STEERING AXLE
S30FT, S35FT, S40FTS [E010];
H1.6FT, H1.8FT, H2.0FTS
(H30FT, H35FT, H40FTS) [F001];
S2.0-3.5FT (S40-70FT, S55FTS ) [F187];
H2.0-3.5FT (H40-70FT) [L177]
PART NO. 1580512 1600 SRM 1133
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
Steering Axle Assembly Repair......................................................................................................................... 2
Remove ........................................................................................................................................................... 2
Disassemble ................................................................................................................................................... 2
Clean .............................................................................................................................................................. 4
Inspect ............................................................................................................................................................ 5
Assemble ........................................................................................................................................................ 6
Install ............................................................................................................................................................. 7
Spindles, Bearings, and Tie Rods Repair ......................................................................................................... 8
Spindles and Bearings................................................................................................................................... 8
S2.0-3.5FT (S40-70FT, S55FTS) [F187] ................................................................................................... 8
Remove and Disassemble ..................................................................................................................... 8
Assemble and Install ............................................................................................................................ 9
S30FT, S35FT, S40FTS (E010), H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, H40FTS) [F001],
and H2.0-3.5FT (H40-70FT) [L177] ......................................................................................................... 10
Remove and Disassemble ..................................................................................................................... 10
Assemble and Install ............................................................................................................................ 10
Tie Rods.......................................................................................................................................................... 11
S2.0-3.5FT (S40-70FT, S55FTS) [F187] ................................................................................................... 11
Remove .................................................................................................................................................. 11
Install..................................................................................................................................................... 12
S30FT, S35FT, S40FTS (E010), H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, H40FTS) [F001],
and H2.0-3.5FT (H40-70FT) [L177] ......................................................................................................... 13
Remove .................................................................................................................................................. 13
Install..................................................................................................................................................... 13
Steering Cylinder Repair................................................................................................................................... 15
Remove and Disassemble.............................................................................................................................. 15
Clean and Inspect .......................................................................................................................................... 15
Assemble and Install ..................................................................................................................................... 15
Torque Specifications ......................................................................................................................................... 16
This section is for the following models:
S30FT, S35FT, S40FTS [E010];
H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, H40FTS) [F001];
S2.0-3.5FT (S40-70FT, S55FTS ) [F187];
H2.0-3.5FT (H40-70FT) [L177]
©2005 HYSTER COMPANY i
"THE
QUALITY
KEEPERS"
HYSTER
APPROVED
PARTS
1600 SRM 1133 General
General
This section has the description and repair proce- The steering axle assembly includes an axle frame,
dures for the steering axle. See the following sections steering cylinder, and two spindle and hub assem-
for additional information on the parts of the steering blies. See Figure 1. The steering axle is articulated
system: Steering Control Unit, Hydraulic Sys- and is connected to the frame by center pivot mounts.
tem and Gear Pumps, Hydraulic System, and
Steering System.
A. CUSHION TRUCKS ONLY B. PNEUMATIC TRUCKS ONLY
1. AXLE FRAME 4. STEERING CYLINDER 7. MOUNT
2. MOUNT 5. TIE ROD 8. HUB ASSEMBLIES
3. BRACKET 6. SPINDLE
Figure 1. Steering Axle
1
Steering Axle Assembly Repair 1600 SRM 1133
The center pivot mounts permit the steering axle to When the piston reaches the end of the stroke, a re-
move in the frame mount when the lift truck travels lief valve in the steering circuit controls the oil pres-
over rough surfaces. sure. The tie rods that connect the spindle arms to
the cylinder are not adjustable.
The end caps of the steering cylinder are also the
mounts for the cylinder and are held to the shell by Each spindle turns on two tapered roller bearings in
the mount capscrews. There are O-rings, seals, and mounts in the axle frame. The preload on the bear-
wipers in the end caps to seal the caps to the shell ings is controlled by shims at the lower bearing cap.
and rod. The ends of the piston rod extend from both
The wheels rotate on two tapered roller bearings and
ends of the cylinder. Asingle pistonandthe seal are
are held on the spindles by a castle nut. The bearing
at the center of the rod. Oil pressure on one side of
preload of the wheels is adjusted by the castle nut.
the piston moves the piston in the bore. The piston
The grease seals protect the bearings from dirt and
pushes an equal amount of oil from the opposite side
water. Wear sleeves protect the hub from wear by the
of the cylinder.
seals.
Steering Axle Assembly Repair
REMOVE 1. Verify wheels are set for straight travel. Put lift
truck on stands so the steering axle will have
enough clearance to be removed. The top of the
WARNING
axle frame must have clearance under the bot-
PUTTING THE LIFT TRUCK ON BLOCKS
tom of the frame at the rear of the lift truck.
The lift truck must be put on blocks for some
2. Disconnect hydraulic lines at steering cylinder.
types of maintenance and repair. The removal
Install plug fittings in cylinder and put caps on
of the mast, drive axle, battery, or counter-
hydraulic lines. Plug fittings will prevent spin-
weight assemblies will cause large changes
dles from turning as axle is removed from under
in the center of gravity. When the lift truck
the lift truck.
is put on blocks, put additional blocks in the
following positions:
3. Slide floor jack or forks of another lift truck under
" If the mast and drive axle are removed, put
steering axle. Raise lifting device until it holds
blocks under the counterweight so the lift
the weight of the axle assembly. Remove four
truck cannot fall backward.
capscrews and nuts that fasten two brackets un-
" If the counterweight is removed, put blocks
der rubber mounts. Remove brackets and slowly
under the mast so that the lift truck cannot
lower axle assembly onto wheels. Carefully roll
fall forward.
axle assembly away from lift truck. See Fig-
ure 2 for S2.0-3.5FT (S40-70FT, S55FTS) [F187]
Put the lift truck on blocks on a solid, even, and
lift trucks, Figure 3 for H2.0-3.5FT (H40-70FT)
level surface. Verify the blocks or stands have
[L177] lift trucks, and Figure 4 for S30FT, S35FT,
enough capacity to hold the lift truck. Use ad-
S40FTS (E010) and H1.6FT, H1.8FT, H2.0FTS
ditional blocks next to the tires as necessary to
(H30FT, H35FT, H40FTS) [F001] lift trucks.
prevent movement of the lift truck. Verify the
lifting devices used during repairs can lift the
DISASSEMBLE
weight of the parts and assemblies.
1. Put axle on blocks so the wheels just touch the
See the Operating Manual or Periodic Mainte-
floor. Remove grease cap. Remove cotter pin,
nance section for your lift truck model, for the
washer, and castle nut. Remove bearing cone.
procedures to put the lift truck on blocks.
NOTE: Identify the outer and inner bearing cones so
The steering axle can be removed without removing
they can be reassembled in their original locations.
the counterweight.
2
1600 SRM 1133 Steering Axle Assembly Repair
2. Slide wheel from spindle. Remove inner bear- 3. If the bearings must be replaced, use a brass drift
ing cone and seal from spindle. See Figure 2 to remove the bearing cups and wear sleeve.
for S2.0-3.5FT (S40-70FT, S55FTS) [F187] lift
NOTE: If the bearing is replaced, then the associated
trucks, Figure 3 for H2.0-3.5FT (H40-70FT)
bearing cup must be replaced also.
[L177] lift trucks, and Figure 4 for S30FT,
S35FT, S40FTS (E010) and H1.6FT, H1.8FT,
4. Repeat procedure for the other wheel.
H2.0FTS (H30FT, H35FT, H40FTS) [F001] lift
trucks.
1. MOUNT 10. COTTER PIN
2. STEER AXLE ASSEMBLY 11. OIL SEAL
3. MOUNT 12. WEAR SLEEVE
4. PLATE 13. BEARING CONE
5. WASHER 14. BEARING CUP
6. LOCK NUT 15. WASHER
7. CAPSCREW 16. CASTLE NUT
8. STEERING CYLINDER 17. HUB CAP
9. LUBRICATION FITTING
Figure 2. Spindle to Tie Rod Assembly, S2.0-3.5FT (S40-70FT, S55FTS) [F187]
3
Steering Axle Assembly Repair 1600 SRM 1133
1. MOUNT 11. OIL SEAL
2. STEERING AXLE ASSEMBLY 12. WEAR SLEEVE
3. MOUNT 13. BEARING CONE
4. BRACKET 14. BEARING CUP
5. NUT 15. HUB
6. WASHER 16. BEARING CUP
7. WASHER 17. BEARING CONE
8. CAPSCREW 18. CASTLE NUT
9. STEERING CYLINDER 19. HUB CAP
10. LUBRICATION FITTING 20. COTTER PIN
Figure 3. Spindle to Tie Rod Assembly, H2.0-3.5FT (H40-70FT) [L177]
CLEAN manufacturer s recommended safety procee-
dures.
WARNING
Clean all parts with solvent. Verify bearings are
Cleaning solvents can be flammable and toxic
clean.
and can cause skin irritation. When using
cleaning solvents, always follow the solvents
4
1600 SRM 1133 Steering Axle Assembly Repair
A. PNEUMATIC TRUCKS ONLY
1. MOUNT 9. BEARING
2. STEER AXLE ASSEMBLY 10. HUB
3. MOUNT 11. BEARING
4. PLATE 12. WASHER
5. CAPSCREW 13. HUB CAP
6. STEERING CYLINDER 14. CASTLE NUT
7. LUBRICATION FITTING 15. COTTER PIN
8. OIL SEAL
Figure 4. Spindle to Tie Rod Assembly, S30FT, S35FT, S40FTS (E010) and H1.6FT, H1.8FT, H2.0FTS
(H30FT, H35FT, H40FTS) [F001]
INSPECT Inspect the spindle and verify that it does not have
any rough or sharp areas that would prevent the
NOTE: If the spindle, bearings, tie rods need to be
bearings from being correctly installed. If necessary,
repaired, go to Spindles, Bearings, and Tie Rods Re-
smooth any rough or sharp areas with a file or emory
pair.
cloth before installing the bearings.
5
Steering Axle Assembly Repair 1600 SRM 1133
ASSEMBLE
NOTE: Refer to the section Periodic Maintenance
8000 SRM 1150 for S2.0-3.5FT (S40-70FT, S55FTS)
[F187] and H2.0-3.5FT (H40-70FT) [L177] lift trucks
and Periodic Maintenance 8000 SRM 1207 for
S30FT, S35FT, S40FTS (E010) and H1.6FT, H1.8FT,
H2.0FTS (H30FT, H35FT, H40FTS) [F001] lift
trucks, for specified lubricant.
1. If necessary, use a bearing press to install new
bearing cups in wheel or hub. See Figure 5
for S2.0-3.5FT (S40-70FT, S55FTS) [F187] lift
trucks, Figure 6 for H2.0-3.5FT (H40-70FT)
[L177] lift trucks, Figure 7 for H1.6FT, H1.8FT,
H2.0FTS (H30FT, H35FT, H40FTS) [F001]
lift trucks, and Figure 8 for H1.6FT, H1.8FT,
H2.0FTS (H30FT, H35FT, H40FTS) [F001] lift
trucks. Install grease seal on spindle. Lubricate
bearing cones with multipurpose grease. Verify
bearings are filled with grease. Install inner
1. SPINDLE 7. BEARING CONE
bearing cone on spindle.
2. HUB CAP 8. BEARING CUP
3. COTTER PIN 9. OIL SEAL
4. CASTLE NUT 10. WEAR SLEEVE
5. BEARING CONE 11. HUB
6. BEARING CUP
Figure 6. Bearing Arrangement, H2.0-3.5FT
(H40-70FT) [L177]
CAUTION
Do not damage the seals during installation.
2. Carefully slide wheel onto spindle. Install outer
bearing cone and install washer.
NOTE: Ensure that the washer is seated properly
against the bearing cone and not against the shaft
shoulder before tightening the castle nut.
3. Install the castle nut and tighten as follows
for your lift truck ( see Figure 2 for S2.0-3.5FT
(S40-70FT, S55FTS) [F187] lift trucks, Figure 3
for H2.0-3.5FT (H40-70FT) [L177] lift trucks,
and Figure 4 for S30FT, S35FT, S40FTS (E010)
and H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT,
H40FTS) [F001] lift trucks).
a. S2.0-3.5FT (S40-70FT, S55FTS) [F187] -
1. WASHER 5. BEARING CONE
Tighten the castle nut to 68 N" m (50 lbf ft).
2. COTTER PIN 6. BEARING CUP
3. HUB CAP 7. WEAR SLEAVE
While rotating the hub in both directions
4. CASTLE NUT 8. OIL SEAL
to properly seat the bearings, loosen the
castle nut 1/4 turn. Tighten nut to 3 N" m
Figure 5. Bearing Arrangement, S2.0-3.5FT
(27 lbf in).
(S40-70FT, S55FTS) [F187]
6
1600 SRM 1133 Steering Axle Assembly Repair
6. Install grease cap.
7. Repeat procedure for other wheel.
1. HUB 5. WASHER
2. OIL SEAL 6. CASTLE NUT
3. BEARING 7. COTTER PIN
4. BEARING 8. HUB CAP
Figure 7. Bearing Arrangement, H1.6FT,
H1.8FT, H2.0FTS (H30FT, H35FT, H40FTS)
[F001]
1. BEARING 5. WASHER
b. H2.0-3.5FT (H40-70FT) [L177] - Tighten the
2. BEARING 6. HUB CAP
castle nut to 200 N" m (147.5 lbf ft). While ro-
3. CASTLE NUT 7. OIL SEAL
tating the hub in both directions to properly
4. COTTER PIN
seat the bearings, loosen the castle nut un-
til wheel hub turns freely with no end play.
Figure 8. Bearing Arrangement, S30FT, S35FT,
Tighten nut to 15 N" m (133 lbf in).
S40FTS (E010)
c. S30FT, S35FT, S40FTS (E010) and H1.6FT,
INSTALL
H1.8FT, H2.0FTS (H30FT, H35FT, H40FTS)
[F001] - Tighten the castle nut to 200 N" m 1. Install rubber mounts and top mount(s) on
(148 lbf ft). While rotating the hub in both di- axle. Verify face of rubber mount with the part
rections to properly seat the bearings, loosen number is away from the axle. Verify part
the castle nut until wheel hub turns freely number will be right side up after axle assem-
with no end play. Tighten nut to 12 N" m bly is installed. See Figure 2 for S2.0-3.5FT
(106 lbf in). (S40-70FT, S55FTS) [F187] lift trucks, Figure 3
for H2.0-3.5FT (H40-70FT) [L177] lift trucks,
4. Pull on the wheel axially to ensure that there is
and Figure 4 for S30FT, S35FT, S40FTS (E010)
no end play. If there is end play, repeat Step 1
and H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT,
through Step 3.
H40FTS) [F001] lift trucks.
5. Adjust castle nut left or right to closest hole
2. Apply lubricant that is approved for use with
alignment position. Lock nut in place with new
rubber to rubber mount. The lubricant is used
cotter pin. If cotter pin cannot be installed, or
to ease assembly of the mount into frame and
there is not at least one full thread visible past
brackets.
the nut, then reposition the washer and repeat
Step 3 through Step 5.
7
Spindles, Bearings, and Tie Rods Repair 1600 SRM 1133
3. Use floor jack or another lift truck to put steering b. H2.0-3.5FT (H40-70FT) [L177] - Tighten four
axle into position in frame. Verify rubber mounts bracket bolts and nuts to 88 N" m (65 lbf ft).
fit inside frame brackets for mounts.
c. S30FT, S35FT, S40FTS (E010) and H1.6FT,
4. Install bottom brackets (see Figure 2 for H1.8FT, H2.0FTS (H30FT, H35FT, H40FTS)
S2.0-3.5FT (S40-70FT, S55FTS) [F187] lift [F001] - Tighten four flange bolts to 41 to
trucks, Figure 3 for H2.0-3.5FT (H40-70FT) 49 N" m (30 to 36 lbf ft).
[L177] lift trucks, and Figure 4 for S30FT,
5. Remove plugs and caps and connect hydraulic
S35FT, S40FTS (E010) and H1.6FT, H1.8FT,
lines to steering cylinder.
H2.0FTS (H30FT, H35FT, H40FTS) [F001] lift
trucks). Then proceed as follows for your lift
6. Operate steering system to remove air from sys-
truck.
tem. Turn steering wheel several times from one
stop to the other. Check for hydraulic leaks.
a. S2.0-3.5FT (S40-70FT, S55FTS) [F187] -
Tighten four bracket bolts and nuts to
90 N" m (66.4 lbf ft).
Spindles, Bearings, and Tie Rods Repair
SPINDLES AND BEARINGS 1. Put the lift truck on blocks.
2. Remove the wheel and bearings. See Steering
S2.0-3.5FT (S40-70FT, S55FTS) [F187]
Axle Assembly Repair, Disassemble.
Remove and Disassemble
CAUTION
WARNING
Do not hit the threads or the nut of the tie rod.
PUTTING THE LIFT TRUCK ON BLOCKS
3. Remove the cotter pin and castle nut. Use a
The lift truck must be put on blocks for some
puller to remove the tie rod end from the spindle
types of maintenance and repair. The removal
arm. To loosen the tie rod end, place a hammer
of the mast, drive axle, battery, or counter-
behind the arm to hold the arm. Hit the spindle
weight assemblies will cause large changes
arm with another large hammer. See Figure 10.
in the center of gravity. When the lift truck
is put on blocks, put additional blocks in the
NOTE: To remove the spindle, the tie rod canbe dis-
following positions:
connected at the retaining pin inside the dust cover.
" If the mast and drive axle are removed, put
4. Loosen the clamps on the dust cover and slide
blocks under the counterweight so the lift
the dust cover off the steering cylinder rod. See
truck cannot fall backward.
Figure 12.
" If the counterweight is removed, put blocks
under the mast so that the lift truck cannot
5. Remove the snap rings from the pin retaining the
fall forward.
tie rod to the steering cylinder rod, then remove
the pin.
Put the lift truck on blocks on a solid, even, and
level surface. Verify the blocks or stands have
6. Remove the grease cap from the spindle. Remove
enough capacity to hold the lift truck. Use ad-
the capscrews from the bearing cap. Remove the
ditional blocks next to the tires as necessary to
bearing cap and shims. If necessary, remove the
prevent movement of the lift truck. Verify the
bearing cup from the bearing cap as shown in
lifting devices used during repairs can lift the
Figure 9.
weight of the parts and assemblies.
7. Tilt the spindle and lift the spindle from the axle.
See the Operating Manual or Periodic Mainte-
See Figure 10. If necessary, remove the bearing
nance section for your lift truck model, for the
and seals from the spindle. If necessary, remove
procedures to put the lift truck on blocks.
the wear sleeve and bearing cup from the axle
frame.
8
1600 SRM 1133 Spindles, Bearings, and Tie Rods Repair
1. PRY BAR 3. BEARING CAP
NOTE: THE LUBRICATION FITTING NEEDS TO BE
2. BEARING CUP 4. O-RING
ORIENTED TOWARDS THE CENTERLINE OF THE
LIFT TRUCK.
Figure 9. Bearing Cup Removal
1. GREASE CAP
8. Repeat the procedure for the other spindle and
2. BEARING ASSEMBLY
tie rod.
3. WEAR SLEEVE
4. SEAL
Assemble and Install
5. SPINDLE
6. OIL SEAL
1. Install new seals on the spindle. Lubricate the
7. BEARING CONE
seals with grease. If necessary, press new bear- 8. BEARING CUP
9. WASHER
ing cones on the spindle.
10. CASTLE NUT
11. COTTER PIN
2. Lubricate the bearings with wheel bearing
12. HUB CAP
grease. Verify the bearings are filled with
13. O-RING
grease. If necessary, press the new bearing cups
14. SHIMS (AS REQUIRED)
into the steering axle frame and bearing cap. In- 15. CAPSCREW AND LOCKWASHER ASSEMBLY
16. LUBRICATION FITTING
stall the wear sleeve in the steering axle frame.
17. BEARING CAP
18. TIE ROD
3. Install the spindle in the steering axle. Install
19. CASTLE NUT
the bearing cap without the O-rings. See Fig-
20. COTTER PIN
ure 10. Measure the clearance between the bear-
ing cap and the axle. Remove the bearing cap and
Figure 10. Spindle Assembly, S2.0-3.5FT
install enough shims to give a preload of 0.00 to
(S40-70FT, S55FTS) [F187]
0.13 mm (0.000 to 0.005 in.).
9
Spindles, Bearings, and Tie Rods Repair 1600 SRM 1133
NOTE: The spindle bearings must have no clearance. See the Operating Manual or Periodic Mainte-
Install shims 0.00 to 0.13 mm (0.000 to 0.005 in.) less nance section for your lift truck model, for the
than the measured gap. procedures to put the lift truck on blocks.
4. Install the O-ring on the bearing cap. Install 1. Put the lift truck on blocks.
the bearing cap and capscrews. Tighten the cap-
2. Remove the wheel and if necessary, the bearings.
screws to 44 N" m (32 lbf ft).
See Steering Axle Assembly Repair, Disassem-
5. Install the tie rod to the spindle arm and steering ble.
cylinder. If removed, tighten the castle nut to
3. If the tie rod is to be replaced, remove the two
163 N" m (120 lbf ft). Tighten the castle nut until
snap rings and pin. To loosen and remove the
the cotter pin canbe installed.
pin, use a brass punch and hammer.
6. Install the grease cap on the top of the steering
4. Disassemble the bottom half of the spindle as fol-
axle.
lows:
7. Install the bearings and wheel. See Steering
a. Remove cotter pin from lock nut and remove
Axle Assembly Repair, Assemble.
lock nut from kingpin. See Figure 11.
8. Repeat the procedure for the other spindle and
b. Remove the oil seal, sleeve, and bearing cone.
tie rod.
NOTE: If the bearing cone is being replaced, the bear-
9. Remove the lift truck from blocks.
ing cup must be replaced.
S30FT, S35FT, S40FTS (E010), H1.6FT,
c. If necessary, remove the bearing cup.
H1.8FT, H2.0FTS (H30FT, H35FT, H40FTS)
5. Disassemble the top half of the spindle as follows:
[F001], and H2.0-3.5FT (H40-70FT) [L177]
a. Remove pin and O-ring from kingpin.
Remove and Disassemble
b. Remove spacer, seal, and bearing cone.
WARNING
PUTTING THE LIFT TRUCK ON BLOCKS NOTE: If the bearing cone is being replaced, the bear-
ing cup must be replaced.
The lift truck must be put on blocks for some
types of maintenance and repair. The removal c. If necessary, remove the bearing cup.
of the mast, drive axle, battery, or counter-
6. Repeat the procedure for the other spindle and
weight assemblies will cause large changes
tie rod.
in the center of gravity. When the lift truck
is put on blocks, put additional blocks in the
Assemble and Install
following positions:
" If the mast and drive axle are removed, put
1. If new spindle bearings are installed, use a press
blocks under the counterweight so the lift
to install new bearing cups into spindle. See Fig-
truck cannot fall backward.
ure 11. Lubricate bearing cones and seal lips
" If the counterweight is removed, put blocks
with grease.
under the mast so that the lift truck cannot
fall forward. 2. Install bearings, seals, sleeves, and O-rings into
spindle. If the groove pin was removed from the
Put the lift truck on blocks on a solid, even, and
kingpin, install new groove pin. Apply grease
level surface. Verify the blocks or stands have
to kingpin. Position spindle in axle and install
enough capacity to hold the lift truck. Use ad-
kingpin.
ditional blocks next to the tires as necessary to
prevent movement of the lift truck. Verify the 3. Install lock nut onto kingpin and tighten lock nut
lifting devices used during repairs can lift the to 90 N" m (66.4 lbf ft). Completely loosen lock
weight of the parts and assemblies. nut, then tighten to 34 N" m (25 lbf ft).
10
1600 SRM 1133 Spindles, Bearings, and Tie Rods Repair
7. Remove the lift truck from blocks.
TIE RODS
S2.0-3.5FT (S40-70FT, S55FTS) [F187]
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 mast, drive axle, battery, or counter-
weight assemblies will cause large changes
in the center of gravity. When the lift truck
is put on blocks, put additional blocks in the
following positions:
" If the mast and drive axle are removed, put
blocks under the counterweight so the lift
truck cannot fall backward.
" If the counterweight is removed, put blocks
under the mast so that the lift truck cannot
fall forward.
Put the lift truck on blocks on a solid, even, and
level surface. Verify the blocks or stands have
enough capacity to hold the lift truck. Use ad-
1. PIN 12. WASHER
ditional blocks next to the tires as necessary to
2. O-RING 13. BEARING (OUTER)
prevent movement of the lift truck. Verify the
3. SPACER 14. BEARING (INNER)
lifting devices used during repairs can lift the
4. SEAL 15. OIL SEAL
weight of the parts and assemblies.
5. BEARING CONE 16. SPINDLE
6. BEARING CUP 17. KINGPIN
7. SLEEVE 18. SNAP RING See the Operating Manual or Periodic Mainte-
8. OIL SEAL 19. WASHER
nance section for your lift truck model, for the
9. LOCK NUT 20. TIE ROD
procedures to put the lift truck on blocks.
10. PIN 21. PIN
11. HUB CAP
1. Put the lift truck on blocks.
Figure 11. Spindle Assembly, S30FT, S35FT,
2. Remove the wheel and bearings. See Steering
S40FTS (E010), H1.6FT, H1.8FT, H2.0FTS
Axle Assembly Repair, Disassemble.
(H30FT, H35FT, H40FTS) [F001], and
H2.0-3.5FT (H40-70FT) [L177]
CAUTION
4. Install tie rod to spindle housing. Align holes and
Do not hit the threads or the nut of the tie rod.
place lubricated pin into the spindle and tie rod.
Install the two snap rings on top and bottom of
3. Remove the cotter pin and castle nut. Use a
pin.
puller to remove the tie rod end from the spindle
arm. To loosen the tie rod end, place a hammer
5. If removed, install the bearings and install the
behind the arm to hold the arm. Hit the spindle
wheel. See Steering Axle Assembly Repair, As-
arm with another large hammer. See Figure 10.
semble.
4. Loosen the clamps on the dust cover and slide
6. Repeat the procedure for the other spindle and
the dust cover off the steering cylinder rod. See
tie rod.
Figure 12.
11
Spindles, Bearings, and Tie Rods Repair 1600 SRM 1133
1. CLAMP 5. STEERING CYLINDER ROD
2. DUST COVER 6. PIN
3. CLAMP 7. TIE ROD
4. SNAP RING
Figure 12. Tie Rod, S2.0-3.5FT (S40-70FT, S55FTS) [F187]
5. Remove the snap rings from the pin retaining the 2. If removed, slide the clamps onto the dust cover.
tie rod to the steering cylinder rod, then remove
3. Slidethedust coveronthetierod. SeeFigure12.
the pin.
4. Slide the tie rod into the steering cylinder rod.
6. Slide the tie rod fromthe cylinder rod.
5. Lubricateandinstall the pintoretainthetierod
7. Remove the dust cover from the tie rod.
and steering cylinder rod together.
8. If necessary, remove the clamps from the dust
6. Install the snap rings.
cover.
7. Slide the dust cover on to the steering rod cylin-
Install
der, against the rod-end shoulder.
1. Install the tie rod to the spindle arm. Install the
castle nut and tighten to 163 N" m (120 lbf ft).
Tighten the castle nut until the cotter pin can be
installed.
12
1600 SRM 1133 Spindles, Bearings, and Tie Rods Repair
8. Slide the clamps flush with the ends of the dust See the Operating Manual or Periodic Mainte-
cover and tighten clamps. nance section for your lift truck model, for the
procedures to put the lift truck on blocks.
9. Install the bearings and wheel. See Steering
Axle Assembly Repair, Assemble. 1. Put the lift truck on blocks.
10. Repeat the procedure for the other tie rod. 2. Remove the wheel and if necessary, the bearings.
See Steering Axle Assembly Repair, Disassem-
11. Remove the lift truck from blocks.
ble.
S30FT, S35FT, S40FTS (E010), H1.6FT,
3. Remove the snap rings from the pin retaining
the tie rod to the spindle. Remove the pin. See
H1.8FT, H2.0FTS (H30FT, H35FT, H40FTS)
Figure 13. To loosen and remove the pin, use a
[F001], and H2.0-3.5FT (H40-70FT) [L177]
brass punch and hammer.
Remove
4. Remove the snap rings from the pin retaining the
tie rod to the steering cylinder rod. Remove the
WARNING
pin.
PUTTING THE LIFT TRUCK ON BLOCKS
5. Slide the tie rod and washers fromthe spindle
The lift truck must be put on blocks for some
housing and steering cylinder rod.
types of maintenance and repair. The removal
of the mast, drive axle, battery, or counter- Install
weight assemblies will cause large changes
1. Place the tie rod and washers in position in the
in the center of gravity. When the lift truck
spindle housing and steering cylinder rod.
is put on blocks, put additional blocks in the
following positions:
2. Align holes and place lubricated pin into the
" If the mast and drive axle are removed, put
spindle and tie rod. Install the two snap rings
blocks under the counterweight so the lift
on top and bottom of pin.
truck cannot fall backward.
" If the counterweight is removed, put blocks
3. Align holes and place lubricated pin into the
under the mast so that the lift truck cannot
steering cylinder rod and tie rod. Install the two
fall forward.
snap rings on top and bottom of pin.
Put the lift truck on blocks on a solid, even, and
4. If removed, install the bearings and install the
level surface. Verify the blocks or stands have
wheel. See Steering Axle Assembly Repair, As-
enough capacity to hold the lift truck. Use ad-
semble.
ditional blocks next to the tires as necessary to
prevent movement of the lift truck. Verify the 5. Repeat the procedure for the other tie rod.
lifting devices used during repairs can lift the
6. Remove the lift truck from blocks.
weight of the parts and assemblies.
13
Spindles, Bearings, and Tie Rods Repair 1600 SRM 1133
Figure 13. Tie Rod, S30FT, S35FT, S40FTS (E010), H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT,
H40FTS) [F001], and H2.0-3.5FT (H40-70FT) [L177]
14
1600 SRM 1133 Steering Cylinder Repair
Legend for Figure 13
A. H2.0-3.5FT (H40-70FT) [L177] B. S30FT, S35FT, S40FTS (E010) AND H1.6FT,
H1.8FT, H2.0FTS (H30FT, H35FT, H40FTS) [F001]
1. SNAP RINGS 4. TIE ROD
2. STEERING CYLINDER ROD 5. PIN
3. WASHERS 6. SPINDLE
Steering Cylinder Repair
REMOVE AND DISASSEMBLE 1. Clean all parts in solvent.
NOTE: The end caps of the steering cylinder are held 2. Inspect piston rod for grooves or damage. Re-
in the shell by the cylinder mount capscrews. To pre- move small scratches with fine emery cloth. In-
vent oil leaks at the caps, hold the caps on the shell spect cylinder bore for damage. Inspect mounts
during removal. for cracks.
NOTE: Hydraulic oil is to be disposed of in accordance
ASSEMBLE AND INSTALL
with local directives.
1. Put O-rings, seals, and wipers in warm hydraulic
1. Disconnect hydraulic lines at steering cylinder.
oil. Install O-rings, seals, and wipers as shown in
See Figure 14. Install caps in fittings on cylinder
Figure 14.
and put fittings on hydraulic lines.
2. Remove the tie rods. See Spindles, Bearings, and CAUTION
Tie Rods Repair, Tie Rods.
Do not damage the O-rings, seals, or wipers
during installation.
3. Remove capscrews that fasten cylinder to axle
frame. Hold end caps on shell and remove steer-
2. Lubricate O-rings, seals, and wipers with O-ring
ing cylinder.
lubricant and carefully install one end cap on
cylinder rod.
4. Hold end of steering cylinder over a container.
Remove plug for hydraulic fitting from each end
3. Carefully slide cylinder rod and end cap into
cap. Push rod toward end of shell that is over
shell. Keep cylinder rod aligned in center of
container. Oil will drain from cylinder. Repeat
shell during installation so the parts are not
procedure for other end.
damaged. Install other end cap into shell. Put
caps on hydraulic fittings of end caps.
5. Carefully remove one end cap from shell and
slide off of rod. Carefully pull rod out of shell,
4. Hold end caps and install cylinder on axle frame
keeping rod centered in shell during removal.
using capscrews. Tighten capscrews to 225 N" m
Remove other end cap from shell. Remove all
(166 lbf ft).
seals, wipers, and O-rings. See Figure 14.
5. Install tie rods. See Spindles, Bearings, and Tie
Rods Repair, Tie Rods.
CLEAN AND INSPECT
6. Remove plugs and caps and connect hydraulic
WARNING
lines to steering cylinder. Operate steering sys-
Cleaning solvents can be flammable and toxic
tem to remove air from cylinders and system.
and can cause skin irritation. When using
Turn steering wheel several times from one stop
cleaning solvents, always follow the solvent
to the other. Check that the steer cylinder oper-
manufacturer s recommended safety proce-
ates lock to lock.
dures.
15
Torque Specifications 1600 SRM 1133
1. ROD 6. SHELL
2. WIPER 7. PISTON SEAL
3. END CAP 8. ROD SEAL
4. O-RING 9. O-RING
5. BACKUP RING 10. HYDRAULIC LINE PORT
Figure 14. Steering Cylinder
Torque Specifications
Axle Mounting Bolts and Nuts King Pin Lock Nut (Initial)
S30FT, S35FT, S40FTS (E010), H1.6FT, H1.8FT,
S2.0-3.5FT (S40-70FT, S55FTS) [F187] H2.0FTS (H30FT, H35FT, H40FTS) [F001],
90 N" m (66.4 lbf ft) and H2.0-3.5FT (H40-70FT) [L177]
90 N" m (66.4 lbf ft)
H2.0-3.5FT (H40-70FT) [L177]
King Pin Lock Nut (Final)
88 N" m (65 lbf ft)
S30FT, S35FT, S40FTS (E010), H1.6FT, H1.8FT,
H2.0FTS (H30FT, H35FT, H40FTS) [F001],
S30FT, S35FT, S40FTS (E010) and H1.6FT,
and H2.0-3.5FT (H40-70FT) [L177]
H1.8FT, H2.0FTS (H30FT, H35FT,
34 N" m (25 lbf ft)
H40FTS) [F001]
41 to 49 N" m (30 to 36 lbf ft)
Spindle Bearing Cap Capscrews
S2.0-3.5FT (S40-70FT, S55FTS) [F187]
Hub Nut (Initial)
44 N" m (32 lbf ft)
S2.0-3.5FT (S40-70FT, S55FTS) [F187]
68 N" m (50 lbf ft)
Tie Rod Nut
S30FT, S35FT, S40FTS (E010) H1.6FT, H1.8FT,
S2.0-3.5FT (S40-70FT, S55FTS) [F187]
H2.0FTS (H30FT, H35FT, H40FTS) [F001],
163 N" m (120 lbf ft)
and H2.0-3.5FT (H40-70FT) [L177]
200 N" m (147.5 lbf ft)
Steer Cylinder Mounting Bolts
225 N" m (166 lbf ft)
Hub Nut (Final)
S2.0-3.5FT (S40-70FT, S55FTS) [F187]
3 N" m(27 lbf in)
H2.0-3.5FT (H40-70FT) [L177]
15 N" m (133 lbf in)
S30FT, S35FT, S40FTS (E010) and H1.6FT,
H1.8FT, H2.0FTS (H30FT, H35FT,
H40FTS) [F001]
12 N" m (106 lbf ft)
16
TECHNICAL PUBLICATIONS
1600 SRM 1133 5/05 (12/04) Printed in U.S.A.