STEERING AXLE

S3.50-5.50XL (S70-120XL) [D004];

S3.50-5.50XM (S70-120XM) [E004, F004];
E3.50-5.50XL (E70-120XL, E70-120XL 3) [C098];
H3.50-5.00XL (H70-110XL) [G005];
H6.00-7.00XL (H135-155XL, H135-155XL 2) [F006, G006];
H8.00-16.00XL (H165-360XL) [D019, E007];
H8.00-16.00XM (H170-360HD) [E019, F007, F019, G007];
E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) [D098]

PART NO. 897108 1600 SRM 326

 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......................................................................................................................... 6
Steering Axle H3.50-5.00XL (H70-110XL) (G005), S3.50-5.50XL (S70-120XL) (D004),
S3.50-5.50XM (S70-120XM) (E004, F004), E3.50-5.50XL (E70-120XL, E70-120XL 3) (C098), and
E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (D098) ................................................................................ 6
Remove....................................................................................................................................................... 6
Install ......................................................................................................................................................... 6
Steering Axle H6.00-7.00XL (H135-155XL, H135-155XL 2) (F006, G006), H8.00-16.00XL
(H165-360XL) (D019, E007), and H8.00-16.00XM (H170-360HD) (E019, F007, F019, G007).................. 7
Remove....................................................................................................................................................... 7
Install ......................................................................................................................................................... 7
Wheels and Hubs Repair (All Units) ................................................................................................................ 8
Remove and Disassemble .............................................................................................................................. 8
Clean .............................................................................................................................................................. 8
Inspect ............................................................................................................................................................ 8
Assemble and Install ..................................................................................................................................... 8
Spindles and Bearings Repair (All Units) ........................................................................................................ 10
Remove ........................................................................................................................................................... 10
Clean .............................................................................................................................................................. 10
Assemble and Install ..................................................................................................................................... 10
Tie Rods Repair (All Units) ............................................................................................................................... 11
Remove ........................................................................................................................................................... 11
Clean .............................................................................................................................................................. 11
Install ............................................................................................................................................................. 11
Steering Cylinder Repair................................................................................................................................... 14
Remove and Disassemble .............................................................................................................................. 14
Clean and Inspect .......................................................................................................................................... 14
Assemble and Install ..................................................................................................................................... 14
Troubleshooting.................................................................................................................................................. 15

This section is for the following models:

S3.50-5.50XL (S70-120XL) [D004];

S3.50-5.50XM (S70-120XM) [E004, F004];
E3.50-5.50XL (E70-120XL, E70-120XL 3) [C098];
H3.50-5.00XL (H70-110XL) [G005];
H6.00-7.00XL (H135-155XL, H135-155XL 2) [F006, G006];
H8.00-16.00XL (H165-360XL) [D019, E007];
H8.00-16.00XM (H170-360HD) [E019, F007, F019, G007];
E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) [D098]

©2005 HYSTER COMPANY i

"THE
QUALITY
KEEPERS"

HYSTER
APPROVED
PARTS
1600 SRM 326
General
This section has the description and repair procedures for the steering axle. For information on the steering
control unit, see the section Steering Control Unit.
Description
The steering axle assembly includes an axle frame,
steering cylinder, tie rods, and two spindle and hub
assemblies. The steering axle is articulated and is
connected to the frame with center pivot mounts.
The center pivot mounts permit the steering axle
to move in the frame mount when the lift truck
travels over rough surfaces. See Figure 1, Figure 2,
Figure 3, and Figure 4.
The center pivots for the axle are installed in rubber
mounts on the following units:
H3.50-5.50XL (H70-110XL) (D004)
S3.50-5.50XL (S70-120XL) (G005)
S3.50-5.50XM (S70-120XM) (E004, F004)
E3.50-5.50XL (E70-120XL, E70-120XL 3) (C098)
E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS)
(D098)
The center pivots for the axle are installed in the
frame of the lift truck and rotate in fiber bushings
on the following units:
H6.00-7.00XL (H135-155XL, H135-155XL 2) (F006,
G006)
H8.00-16.00XL (H165-360XL) (D019, E007)
H8.00-16.00XM (H170-360HD) (E019, F007, F019,
G007)
Description
The end caps of the steering cylinder are also the
mounts for the cylinder and are held to the axle by
capscrews. The ends of the piston rod extend from
both ends of the cylinder. A single piston and the
seal are at the center of the piston rod. Oil pressure
on one side of the piston moves the piston in the bore.
The piston pushes an equal amount of oil from the
opposite side of the cylinder. The oil returns to the
steering control unit.
When the piston in the steering cylinder reaches the
end of the stroke, a relief valve controls the oil pres-
sure. The relief valve for the steering system is in
the manifold block that is installed on the steering
control unit.
Each spindle turns on two tapered roller bearings in
the axle frame. The preload on the bearings is con-
trolled by shims at the lower bearing cap. The tie
rods that connect the spindle arms to the cylinder do
not have an adjustment.
The wheel hubs rotate on two tapered roller bear-
ings and are held on the spindles by a castle nut.
The bearing preload of the wheel hubs is adjusted by
the castle nut. The grease seals protect the bearings
from dirt and water. Wear sleeves prevent the seals
from causing wear on the hub.
1
Description 1600 SRM 326

1. STEERING AXLE 11. BEARING CUP 21. SEALANT

2. COVER 12. SEAL 22. STEER CYLINDER
3. CLAMP 13. WEAR SLEEVE 23. OIL SEAL
4. COTTER PIN 14. SPINDLE (RH) 24. CAP (HUB)
5. SNAP RING 15. SPINDLE (LH) 25. WASHER
6. TIE ROD AND BUSHING 16. O-RING 26. MOUNT
7. NUT 17. SHIM 27. PLATE
8. CAPSCREW 18. BEARING CAP 28. LOCKWASHER
9. CAP 19. LUBE FITTING 29. WHEEL
10. BEARING CONE 20. SCREW 30. GREASE FITTING

Figure 1. Steering Axle E3.50-5.50XL (E70-120XL, E70-120XL 3) (C098), S3.50-5.50XL (S70-120XL)

(D004), S3.50-5.50XM (S70-120XM) (E004, F004) and E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS)
(D098)

Legend for Figure 2

1. HUB ASSEMBLY 11. BEARING CONE 21. TIE ROD
2. STUD 12. BEARING CAP 22. BUSHING
3. BEARING CUP 13. SHIM 23. ANCHOR
4. WEAR SLEEVE 14. OIL SEAL 24. STEERING CYLINDER
5. HUB CAP 15. LUBE FITTING 25. FITTING
6. COTTER PIN 16. PIN 26. O-RING
7. NUT 17. PLUG 27. FLANGE
8. WASHER 18. SPINDLE 28. LUG NUT
9. LOCKWASHER 19. FRAME 29. HANGER CUP
10. CAPSCREW 20. SHAFT

2
1600 SRM 326 Description

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

3
Description 1600 SRM 326

1. STEERING AXLE 18. SNAP RING

2. STEER CYLINDER 19. O-RING
3. SPINDLE (LH) 20. GREASE FITTING
4. SEAL 21. COTTER PIN
5. BEARING CONE 22. MOUNT
6. SPINDLE (RH) 23. PLATE
7. HUB 24. WASHER
8. BEARING CUP 25. NUT
9. STUD (WHEEL) 26. LUG NUT
10. WEAR SLEEVE 27. PIN
11. TIE ROD 28. PLUG AND SEALANT
12. CAPSCREW 29. CLAMP
13. NUT (SPINDLE) 30. OIL SEAL
14. CAP (HUB) 31. BEARING CAP
15. SHIM 32. CAPSCREW
16. CAP ASSEMBLY 33. COVER
17. PIN

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

Legend for Figure 4

1. STEERING AXLE 10. BEARING CONE 19. STUD
2. SHAFT 11. BEARING CUP 20. WHEEL NUT
3. SEAL 12. WEAR SLEEVE 21. WASHER
4. PIN 13. SPINDLE 22. COTTER PIN
5. SNAP RING 14. O-RING 23. CAP
6. TIE ROD 15. SHIM 24. GREASE FITTING
7. CAPSCREW 16. SCREW 25. BUSHING
8. LOCKWASHER 17. OIL SEAL 26. BEARING CAP
9. PLUG 18. HUB 27. STEER CYLINDER

4
1600 SRM 326 Description

Figure 4. Steering Axle H6.00-7.00XL (H135-155XL, H135-155XL 2) (F006, G006)

5
Steering Axle Assembly Repair
Steering Axle Assembly Repair
STEERING AXLE H3.50-5.00XL
(H70-110XL) (G005), S3.50-5.50XL
(S70-120XL) (D004), S3.50-5.50XM
(S70-120XM) (E004, F004), E3.50-5.50XL
(E70-120XL, E70-120XL 3) (C098), AND
E3.50-5.50XL, E4.50XLS (E70-120Z,
E100ZS) (D098)
Remove
WARNING
Put the lift truck on blocks. Follow the proce-
dures for raising the lift truck described in the
Operating Manual for this lift truck. The sur-
face must be solid, even, and level. Make sure
the blocks are solid, one-piece units. Make sure
the lifting devices used during repairs can lift
the weight of the parts.
The steering axle can be removed without removing
the counterweight.
1. Make sure wheels are set for straight travel. Put
blocks under frame in front of steer wheels and
under counterweight so steering axle can be re-
moved. The top of the axle frame must have
clearance under the counterweight so that the
steering axle can be removed.
2. It is not required, but it can make removal of the
axle easier if wheels are removed. See Wheels
and Hubs Repair (All Units) for wheel removal.
Disconnect hydraulic lines at steering cylinder.
Install caps on cylinder and put plugs in hy-
draulic lines. Caps will prevent spindles from
turning when axle is removed from the lift truck.
3. Slide a floor jack or forks of another lift truck
under steering axle. Raise lifting device until it
holds the weight of the axle assembly. Remove
four capscrews and nuts that fasten two brack-
ets under rubber mounts. Remove brackets and
6
1600 SRM 326
slowly lower axle assembly. Carefully remove
axle assembly from under lift truck.
Install
1. Install rubber mounts on axle. Make sure part
number is away from axle frame and tapered
edge of rubber mount is at the top. See Fig-
ure 1and Figure 3.
2. Apply a lubricant that is approved for use with
rubber (tire lubricant) to the rubber mounts.
Lubricant is used where rubber mount fits into
frame brackets.
3. Use a floor jack or another lift truck to put steer-
ing axle into position in the frame. Make sure
rubber mounts fit inside frame brackets for the
mounts. If necessary, lower weight of the lift
truck onto axle to make sure rubber mounts fit
completely in frame brackets.
4. Install bottom brackets for rubber mounts.
H3.50-5.00XL (H70-110XL) (G005) units.
Tighten four bolts for brackets to 72 N•m
(53 lbf ft).
S3.50-5.50XL (S70-120XL) (D004), S3.50-
5.50XM (S70-120XM) (E004, F004), E3.50-
5.50XL (E70-120XL, E70-120XL 3) (C098), and
E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS)
(D098) units. Tighten four bolts to 110 N•m
(81 lbf ft).
5. Remove plugs and caps and connect hydraulic
lines to steering cylinder. Install wheels if they
were removed.
6. Operate steering system to remove air from sys-
tem. Turn steering wheel several times from one
wheel stop to other wheel stop. Check for hy-
draulic leaks.
1600 SRM 326
STEERING AXLE H6.00-7.00XL
(H135-155XL, H135-155XL 2) (F006,
G006), H8.00-16.00XL (H165-360XL) (D019,
E007), AND H8.00-16.00XM (H170-360HD)
(E019, F007, F019, G007)
Remove
WARNING
Put the lift truck on blocks. Follow the proce-
dures for raising the lift truck described in the
Operating Manual for this lift truck. The sur-
face must be solid, even, and level. Make sure
the blocks are solid, one-piece units. Make sure
the lifting devices used during repairs can lift
the weight of the parts.
The steering axle can be removed without removing
the counterweight.
1. Make sure wheels are set for straight travel. Put
blocks under frame in front of steer wheels, so
steering axle can be removed. Top of axle frame
must have clearance under counterweight so
steering axle can be removed.
2. It is not required, but it can make removal of
the axle easier if the wheels are removed. Dis-
connect hydraulic lines at steering cylinder. In-
stall caps on cylinder and put plugs in hydraulic
lines. Caps will prevent spindles from turning
when axle is removed from under the lift truck.
3. Remove two dust covers from openings of bearing
caps.
4. Slide a floor jack or forks of another lift truck
under steering axle. Raise lifting device until it
holds weight of axle assembly. Remove four cap-
screws and washers that fasten two bearing caps
to frame. Remove bearing caps and slowly lower
axle assembly. Carefully remove axle assembly
from under lift truck.
Steering Axle Assembly Repair
Install
WARNING
Excessive play in the pivot bushings will result
in increased shock loadings to the pivot pins
and increased movement of the axle, and may
affect steering responsiveness. If movement in
the pivot bushings is more than 4 mm (0.16 in.),
or damage to the O-ring seals exists, replace
the bushings, flanges, and O-rings.
1. Install O-ring, spacer, and shims on each pivot
shaft. Lubricate pivot shafts with multipurpose
grease and install fiber bushing. See Figure 2
and Figure 4.
2. Use a floor jack or another lift truck to put steer-
ing axle into position in frame. Make sure fiber
bushings fit into mounts of frame.
3. Install bearing caps.
H6.00-7.00XL (H135-155XL, H135-155XL 2)
(F006, G006) units. Tighten capscrews to
320 N•m (236 lbf ft).
H8.00-16.00XL (H165-360XL) (D019, E007),
and H8.00-16.00XM (H170-360HD) (E019,
F007, F019, G007) units. Tighten capscrews to
380 N•m (280 lbf ft). After installation, make
sure there is zero clearance between shims and
frame. Add or remove shims as necessary to get
zero clearance.
4. Install dust covers in openings of bearing caps.
5. Remove plugs and caps, and connect hydraulic
lines to steering cylinder. Install wheels if they
were removed.
6. Operate steering system to remove air from sys-
tem. Turn steering wheel several times from one
wheel stop to other wheel stop. Check for hy-
draulic leaks.
7
Wheels and Hubs Repair (All Units) 1600 SRM 326

Wheels and Hubs Repair (All Units)

REMOVE AND DISASSEMBLE

WARNING
Completely remove the air from the tire before
removing the tire and wheel from lift truck.
Air pressure in the tires can cause the tire and
wheel parts to explode, causing serious injury
or death.

1. Raise axle to remove weight from tires, but have

tires still touching the floor. Loosen wheel nuts
just enough so they can be easily removed. Raise
axle so tires can be removed. Use a tire jack to
remove tires and wheels.

2. If a tire jack is not available, raise axle only

enough so tires are just touching the floor. Slide
tires from axle while they are still on the floor.

3. Remove wheels. Remove grease cap. Remove

cotter pin and castle nut. Remove bearing cone.
Slide hub from spindle. Remove inner bearing
cone and seal from spindle.

4. If wheel bearings must be replaced, use pry bars

to remove bearing cups and the wear sleeve. See
Figure 5.
1. PRY BAR 3. BEARING CAP
5. Remove grease seal from spindle. 2. BEARING CUP 4. O-RING

6. Repeat procedure for other hub. Figure 5. Bearing Cup Removal

CLEAN ASSEMBLE AND INSTALL

WARNING
Cleaning solvents can be flammable and toxic
and can cause skin irritation. When using
cleaning solvents, always follow the recom-
mendations of the manufacturer.
Clean all parts with solvent. Make sure bearings are
clean and dry.
INSPECT
Inspect spindle to ensure it does not have any rough
or sharp areas that would prevent the bearings from
being correctly installed. If necessary, smooth any
rough or sharp areas before installing the bearings.
1. If bearings in hubs must be replaced, use a press
to install new bearing cups in hub. Install a new
wear sleeve in wheel hub.
CAUTION
Do not damage the seals during installation.
2. Install grease seal on spindle. Lubricate bearing
cones and seal surfaces with grease. Make sure
bearings are filled with grease. Install bearing
cone on spindle.
3. Carefully slide hub onto spindle. On some units,
the hub weighs enough to require a lifting device
during installation. Install outer bearing cone.

8
1600 SRM 326 Wheels and Hubs Repair (All Units)

S3.50-5.50XL (S70-120XL) (D004), S3.50-
5.50XM (S70-120XM) (E004, F004), E3.50-
5.50XL (E70-120XL, E70-120XL 3 ) (C098),
and E3.50-5.50XL, E4.50XLS (E70-120Z,
E100ZS) (D098) units. Install solid wheel and
hub assembly onto spindle and install outer
bearing cone.
NOTE: For newer E3.50-5.50XL (E70-120XL,
E70-120XL 3) (C098) lift truck models and
E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS)
(D098) lift truck models, go to Step 5.
a. Lubricate studs and nuts as shown in Fig-
ure 6. Do not get any oil on outer surfaces
of wheel or flange of nut.
b. Start with wheel nut at the top and tighten
nuts to 65 to 130 N•m (48 to 96 lbf ft) in
sequence shown. Make sure there is no dirt
between wheel and hub. The wheel must fit
over the pilot surface and be tight against the
hub. Tighten nuts to 640 to 680 N•m (472 to
502 lbf ft).

4. Install castle nut. Tighten castle nut to 203 N•m WARNING

(150 lbf ft) while rotating wheel hub. Loosen cas-
tle nut to less than 27 N•m (20 lbf ft). Tighten
castle nut to 34 N•m (25 lbf ft). Tighten cas-
tle nut until cotter pin can be installed. Install
grease cap.
5. Tighten castle nut to 68 N•m (50 lbf ft). Back
off one quarter turn. Torque castle nut to 3 N•m
(25 lbf in). Insert and bend one prong of cotter
pin.
When the wheels have been installed, check
all wheel nuts after 2 to 5 hours of operation.
Tighten the nuts to the correct torque. When
the nuts stay tight after an 8-hour check, the
interval for checking can be extended to time
specified in the Periodic Maintenance section.
8. Repeat procedure for other wheel.

WARNING
Add air to the tires only in a safety cage. In-
spect safety cage for damage before use. When
adding air, use a clip on chuck with enough
hose to let the operator stand clear of the cage.

6. Install wheel on hub. Be careful not to damage

threads on studs.

7. H3.50-5.00XL (H70-110XL) (G005), H6.00-

7.00XL (H135-155XL, H135-155XL 2) (F006,
G006) units. Install wheels on the hubs.

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

Tighten nuts to 645 N•m (476 lbf ft).

H6.00-7.00XL (H135-155XL, H135-155XL 2)

(F006), and H6.00-7.00XL (H135-155XL X. NO LUBRICANT
(G006) units. Tighten nuts to 610 to 680 N•m
(450 to 502 lbf ft). 1. WHEEL RIM 4. WHEEL NUT
2. HUB 5. FLANGE
H8.00-16.00XL (H165-360XL) (D019, E007), 3. WHEEL STUD 6. LUBRICATE
and H8.00-16.00XM (H170-360HD) (E019,
Figure 6. Wheels Installation
F007, F019, G007) units. Use the following
procedure to install wheels on the hub:

9
Spindles and Bearings Repair (All Units)
Spindles and Bearings Repair (All Units)
REMOVE
CAUTION
Do not hit the threads or the nut of the tie rod.
1. Disconnect tie rods as described in Tie Rods Re-
pair (All Units) procedures.
2. Remove grease cap from spindle. Remove cap-
screws from bearing cap and shims. If necessary,
remove bearing cup from bearing cap. See Fig-
ure 5.
3. Tilt spindle and lift spindle from axle. If bearing
must be replaced, remove bearing and seals from
spindle. If wear sleeve and bearing cup must be
replaced, remove them from axle frame. See Fig-
ure 5.
4. Repeat procedure for other spindle.
CLEAN
WARNING
Cleaning solvents can be flammable and toxic
and can cause skin irritation. When using
cleaning solvents, always follow the recom-
mendations of the manufacturer.
Clean all parts in solvent. Make sure bearings are
clean and dry.
ASSEMBLE AND INSTALL
1. Install new seals on spindle. Lubricate seals with
grease. See Figure 1, Figure 2, Figure 3, Fig-
ure 4, Figure 7, and Figure 8.
2. Lubricate bearings with wheel bearing grease.
Make sure bearings are filled with grease. If nec-
essary, press new bearing cups into steering axle
frame and bearing cap. Install wear sleeve in
steering axle frame.
3. Install spindle in steering axle and make the fol-
lowing bearing adjustment:
a. H3.50-5.00XL (H70-110XL) (G005),
S3.50-5.50XL (S70-120XL) (D004),
10
1600 SRM 326
S3.50-5.50XM (S70-120XM) (E004, F004),
E3.50-5.50XL (E70-120XL, E70-120XL 3)
(C098), H6.00-7.00XL (H135-155XL,
H135-155XL 2) (F006, G006), and
E3.50-5.50XL, E4.50XLS (E70-120Z,
E100ZS) (D098) units. Install bearing
cap without O-ring. Measure clearance
between bearing cap and axle. Remove
bearing cap and install enough shims to
give a preload 0.00 to 0.127 mm (0.000
to 0.005 in.). Install O-ring on bear-
ing cap. Install bearing cap and cap-
screws. Tighten capscrews to 45 N•m
(33 lbf ft) for H3.50-5.00XL (H70-110XL)
(G005), S3.50-5.50XL (S70-120XL) (D004),
S3.50-5.50XM (S70-120XM) (E004, F004),
E3.50-5.50XL (E70-120XL, E70-120XL 3)
(C098), and H6.00-7.00XL (H135-155XL,
H135-155XL 2) (F006, G006) units and
52 N•m (38 lbf ft) for E3.50-5.50XL,
E4.50XLS (E70-120Z, E100ZS) (D098).
NOTE: Spindle bearings must have no clearance. In-
stall shims 0.00 to 0.13 mm (0.000 to 0.005 in.) less
than measured clearance.
b. H8.00-16.00XL (H165-360XL) (D019,
E007), and H8.00-16.00XM (H170-360HD)
(E019, F007, F019, G007) units. Install
bearing cap without shims. Tighten three
capscrews to 20 N•m (15 lbf ft). Rotate
spindle, then tighten capscrews to 20 N•m
(15 lbf ft) again. Loosen capscrews and
tighten again to 14 N•m (10 lbf ft). Mea-
sure gap. Install correct amount of shims to
equal the gap. Tighten capscrews to 77 N•m
(56.8 lbf ft).
4. Install grease cap on top of steering axle. Use a
sealant between grease cap and steering axle.
5. Install tie rod as described in Tie Rods Repair (All
Units) procedures.
6. Repeat procedure for other spindle.
1600 SRM 326
Tie Rods Repair (All Units)
REMOVE
CAUTION
Do not hit the threads or the nut of the tie rod.
1. H3.50-5.00XL (H70-110XL) (G005), S3.50-
5.50XL (S70-120XL) (D004), S3.50-5.50XM
(S70-120XM) (E004, F004), E3.50-5.50XL
(E70-120XL, E70-120XL 3) (C098), H6.00-
7.00XL (H135-155XL, H135-155XL 2) (F006,
G006), and E3.50-5.50XL, E4.50XLS (E70-
120Z, E100ZS) (D098) units. Use the following
procedure to remove tie rods on these lift trucks
(see Figure 1, Figure 3, Figure 4):
a. Remove cotter pin and castle nut. To loosen
stud, hold a large hammer behind spindle
arm of spindle. Hit side of spindle arm with
another large hammer. The shock of the
hammer from hitting the spindle arm will
normally loosen tapered stud.
b. Spindle and tie rod can be removed as a unit.
Disconnect tie rod at retaining pin inside
dust cover.
S3.50-5.50XL (S70-120XL) (D004), S3.50-
5.50XM (S70-120XM) (E004, F004), E3.50-
5.50XL (E70-120XL, E70-120XL 3) (C098),
and E3.50-5.50XL, E4.50XLS (E70-120Z,
E100ZS) (D098) units. It is necessary to
raise steer wheels 8 to 15 cm (3 to 6 in.) from
the floor. Remove lower snap ring, and use a
hammer and a drift to push pins for tie rods
upward. See Figure 7.
2. H8.00-16.00XL (H165-360XL) (D019, E007),
and H8.00-16.00XM (H165-360HD) (E019,
F007, F019, G007) units. Remove capscrew,
anchor pin, and tie rod pin from each end of the
tie rod. See Figure 8.
CLEAN
WARNING
Cleaning solvents can be flammable and toxic
and can cause skin irritation. When using
Tie Rods Repair (All Units)
cleaning solvents, always follow the recom-
mendations of the manufacturer.
Clean all parts except the ends of the tie rods in sol-
vent. Make sure bearings are clean.
INSTALL
1. Use the following procedure to install tie rod to
spindle arm or steering cylinder (see Figure 1,
Figure 3, Figure 4, Figure 7, and Figure 8):
a. H3.50-5.00XL (H70-110XL) (G005),
S3.50-5.50XL (S70-120XL) (D004),
E3.50-5.50XL (E70-120XL, E70-120XL 3)
(C098), H6.00-7.00XL (H135-155XL,
H135-155XL 2) (F006, G006), and
E3.50-5.50XL, E4.50XLS (E70-120Z,
E100ZS) (D098) units. Install tie rod
end into spindle arm and tighten castle nut
to 165 N•m (122 lbf ft). For E3.50-5.50XL,
E4.50XLS (E70-120Z, E100ZS) (D098)
units tighten castle nut to 175 N•m
(129 lbf ft). If the hole in the tie rod end
and the slot in the castle nut do not align,
tighten castle nut until cotter pin can be
installed.
b. S3.50-5.50XM (S70-120XM) (E004, F004)
units. Install tie rod end into spindle arm
and tighten castle nut to 175 N•m (129 lbf ft).
If the hole in the tie rod end and the slot in
the castle nut do not align, tighten castle nut
until cotter pin can be installed.
c. H8.00-16.00XL (H165-360XL) (D019,
E007) and H8.00-16.00XM (H170-360HD)
(E019, F007, F019, G007) units. Install
seals on tie rod bushings. Use an alignment
pin to align seals with bushings. Lubricate
pin with an antiseize compound and install
tie rod pin into the tie rod and cylinder rod or
spindle arm. Grease fittings on tie rod pins
must face downward. Install anchor pin and
capscrew to fasten the pin. Tighten capscrew
in the anchor pin to 44 N•m (32 lbf ft).
NOTE: Tie rods do not have an adjustment.
11
Tie Rods Repair (All Units) 1600 SRM 326

1. STEER AXLE 14. BEARING CUP

2. STEERING CYLINDER 15. SEAL
3. BOOT 16. WEAR SLEEVE
4. CLAMP 17. R.H. SPINDLE
5. CLAMP 18. CAP
6. PIN 19. BEARING CONE
7. SNAP RING 20. SEAL
8. TIE ROD ASSEMBLY 21. SEAL
9. CASTLE NUT 22. O-RING
10. COTTER PIN 23. SHIM(S)
11. WASHER 24. CAPSCREW
12. L.H. SPINDLE 25. LUBE FITTING
13. BEARING CONE 26. BEARING CAP

Figure 7. Steering Axle S3.50-5.50XL (S70-120XL) (D004), S3.50-5.50XM (S70-120XM) (E004, F004),
E3.50-5.50XL (E70-120XL, E70-120XL 3) (C098), and E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS)
(D098)

12
1600 SRM 326 Tie Rods Repair (All Units)

A. H8.00-12.00XL (H165-280XL) (D019) AND H8.00-12.00XM (H170-280HD) (E019, F019)

B. H13.00-16.00XL (H300-360XL) (E007) AND H13.00-16.00XM (H300-360HD) (F007, G007)
1. AXLE FRAME 13. WHEEL HUB
2. STEERING CYLINDER 14. HUB CAP
3. ANCHOR PIN 15. NUT
4. CAPSCREW 16. COTTER PIN
5. PIN, TIE ROD 17. BEARING ASSEMBLY
6. TIE ROD 18. ADHESIVE
7. BEARING CUP 19. GREASE FITTING
8. BEARING CONE 20. BEARING CAP
9. GREASE CAP 21. SHIMS
10. SEAL 22. BUSHING, TIE ROD
11. WEAR SLEEVE 23. PILOT SURFACE
12. SPINDLE

Figure 8. Steering Axle H8.00-16.00XL (H165-360XL) (D019, E007) and H8.00-16.00XM (H170-360HD)
(E019, F007, F019, G007)

13
Steering Cylinder Repair
Steering Cylinder Repair
REMOVE AND DISASSEMBLE
NOTE: End caps of the steering cylinder are held in
the shell by the cylinder mount capscrews. To pre-
vent oil leaks at the caps, hold caps on shell during
removal. See Figure 9.
1. Disconnect hydraulic lines at steering cylinder.
Install caps on cylinder fittings and put plugs in
hydraulic lines.
2. Disconnect tie rods as described in the Tie Rods
Repair (All Units) procedures.
3. Loosen the capscrews that hold the cylinder to
the axle frame (do not remove capscrews) enough
to move the end caps to the maximum outer po-
sition of the mounting place.
4. Move the shell to one side of the assembly, to cap
one side of the shell.
5. Measure the distance from the shell to the end
gap and install shims to fit.
6. Remove capscrews and washers that fasten
cylinder to axle frame. Hold end caps on shell
and remove steering cylinder.
7. Hold end of steering cylinder over a drain pan.
Remove hydraulic fitting cap from each end cap.
Push rod toward end of shell that is over drain
pan. Oil will drain from cylinder. Repeat proce-
dure for other end.
8. Remove one end cap from shell. Carefully pull
rod from shell. Keep rod in center of shell dur-
ing removal. Remove end cap from rod. Re-
move other end cap from shell. Remove all seals,
wipers, and O-rings.
CLEAN AND INSPECT
WARNING
Cleaning solvents can be flammable and toxic
and can cause skin irritation. When using
cleaning solvents, always follow the recom-
mendations of the manufacturer.
Compressed air can move particles so they
cause injury to the user or to other personnel.
Make sure the path of the compressed air is
14
1600 SRM 326
away from all personnel. Wear protective gog-
gles or a face shield to prevent injury to the
eyes.
1. Clean all parts in solvent. Use compressed air to
dry parts.
2. Inspect piston rod for grooves or damage. Re-
move small scratches with fine emery cloth. In-
spect cylinder bore for damage. Inspect mounts
for cracks.
ASSEMBLE AND INSTALL
CAUTION
Do not damage the O-rings, seals, or wipers
during installation.
1. Lubricate O-rings, seals, and wipers with O-ring
lubricant. Install O-rings, seals, and wipers. See
Figure 9.
2. Carefully slide rod into shell. Keep rod in center
of shell during installation. Slide end cap into
shell. Install other end cap on rod and shell. Put
caps on hydraulic fittings of end caps.
3. Hold end caps and install cylinder on axle frame
using capscrews and washers. Make sure end
caps are fully engaged with shell.
H3.50-5.00XL (H70-110XL) (G005), S3.50-
5.50XL (S70-120XL) (D004), S3.50-5.50XM
(S70-120XM) (E004, F004), E3.50-5.50XL
(E70-120XL, E70-120XL 3) (C098), and
E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS)
(D098) units. Tighten capscrews to 225 N•m
(166 lbf ft).
H6.00-7.00XL (H135-155XL, H135-155XL 2)
(F006, G006) units. Tighten capscrews to
245 N•m (181 lbf ft).
H8.00-16.00XL (H165-360XL) (D019, E007),
and H8.00-16.00XM (H170-360HD) (E019,
F007, F019, G007) units. Tighten capscrews to
435 N•m (320 lbf ft).
4. Install tie rods as described in the Tie Rods Re-
pair (All Units) procedures.
1600 SRM 326 Troubleshooting

5. Remove plugs and caps, and connect hydraulic cylinders and system. Turn steering wheel sev-
lines to steering cylinder. Start engine, and eral times from one wheel stop to the other wheel
operate steering system to remove air from stop.

1. SHELL 5. O-RING
2. END CAP 6. BACKUP RING
3. PISTON ROD 7. ROD SEAL
4. PISTON SEAL 8. WIPER SEAL

Figure 9. Steering Cylinder

Troubleshooting

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

The steering wheels do not The hydraulic oil level is low or there Fill tank. Check for leaks.
move when the steering is no hydraulic oil in the tank.
wheel is turned.

The steering control unit is dam- Repair or install new control unit.
aged.

No oil flow from the steering control Repair or install new components.
unit to the steering cylinder. Check for leaks.

Slow or difficult steering. Relief valve for the steering system Adjust or install new relief valve.
needs adjustment.

Low oil pressure from the hydraulic Check for restrictions. See Trou-
pump. bleshooting Chart in the Hydraulic
System SRM for your lift truck.

Seal in the steering cylinder has a Install new seal.

leak.

Steering control unit is worn or has Repair or install new control unit.
damage.

15
Troubleshooting 1600 SRM 326

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

Steering wheel turns the The hydraulic lines are not con- Connect lines properly. Remove air
tires in the wrong direction. nected correctly at the steering from system.
cylinder or at the steering control
unit.

Steering function contin- The steering control unit was assem- Repair or install new control unit.
ues after the steering wheel bled wrong or has damage.
stops.

There is air in the steering The oil level in the tank is low. Add hydraulic oil as necessary.
system. Check for leaks.

Air was not removed after repair to Remove air from system.
the hydraulic or steering system.

The hydraulic pump has an air leak Repair system. Remove air from sys-
at the inlet. tem.

16
 TECHNICAL PUBLICATIONS

1600 SRM 326 3/05 (10/03)(9/03)(11/01)(8/01)(8/00)(6/94)(7/89)(5/88)(5/86) Printed in U.S.A.