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 2) [A216];
J2.00-3.20XM (J40-60Z) [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 ............................................................................................................................................................... 1
Description ......................................................................................................................................................... 1
Steering Axle Assembly Repair......................................................................................................................... 2
Remove ........................................................................................................................................................... 2
Install ............................................................................................................................................................. 2
Wheels and Hubs Repair ................................................................................................................................... 3
Remove and Disassemble .............................................................................................................................. 3
Clean .............................................................................................................................................................. 3
Assemble and Install ..................................................................................................................................... 3
Spindles, Bearings, and Tie Rods Repair ......................................................................................................... 5
Remove ........................................................................................................................................................... 5
Install ............................................................................................................................................................. 5
Steering Cylinder Repair................................................................................................................................... 6
Remove and Disassemble .............................................................................................................................. 6
Clean and Inspect .......................................................................................................................................... 7
Assemble and Install ..................................................................................................................................... 7
Torque Specifications ......................................................................................................................................... 7
Troubleshooting.................................................................................................................................................. 8

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 2) [A216];
J2.00-3.20XM (J40-60Z) [A416];
H2.00-3.20XM (H45-65XM) [H177]

©2003 HYSTER COMPANY i

"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, the end caps are used to keep the oil inside the steer-
steering cylinder, and two spindle and hub assem- ing cylinder. The ends of the piston rod extend from
blies. See Figure 1. The steering axle is connected both ends of the cylinder. A single piston and the seal
to the frame with center pivot mounts. The center are at the center of the rod. Oil pressure on one side
pivot mounts on the axle frame are fastened to the of the piston moves the piston in the bore. When the
lift truck frame with rubber mounts. The steering piston moves in the bore, it pushes an equal amount
axle can make an articulated motion and gives the of oil from the opposite end of the cylinder. This oil
lift truck a smoother travel over rough surfaces. returns to the steering control unit.

The end caps of the steering cylinder are also the When the piston reaches the end of the stroke, a relief
mounts for the cylinder and are held to the shell by valve controls the oil pressure so the components are
the mount capscrews. O-rings, seals, and wipers in not damaged. Tie rods connect the spindle arms to
the cylinder.

1. SPINDLE AND HUB ASSEMBLY 4. RUBBER MOUNT

2. AXLE FRAME 5. STEERING CYLINDER
3. BRACKET 6. NUT AND BOLT

Figure 1. Steering Axle

1
Steering Axle Assembly Repair 1600 SRM 316

Each spindle turns on two tapered roller bearings. The wheel or hub rotates on two tapered roller bear-
The spindle and bearings are held in the axle frame ings and is held on the spindle by a castle nut. The
by a kingpin. The preload on the bearings is con- preload on the bearings in the hub is adjusted by the
trolled by a threaded nut on the bottom of the king- castle nut. A grease seal in the inner hub and a hub
pin. 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 from turning when axle is removed from under
lift truck.
WARNING 3. Slide a floor jack or forks of another lift truck
PUTTING THE LIFT TRUCK ON BLOCKS under steering axle. Raise lifting device until it
holds the weight of the axle assembly. Remove
The lift truck must be put on blocks for some
four capscrews and nuts that fasten two brack-
types of maintenance and repair. The removal
ets under rubber mounts. Remove brackets and
of the following assemblies will cause large
slowly lower axle assembly onto wheels. Care-
changes in the center of gravity: drive axle,
fully roll axle assembly from under lift truck.
battery, or counterweight. When the lift truck
is put on blocks, put additional blocks in the
following positions:
INSTALL
1. If the mast and drive axle are removed, put 1. Install rubber mounts on axle as follows (see Fig-
blocks under the counterweight so the lift ure 1):
truck cannot fall backward.
2. If the battery (electric lift trucks) or coun- a. E1.25-1.75XL (E25-35XL), J2.00-3.00XL
terweight is removed, put blocks under the (J40-60XL), H2.00-3.20XM (H40-65XM),
mast so the lift truck cannot fall forward. J2.00-3.20XM (J40-60XM, J40-60XM 2)
(A216), and J2.00-3.20XM (J40-60Z) (A416):
Put the lift truck on blocks on a solid, even, and Make sure PART NO. on the mounts is right
level surface. Make sure the blocks of stands side up and facing away from axle frame.
have enough capacity to hold the lift truck. Use
additional blocks next to the tires as necessary b. J1.25-1.75XL (Europe only): Make sure
to prevent movement of the lift truck. Make PART NO. on mounts is upside down and
sure the lifting devices used during repairs can facing away from axle frame.
lift the weight of the parts and assemblies.
2. Apply a lubricant that is approved for use with
NOTE: The steering axle assembly without the rubber to rubber mount. The lubricant is used
wheels weighs approximately 115 kg (250 lb). where the rubber mount fits into the frame
brackets.
The steering axle can be removed without remov-
ing the counterweight. If necessary, remove counter- 3. Use a floor jack or another lift truck to put steer-
weight as described in the Frame section. ing axle into position in frame. Make sure rubber
mounts fit inside frame brackets for mounts.
1. Make sure wheels are set for straight travel. Put
lift truck on blocks so steering axle can be re- 4. Install bottom brackets. Tighten four bracket
moved. The top of the axle frame must have capscrews and nuts to 88 N•m (65 lbf ft).
clearance under the counterweight so the steer-
ing axle can be removed. See Figure 1. 5. Remove plugs and caps and connect hydraulic
lines to steering cylinder.
2. Disconnect hydraulic lines at steering cylinder.
Install caps on cylinder and put plugs in hy- 6. Operate steering system to remove air from sys-
draulic lines. The caps will prevent spindles tem. Turn steering wheel several times from one
stop to the other stop. Check for hydraulic leaks.

2
1600 SRM 316 Wheels and Hubs Repair

Wheels and Hubs Repair

REMOVE AND DISASSEMBLE 2. If the wheel bearings must be replaced, use a
brass drift to remove bearing cups and wear
WARNING sleeve.
PUTTING THE LIFT TRUCK ON BLOCKS 3. Repeat procedure for other wheel.
The lift truck must be put on blocks for some
types of maintenance and repair. The removal
CLEAN
of the following assemblies will cause large
changes in the center of gravity: drive axle, WARNING
battery, or counterweight. When the lift truck Cleaning solvents can be flammable and toxic
is put on blocks, put additional blocks in the and can cause skin irritation. When using
following positions: cleaning solvents, always follow the solvent
1. If the mast and drive axle are removed, put manufacturer’s recommended safety proce-
blocks under the counterweight so the lift dures.
truck cannot fall backward.
2. If the battery (electric lift trucks) or coun- Clean all parts with solvent. Make sure bearings are
terweight is removed, put blocks under the clean.
mast so that the lift truck cannot fall for-
ward. ASSEMBLE AND INSTALL

Put the lift truck on blocks on a solid, even, and CAUTION

level surface. Make sure the blocks of stands
Do not damage the seals during installation.
have enough capacity to hold the lift truck. Use
additional blocks next to the tires as necessary 1. If wheel bearings must be replaced, use a press
to prevent movement of the lift truck. Make to install new bearing cups in wheel or hub. See
sure the lifting devices used during repairs can Figure 2. Install new wear sleeve in wheel or
lift the weight of the parts and assemblies. hub. Install grease seal on spindle. Lubricate
bearing cones with grease. Make sure bearings
WARNING are filled with grease. Install bearing cone on
spindle.
Completely deflate the tires before removing
them from the lift truck. Air pressure in the 2. Carefully slide wheel or hub onto spindle. Install
tires can cause the tire and rim parts to ex- outer bearing cone.
plode, causing serious injury or death.
3. Install castle nut. Tighten castle nut to 200 N•m
Never loosen the nuts that hold the inner and (150 lbf ft) while wheel is rotated. Loosen nut
outer wheel halves together when there is air to less than 27 N•m (20 lbf ft). Tighten nut to
pressure in the tire. 34 N•m (25 lbf ft). If cotter pin cannot be in-
stalled with nut tightened to 34 N•m (25 lbf ft),
1. Put axle on blocks so tires are raised from floor.
tighten castle nut until cotter pin can be in-
Remove grease cap. Remove cotter pin and castle
stalled. Install cotter pin.
nut. Remove outer bearing cone. Slide wheel
from spindle. Remove inner bearing cone and 4. Repeat procedure for other wheel.
seal from spindle. See Figure 2.

3
Wheels and Hubs Repair 1600 SRM 316

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

1. AXLE FRAME 16. SEAL
2. WASHER 17. BEARING CONE
3. BOLT 18. BEARING CUP
4. BELLEVILLE WASHER 19. SPINDLE
5. RUBBER MOUNT 20. SPACER
6. BRACKET 21. O-RING
7. NUT 22. KINGPIN
8. STEERING CYLINDER 23. GROOVE PIN
9. PIN 24. WEAR SLEEVE
10. SNAP RING 25. HUB*
11. BUSHING 26. STUD*
12. TIE ROD 27. WHEEL NUT*
13. GREASE FITTING 28. COTTER PIN
14. CASTLE NUT 29. GREASE CAP
15. SLEEVE

*PNEUMATIC TIRES ONLY

Figure 2. Steering Axle

4
1600 SRM 316 Spindles, Bearings, and Tie Rods Repair

Spindles, Bearings, and Tie Rods Repair

REMOVE (25 lbf ft), tighten castle nut until cotter pin can
be installed. Install cotter pin.
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.
2. 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: 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 1. O-RING 8. SPINDLE
Figure 3. Remove pin to disconnect tie rod from spin- 2. KINGPIN 9. SEAL
dle. Remove cotter pin and castle nut from bottom of 3. GROOVE PIN 10. WEAR SLEEVE
4. SPACER 11. CASTLE NUT
kingpin. Use a driver to remove kingpin. Remove 5. SEAL 12. COTTER PIN
sleeve and then spindle from axle. Use a driver to 6. BEARING CONE 13. GREASE CAP
remove bearings and seals from spindle. 7. BEARING CUP 14. SLEEVE

INSTALL Figure 3. Spindle Assembly

1. Use new bearings and seals. See Figure 2 and 2. Connect tie rods. Make sure belleville washers
Figure 3. Apply grease to bearings and kingpin are installed on both sides of bushings.
as they are installed in axle. Install bearings in
3. Install wheels or hubs. See the section
spindle. Install seals in correct position. Align
Wheels and Hubs Repair for proper installa-
spindle in axle and install kingpin. Make sure
tion procedure. On H2.00-3.20XM (H40-65XM),
new O-ring is installed at top of kingpin. Install
J2.00-3.20XM (J40-60XM, J40-60XM 2) (A216),
sleeve on bottom of kingpin. Install castle nut
J2.00-3.20XM (J40-60Z) (A416) tighten wheel
and tighten it to 90 N•m (66 lbf ft). Loosen cas-
nuts to 237 to 305 N•m (175 to 225 lbf ft).
tle nut to less than 34 N•m (25 lbf ft). Tighten
On J1.25-1.75XL (J25-35XL) and J2.00-3.00XL
nut to 34 N•m (25 lbf ft). If cotter pin can-
(J40-60XL), tighten wheel nuts to 155 N•m
not be installed with nut tightened to 34 N•m
(115 lbf ft).

5
Steering Cylinder Repair 1600 SRM 316

Steering Cylinder Repair

REMOVE AND DISASSEMBLE Put the lift truck on blocks on a solid, even, and
level surface. Make sure the blocks of stands
WARNING have enough capacity to hold the lift truck. Use
additional blocks next to the tires as necessary
PUTTING THE LIFT TRUCK ON BLOCKS
to prevent movement of the lift truck. Make
The lift truck must be put on blocks for some sure the lifting devices used during repairs can
types of maintenance and repair. The removal lift the weight of the parts and assemblies.
of the following assemblies will cause large
NOTE: The end caps of the steering cylinder are held
changes in the center of gravity: drive axle,
in the shell by the cylinder mount capscrews. To pre-
battery, or counterweight. When the lift truck
vent oil leaks at the caps, hold caps on shell during
is put on blocks, put additional blocks in the
removal.
following positions:
1. If the mast and drive axle are removed, put 1. Disconnect hydraulic lines at steering cylinder.
blocks under the counterweight so the lift See Figure 4. Install caps in fittings on cylinders
truck cannot fall backward. and put caps on hydraulic lines.
2. If the battery (electric lift trucks) or coun-
terweight is removed, put blocks under the 2. Remove snap rings from pins in tie rods. Remove
mast so the lift truck cannot fall forward. pins.

1. ROD 4. O-RING 7. PISTON SEAL

2. WIPER 5. BACKUP RING 8. ROD SEAL
3. END CAP 6. SHELL 9. QUADRANT RING

Figure 4. Steering Cylinder

6
1600 SRM 316 Torque Specifications

3. Remove capscrews or nuts and bolts that fasten

cylinder to axle frame. Hold end caps on shell CAUTION
and remove steering cylinder. Do not damage the O-rings, seals, or wipers
during installation.
4. Hold end of steering cylinder over drain pan. Re-
move cap for hydraulic fitting from each end cap. 2. Lubricate O-rings, seals, and wipers with O-ring
Push rod toward end of shell that is over drain lubricant and install them in end caps. Install
pan. Oil will drain from cylinder. Repeat proce- one end cap on cylinder rod.
dure for other end.
3. Carefully slide cylinder rod and piston into shell.
5. Carefully slide one end cap from shell. Carefully Keep cylinder rod aligned in center of shell dur-
pull cylinder rod and piston from shell. Keep ing installation so parts are not damaged. Care-
cylinder rod aligned in center of shell during re- fully slide end cap into shell. Carefully install
moval so parts are not damaged. Remove end cap other end cap on rod and shell. Put caps on hy-
from rod. Remove other end cap from shell. Re- draulic fittings of end caps.
move all seals, wipers, and O-rings.
NOTE: On J2.00-3.00XL (J40-60XL) units, the nuts
CLEAN AND INSPECT are against the end caps.

4. Hold end caps and install cylinder on axle

WARNING frame using capscrews or nuts and capscrews.
Cleaning solvents can be flammable and toxic On H2.00-3.20XM (H40-65XM), J2.00-3.20XM
and can cause skin irritation. When using (J40-60XM, J40-60XM 2) (A216), J2.00-3.20XM
cleaning solvents, always follow the solvent (J40-60Z) (A416), tighten capscrews to 225 N•m
manufacturer’s recommended safety proce- (166 lbf ft). On E/J1.25-1.75XL (E/J25-35XL)
dures. and J2.00-3.00XL (J40-60XL), tighten capscrews
and nuts to 165 N•m (122 lbf ft).
1. Clean all parts in solvent.
5. Install tie rods between cylinder and spindles.
2. Inspect piston rod for grooves or damage. Re- Make sure belleville washers are on each side
move small scratches with fine emery cloth. In- of the bushings in the tie rods. Install pins and
spect cylinder bore for damage. Inspect mounts snap rings.
for cracks.
6. Remove caps and connect hydraulic lines to
ASSEMBLE AND INSTALL steering cylinder. Operate steering system to
remove air from cylinder and hydraulic system.
1. Put seals and wipers in warm hydraulic oil. In- Turn steering wheel several times from one stop
stall quadrant ring and piston seal as shown in to the other.
Figure 4.

Torque Specifications
Steer Axle Mount Bracket Hardware Wheel Nuts
88 N•m (65 lbf ft) H2.00-3.20XM (H40-65XM), J2.00-3.20XM
(J40-60XM J40-60XM2) (A216), J2.00-3.20XM
Wheel/Hub Nut (J40-60Z) (A416) 237 to 305 N•m (175 to 225 lbf ft)
Initial Torque 200 N•m (150 lbf ft) J1.25-1.75XL (J25-35XL) 155 N•m (116 lbf ft)
Final Torque 34 N•m (25 lbf ft) J2.00-3.00XL (J40-60XL) 155 N•m (116 lbf ft)
Kingpin Nut Steer Cylinder Mount Hardware
Initial Torque 90 N•m (66 lbf ft) H2.00-3.20XM (H40-65XM), J2.00-3.20XM
Final Torque 34 N•m (25 lbf ft) (J40-60XM J40-60XM2) (A216), J2.00-3.20XM
(J40-60Z) (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)

7
Troubleshooting 1600 SRM 316

Troubleshooting

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

There is no action when the There is no oil or not enough oil in Fill tank to correct level.
steering wheel is turned. the hydraulic tank.

The lines are loose at the control unit Tighten fittings.

or manifold block.

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

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 oil level is low. There is no oil in Fill tank to correct level.
The steering wheel is hard the tank.
to turn.

The lines to the control unit are dam- Repair oil lines.
aged.

The sleeve and spool in the control Repair steering control unit.
unit are worn.

The parts of the metering section are Repair steering control unit.
worn.

The check valve in the control unit Clean or repair steering control unit.
does not open.

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

Priority valve is not operating cor- Clean or repair priority valve.

rectly.

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 The lines at the control unit are not Connect lines correctly.
tires in the wrong direction. correctly connected.

8
1600 SRM 316 Troubleshooting

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

The tires continue to turn af- The neutral position springs are bro- Repair steering control unit.
ter the steering wheel stops. ken.

The sleeve or spool has damage. Repair steering control unit.

Steering wheel kicks back in Center shaft is not correctly aligned Correctly assemble steering control
both directions. with metering section. unit.

9
 NOTES

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 TECHNICAL PUBLICATIONS

1600 SRM 316 3/03 (3/95)(4/93)(11/85)(5/85) Printed in United Kingdom