (3/03)(3/95)(4/93)(11/85)(5/85) Printed in United Kingdom

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