Hyster F004 (S4.50XM Europe) Forklift Service Repair Manual

SERVICE REPAIR S3.50-5.50XM (Europe) [F004]

PART NO. 1510478

8000 SRM 988

8000 SRM 988

Electrical System

Tire Sizes Model

Steering

Drive

S3.50 (S70XM)

18 × 6 × 12.1

22 × 9 × 16

S4.00 (S80XM)

18 × 7 × 12.1

22 × 9 × 16

S4.50-5.50XM (S100-120XM)

18 × 8 × 12.1

22 × 12 × 16

Hydraulic System Item

Specification

Hydraulic System Capacity

39.3 liter (10.4 gal)

Hydraulic Tank Capacity (Total Tank Capacity)

35.5 liter (9.4 gal)

Relief Pressures* Main Control Valve Lift Circuit

22.0 MPa (3200 psi)

Tilt and Auxiliary Circuit

15.5 MPa (2250 psi)

Steering Circuit

10.7 MPa (1550 psi)

Hydraulic Pump** Capacity

89 liter/min (23.5 gal/min)

Priority Flow

None

*Oil temperature 50 to 100 C (120 to 210 F) and engine speed at 2500 rpm. **Oil temperature 80 to 100 C (176 to 210 F) and engine speed at 2550 rpm.

Electrical System Alternator Output GM V-6

Perkins

38 Amps @ 650 rpm (Hot) 62 Amps @ 2200 rpm (Hot) 42 Amps @ 650 rpm (Hot) 62 Amps @ 2500 rpm (Hot) All Models - 12 Volt, Negative Ground

1

Capacities

8000 SRM 988

Engine Specifications Item

GM V-6 4.3

Perkins 1004-4

6

4

1-6-5-4-3-2

1-3-4-2

Bore

102.00 mm (4.00 in.)

103.00 mm (4.055 in.)

Stroke

88.40 mm (3.50 in.)

127.00 mm (5.00 in.)

Number of Cylinders Firing Order

3

4.3 liter (262.4 in. )

4.0 liter (244.0 in. 3 )

9.3:1

18.5:1

675 to 725 rpm

725 to 775 rpm

2400 to 2500 rpm

2450 to 2550 rpm

Broken in Engine

1810 (Gas) 1735 (LPG) +300/-50 rpm

2050 rpm ±50 rpm

New Engine

1710 (Gas) 1635 (LPG) +300/-50 rpm

1950 rpm ±50 rpm

0 BTDC at 650 rpm

2 BTDC (Static)

207 to 380 kPa (30 to 55 psi)

280 kPa (41 psi)

Intake

Not adjustable

0.20 mm (0.008 in.) Cold

Exhaust

Not adjustable

0.45 mm (0.018 in.) Cold

Displacement Compression Ratio Idle Speed Governor Speed Stall Speed

Timing Oil Pressure (Minimum) Valve Clearance

Capacities Item

Quantity

Engine Oil GM V-6

4.7 liter (5.0 qt)

Perkins 1004-4

8.0 liter (8.5 qt)

Cooling System

18.9 liter (20.0 qt)

Hydraulic Tank (Total Tank Capacity)

35.5 liter (9.4 gal)

Transmission

15.1 liter (16.0 qt)

Differential Fuel Tank Brake Fluid

2

5.7 liter (6.0 qt) 34.0 liter (9.1 gal) 0.2 liter (0.5 pt)

8000 SRM 988

Lift Truck Weights

Lift Truck Weights Unit

kg

lb

S3.50XM (S70XM)

5,515

11,937

S4.00XM (S80XM)

5,780

12,742

S4.00XM BCS (S80XM BCS)

5,995

13,217

S4.50XM (S100XM)

6,768

14,920

S4.50XM BCS (S100XM BCS)

7,245

15,973

S5.50XM (S120XM)

7,433

16,387

S5.50XMS (S120XMS)

7,527

16,589

S5.50XMSPRS (S120XMSPRS)

7,820

17,241

NOTE: Lift trucks equipped with overhead guard, mast, carriage, load backrest, forks, and LPG engine.

NOTE: S3.50-4.00XM (S70-80XM) and S4.00XM BCS (S80XM BCS) have 3099 mm (122 in.) two-stage LFL mast.

S4.50-5.50XM (S100-120XM), S4.50XM BCS (S100XM BCS), S5.50XMS (S120XMS), and S5.50XMSPRS (S120XMSPRS) have 2845 mm (112 in.) two-stage LFL mast.

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Transmission Pressures (Single-Speed Powershift)

8000 SRM 988

Transmission Pressures (Single-Speed Powershift) Port No.

Transmission Pressures*

1

System Pressure

1170 to 1380** kPa (170 to 200 psi) **Relief pressure 1379 kPa (200 psi)

2

Forward Clutch

895 to 1035 kPa (130 to 150 psi)

3

Reverse Clutch

895 to 1035 kPa (130 to 150 psi)

4

Torque Converter

655 to 760 kPa (95 to 110 psi)

5

Lubrication Pressure

35 to 105 kPa (5 to 15 psi)

6

Modulator Pressure

Pressure Variation

*Oil temperature at least 50 to 65 C (120 to 150 F) and engine speed at 2000 rpm.

NOTE: The difference between Forward and Reverse clutch pressure must not be more than: • Manufacturing limit 48 kPa (7 psi) • Service limit 70 kPa (10 psi)

4

8000 SRM 988

Mast Speeds

Mast Speeds Two-Stage Full Free-Lift Mast Unit

Lifting No Load

Lowering Rated Load

No Load

Rated Load

m/sec

ft/min

m/sec

ft/min

m/sec

ft/min

m/sec

ft/min

S3.50-4.00XM (S70-80XM)

0.60

118

0.56

111

0.36

70

0.50

99

S4.50XM (S100XM)

0.51

101

0.48

94

0.32

63

0.45

89

S5.50XM (S120XM)

0.51

101

0.44

87

0.32

63

0.47

92

Two-Stage Limited Free-Lift Mast Unit

Lifting No Load

Lowering Rated Load

No Load

Rated Load

m/sec

ft/min

m/sec

ft/min

m/sec

ft/min

m/sec

ft/min

S3.50-4.00XM (S70-80XM)

0.68

134

0.62

123

0.47

93

0.55

108

S4.50-5.50XM (S100-120XM)

0.55

108

0.53

105

0.42

82

0.51

100

Three-Stage Full Free-Lift Unit

Lifting No Load

Lowering Rated Load

No Load

Rated Load

m/sec

ft/min

m/sec

ft/min

m/sec

ft/min

m/sec

ft/min

S3.50-4.00XM (S70-80XM)

0.63

124

0.58

114

0.44

87

0.53

105

S4.50XM (S100XM)

0.52

102

0.51

100

0.39

76

0.47

92

S5.50XM (S120XM)

0.52

102

0.45

89

0.39

76

0.47

92

5

Torque Specifications

8000 SRM 988

Torque Specifications FRAME

TRANSMISSION

Counterweight Capscrew 1022 N•m (755 lbf ft)

Transmission Cover Capscrews 40 N•m (30 lbf ft)

ENGINE - GM V-6

Oil Pump Capscrews 40 N•m (30 lbf ft)

Intake Manifold Capscrews 47 N•m (35 lbf ft) Valve Cover Capscrews 10 N•m (7 lbf ft) Exhaust Manifold Capscrews 35 N•m (25 lbf ft) Center Port 25 N•m (20 lbf ft) Outer Ports 50 N•m (35 lbf ft) Camshaft Sprocket Capscrews 25 N•m (20 lbf ft) Vibration Damper Capscrew 81 N•m (60 lbf ft) Main Bearing Cap Capscrews 70 N•m (50 lbf ft) Connecting Rods 45 N•m (35 lbf ft) Flywheel Capscrews 80 N•m (60 lbf ft) Flywheel Housing Capscrews 50 N•m (40 lbf ft) Engine Mount to Engine Capscrews 30 N•m (25 lbf ft) Engine Mount to Mount Plate Bolts 65 N•m (50 lbf ft) Engine Mount to Flywheel Housing Capscrews 165 N•m (120 lbf ft) Engine Mount Bolts 120 N•m (90 lbf ft)

ENGINE - PERKINS Engine Mount to Engine Capscrews 65 N•m (50 lbf ft) Engine Mount Bolts 120 N•m (90 lbf ft)

6

Torque Converter Housing Capscrews 40 N•m (30 lbf ft) Control Valve Capscrews 20 N•m (15 lbf ft) Differential Case Capscrews 140 N•m (105 lbf ft) Ring Gear Capscrews 140 N•m (105 lbf ft) Output Gear Nut 750 N•m (550 lbf ft) Torque Converter Drive Plate Capscrews 45 N•m (35 lbf ft) Differential Bearing Caps 225 N•m (166 lbf ft)

DRIVE AXLE Brake Assembly to Axle Nuts 340 to 375 N•m (251 to 277 lbf ft) Axle Mount to Frame 320 to 350 N•m (235 to 258 lbf ft) Axle Shaft Flange Capscrews 225 to 250 N•m (166 to 184 lbf ft) Axle Housing to Transmission Capscrews 65 N•m (48 lbf ft) Hub Adjustment Nut 205 N•m (151 lbf ft) Initial 35 N•m (26 lbf ft) Final Wheel Nuts 610 to 680 N•m (450 to 502 lbf ft)

STEERING SYSTEM Axle Mount Capscrews 90 N•m (66 lbf ft)

8000 SRM 988 Bearing Cap for Spindle 45 N•m (35 lbf ft) Tie Rod Castle Nut 175 N•m (129 lbf ft) Steering Cylinder Capscrews 225 N•m (166 lbf ft) Wheel Bearing Adjustment Nut 200 N•m (148 lbf ft) Initial 35 N•m (26 lbf ft) Final

BRAKE SYSTEM Back Plate Capscrews 340 N•m (251 lbf ft)

HYDRAULIC SYSTEM Capscrews for Special Blocks for Pump Drive Chain 20 N•m (15 lbf ft)

MAIN CONTROL VALVE Through Bolt Nuts (5/16 in.)

20 N•m (15 lbf ft) Through Bolts Nuts (3/8 in.)

45 N•m (35 lbf ft)

Torque Specifications

TILT CYLINDERS Piston Nut 400 to 440 N•m (295 to 325 lbf ft) Retainer 400 to 500 N•m (295 to 370 lbf ft) Rod End Lock Capscrews 90 N•m (66 lbf ft) Anchor Pin Retainer Capscrews 77 N•m (57 lbf ft)

LIFT CYLINDERS Main Lift Cylinder Retainer Cap 340 to 410 N•m (251 to 302 lbf ft) Free-Lift Cylinder Retainer Cap 400 to 475 N•m (295 to 350 lbf ft) Free-Lift Cylinder Mount Capscrews 121 N•m (89 lbf ft)

MAST Pivot Pin Capscrews 320 N•m (236 lbf ft) Sideshift Carriage Lower Hook Capscrews 78 N•m (58 lbf ft) Side Roller Mount Capscrews 90 N•m (66 lbf ft)

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1600 SRM 326

Description

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.

1.

2.

3.

4.

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6.

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10.

11.

STEERING AXLE COVER CLAMP COTTER PIN SNAP RING TIE ROD AND BUSHING CASTLE NUT CAPSCREW CAP BEARING CONE BEARING CUP

12.

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22.

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.

SEAL WEAR SLEEVE SPINDLE (RH) SPINDLE (LH) O-RING SHIM BEARING CAP LUBE FITTING SCREW SEALANT STEER CYLINDER

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30.

31.

OIL SEAL CAP (HUB) WASHER MOUNT PLATE LOCKWASHER WHEEL GREASE FITTING PIN

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/E098) 1

Description

1600 SRM 326

Figure 2. Steering Axle H8.00-16.00XL (H165-360XL) (D019, E007), H8.00-12.00XM (H170-280HD) (F007, G007, H007), H13.00-14.00XM (H300-330HD) (E019, F019, G019), H16.00XM-6 (H360HD) (E019, F019, G019), H10.00-12.00XM-12EC (H360HD-EC) (E019, F019, G019)

2

1600 SRM 326

Description Legend for Figure 2

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

HUB ASSEMBLY STUD BEARING CUP WEAR SLEEVE HUB CAP COTTER PIN NUT WASHER LOCKWASHER CAPSCREW BEARING CONE BEARING CAP SHIM OIL SEAL LUBE FITTING

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

STEERING AXLE STEER CYLINDER SPINDLE (LH) SEAL BEARING CONE SPINDLE (RH) HUB BEARING CUP STUD (WHEEL) WEAR SLEEVE TIE ROD

16.

17.

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27.

28.

29.

12.

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21.

22.

CAPSCREW NUT (SPINDLE) CAP (HUB) SHIM CAP ASSEMBLY PIN SNAP RING O-RING GREASE FITTING COTTER PIN MOUNT

PIN PLUG SPINDLE FRAME SHAFT TIE ROD BUSHING ANCHOR STEERING CYLINDER FITTING O-RING FLANGE LUG NUT HANGER CUP

23.

24.

25.

26.

27.

28.

29.

30.

31.

32.

33.

PLATE WASHER NUT LUG NUT PIN PLUG AND SEALANT CLAMP OIL SEAL BEARING CAP CAPSCREW COVER

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

3

Description

1600 SRM 326

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

4

1600 SRM 326

Description Legend for Figure 4

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

STEERING AXLE SHAFT SEAL PIN SNAP RING TIE ROD CAPSCREW LOCKWASHER PLUG BEARING CONE BEARING CUP WEAR SLEEVE SPINDLE O-RING

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/ E098) 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) H8.00-12.00XM (H170-280HD) (F007, G007, H007), H13.00-14.00XM (H300-330HD) (E019, F019, G019), H16.00XM-6 (H360HD) (E019, F019, G019), H10.0012.00XM-12EC (H360HD-EC) (E019, F019, G019) 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

15.

16.

17.

18.

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26.

27.

SHIM SCREW OIL SEAL HUB STUD WHEEL NUT WASHER COTTER PIN CAP GREASE FITTING BUSHING BEARING CAP STEER CYLINDER

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 pressure. 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 controlled 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 bearings 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.

5

Steering Axle Assembly Repair

1600 SRM 326

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/E098) Remove WARNING Put the lift truck on blocks. Follow the procedures for raising the lift truck described in the Operating Manual for this lift truck. The surface 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 removed. 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 hydraulic 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 brackets under rubber mounts. Remove brackets and

6

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 Figure 1 and 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 steering 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 88 N•m (65 lbf ft).

S3.50-5.50XL (S70-120XL) (D004), S3.505.50XM (S70-120XM) (E004, F004), E3.505.50XL (E70-120XL, E70-120XL 3) (C098), and E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (D098/E098) 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 system. Turn steering wheel several times from one wheel stop to other wheel stop. Check for hydraulic leaks.

1600 SRM 326

Steering Axle Assembly Repair

STEERING AXLE H6.00-7.00XL (H135-155XL, H135-155XL 2) (F006, G006), H8.00-16.00XL (H165-360XL) (D019, E007), AND H8.00-12.00XM (H170-280HD) (F007, G007, H007), H13.00-14.00XM (H300-330HD) (E019, F019, G019), H16.00XM-6 (H360HD) (E019, F019, G019), H10.00-12.00XM-12EC (H360HD-EC) (E019, F019, G019)

Install

Remove

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.

WARNING Put the lift truck on blocks. Follow the procedures for raising the lift truck described in the Operating Manual for this lift truck. The surface 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. Disconnect hydraulic lines at steering cylinder. Install 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 capscrews 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.

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.

2. Use a floor jack or another lift truck to put steering 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 H8.00-12.00XM (H170-280HD) (F007, G007, H007), H13.00-14.00XM (H300-330HD) (E019, F019, G019), H16.00XM-6 (H360HD) (E019, F019, G019), H10.00-12.00XM-12EC (H360HD-EC) (E019, F019, G019) 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 system. Turn steering wheel several times from one wheel stop to other wheel stop. Check for hydraulic 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.

CLEAN WARNING Cleaning solvents can be flammable and toxic and can cause skin irritation. When using cleaning solvents, always follow the recommendations 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.

ASSEMBLE AND INSTALL 3. Remove hub cap, cotter pin and washer.

For 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/E098) lift truck models, see Figure 1, for H8.00-16.00XL (H165-360XL) (D019, E007) and H8.00-12.00XM (H170-280HD) (F007, G007, H007), H13.00-14.00XM (H300-330HD) (E019, F019, G019), H16.00XM-6 (H360HD) (E019, F019, G019), H10.00-12.00XM-12EC (H360HD-EC) (E019, F019, G019) lift truck models, see Figure 2, for H3.50-5.00XL (H70-110XL) (G005) lift truck models see figure Figure 3, and for H6.00-7.00XL (H135-155XL, H135-155XL 2) (F006, G006) lift truck models, see Figure 4.

Remove outer bearing cone, outer bearing cup, and remove hub from spindle.

4. Remove inner bearing cone, inner bearing cup and wear sleeve.

5. Remove grease seal from spindle.

6. Repeat procedure for other hub.

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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.

S3.50-5.50XL (S70-120XL) (D004), S3.505.50XM (S70-120XM) (E004, F004), E3.505.50XL (E70-120XL, E70-120XL 3 ) (C098), and E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (D098/E098) units. Install solid wheel and hub assembly onto spindle and install outer bearing cone.

1600 SRM 326

Wheels and Hubs Repair (All Units)

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/E098) lift truck models, go to Step 5.

4. Install washer and castle nut. Tighten castle nut to 203 N•m (150 lbf ft) while rotating wheel hub.

Loosen castle nut to less than 27 N•m (20 lbf ft).

Tighten castle nut to 34 N•m (25 lbf ft). Tighten castle 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). Tighten nut to nearest slot and lock in place with cotter pin.

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).

WARNING 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. Inspect 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), H6.007.00XL (H135-155XL, H135-155XL 2) (F006, G006) units. Install wheels on the hubs.

H3.50-5.00XL (H70-110XL) (G005) Tighten nuts to 645 N•m (476 lbf ft).

units.

H6.00-7.00XL (H135-155XL, H135-155XL 2) (F006), and H6.00-7.00XL (H135-155XL (G006) units. Tighten nuts to 610 to 680 N•m (450 to 502 lbf ft).

H8.00-16.00XL (H165-360XL) (D019, E007), and H8.00-12.00XM (H170-280HD) (F007, G007, H007), H13.00-14.00XM (H300-330HD) (E019, F019, G019), H16.00XM-6 (H360HD) (E019, F019, G019), H10.00-12.00XM-12EC (H360HD-EC) (E019, F019, G019) units. Use the following procedure to install wheels on the hub:

X. NO LUBRICANT 1. WHEEL RIM 2. HUB 3. WHEEL STUD

4. WHEEL NUT 5. FLANGE 6. LUBRICATE

Figure 5. Wheels Installation

a. Lubricate studs and nuts as shown in Figure 5. Do not get any oil on outer surfaces of wheel or flange of nut.

9

Spindles and Bearings Repair (All Units)

1600 SRM 326

Spindles and Bearings Repair (All Units) REMOVE 1. Remove wheels and hubs as described in Wheels and Hubs Repair (All Units)

(G005) , see Figure 3. For Lift truck models H6.00-7.00XL (H135-155XL, H135-155XL 2) (F006, G006), see Figure 4.

5. Repeat procedure for other spindle.

CAUTION Do not hit the threads or the nut of the tie rod.

2. Disconnect tie rods as described in Tie Rods Repair (All Units) procedures.

3. Remove grease cap from spindle, For lift truck models 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/E098), see Figure 1. For lift truck models H8.00-16.00XL (H165-360XL) (D019, E007) and H8.00-12.00XM (H170-280HD) (F007, G007, H007), H13.00-14.00XM (H300-330HD) (E019, F019, G019), H16.00XM-6 (H360HD) (E019, F019, G019), H10.00-12.00XM-12EC (H360HD-EC) (E019, F019, G019) see Figure 2.

For lift truck models H3.50-5.00XL (H70-110XL) (G005) , see Figure 3. For Lift truck models H6.00-7.00XL (H135-155XL, H135-155XL 2) (F006, G006), see Figure 4. Remove capscrews from bearing cap and shims. If necessary, remove bearing cup from bearing cap. See Figure 6.

4. Tilt spindle and lift spindle from axle. If bearings must be replaced, remove upper and lower bearings and seals from spindle. If wear sleeves and bearing cups must be replaced, remove them from axle frame. For lift truck models 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/E098), see Figure 1. For lift truck models H8.00-16.00XL (H165-360XL) (D019, E007) and H8.00-12.00XM (H170-280HD) (F007, G007, H007), H13.00-14.00XM (H300-330HD) (E019, F019, G019), H16.00XM-6 (H360HD) (E019, F019, G019), H10.00-12.00XM-12EC (H360HD-EC) (E019, F019, G019) see Figure 2.

For lift truck models H3.50-5.00XL (H70-110XL)

10

CLEAN WARNING Cleaning solvents can be flammable and toxic and can cause skin irritation. When using cleaning solvents, always follow the recommendations of the manufacturer.

Clean all parts in solvent. Make sure bearings are clean and dry.

1. PRY BAR 2. BEARING CUP

3. BEARING CAP

Figure 6. Bearing Cup Removal

1600 SRM 326

ASSEMBLE AND INSTALL 1. Install new seals on spindle. Lubricate seals with grease. See Figure 1, Figure 2, Figure 3, Figure 4, Figure 7, and Figure 8.

2. Lubricate bearings with wheel bearing grease.

Make sure bearings are filled with grease. If necessary, 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 following bearing adjustment: a. 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/E098) 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 bearing cap. Install bearing cap and capscrews.

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),

Spindles and Bearings Repair (All Units) 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/E098).

NOTE: Spindle bearings must have no clearance. Install 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 H8.00-12.00XM (H170-280HD) (F007, G007, H007), H13.00-14.00XM (H300-330HD) (E019, F019, G019), H16.00XM-6 (H360HD) (E019, F019, G019), H10.00-12.00XM-12EC (H360HDEC) (E019, F019, G019) 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). Measure 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.

11

Tie Rods Repair (All Units)

1600 SRM 326

Tie Rods Repair (All Units) REMOVE 1. Remove wheels and hubs as described in Wheel and Hub Repair (All Units) procedures.

CAUTION Do not hit the threads or the nut of the tie rod.

NOTE: Spindle and tie rod can be removed as a unit or separately.

2. H3.50-5.00XL (H70-110XL) (G005), S3.505.50XL (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/E098) 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. Disconnect tie rod at retaining pin inside dust cover. 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.

3. H8.00-16.00XL (H165-360XL) (D019, E007), and H8.00-12.00XM (H170-280HD) (F007, G007, H007), H13.00-14.00XM (H300-330HD) (E019, F019, G019), H16.00XM-6 (H360HD) (E019, F019, G019), H10.00-12.00XM-12EC (H360HD-EC) (E019, F019, G019) units. Remove capscrew, anchor pin, and tie rod pin from each end of the tie rod. See Figure 8.

4. H6.00-7.00XL (H135-155XL, H135-155XL 2) (F006, G006) units. Remove two snap rings

12

and pin from tie rod and steer cylinder rod. Remove two snap rings and pin from tie rod and spindle arm. Remove tie rod from steer cylinder rod and spindle arm. See Figure 4.

CLEAN WARNING Cleaning solvents can be flammable and toxic and can cause skin irritation. When using cleaning solvents, always follow the recommendations of the manufacturer.

Clean all parts except the ends of the tie rods in solvent. 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): (H70-110XL) (G005), a. H3.50-5.00XL (S70-120XL) (D004), S3.50-5.50XL E3.50-5.50XL (E70-120XL, E70-120XL 3) (H135-155XL, (C098), H6.00-7.00XL (F006, G006), and H135-155XL 2) E4.50XLS (E70-120Z, E3.50-5.50XL, Install E100ZS) (D098/E098) units. tie rod end into spindle arm and tighten castle nut to 165 N•m (122 lbf ft). For E4.50XLS (E70-120Z, E3.50-5.50XL, E100ZS) (D098/E098) 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.

1600 SRM 326

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8.

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STEER AXLE STEERING CYLINDER BOOT CLAMP CLAMP PIN SNAP RING TIE ROD ASSEMBLY CASTLE NUT COTTER PIN WASHER L.H. SPINDLE BEARING CONE

Tie Rods Repair (All Units)

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BEARING CUP SEAL WEAR SLEEVE R.H. SPINDLE CAP BEARING CONE SEAL SEAL O-RING SHIM(S) CAPSCREW LUBE FITTING 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/E098) c. H8.00-16.00XL (H165-360XL) (D019, E007) and H8.00-12.00XM (H170-280HD) (F007, G007, H007), H13.00-14.00XM (H300-330HD) (E019, F019, G019), H16.00XM-6 (H360HD) (E019, F019, G019), H10.00-12.00XM-12EC (H360HDEC) (E019, F019, G019) 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.

13

Tie Rods Repair (All Units)

1600 SRM 326

A. H8.00-12.00XL (H165-280XL) (E007) AND H8.00-12.00XM (H170-280HD) (F007, G007, H007) B. H13.00-16.00XL (H300-360XL) (D019), H13.00-14.00XM (H300-330HD) (E019, F019, G019), H16.00XM-6 (H360HD) (E019, F019, G019), AND H10.00-12.00XM-12EC (H360HD-EC) (E019, F019, G019) 1.

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AXLE FRAME STEERING CYLINDER ANCHOR PIN CAPSCREW PIN, TIE ROD TIE ROD BEARING CUP BEARING CONE GREASE CAP SEAL WEAR SLEEVE SPINDLE

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WHEEL HUB HUB CAP NUT COTTER PIN BEARING ASSEMBLY ADHESIVE GREASE FITTING BEARING CAP SHIMS BUSHING, TIE ROD PILOT SURFACE

Figure 8. Steering Axle H8.00-16.00XL (H165-360XL) (D019, E007) and H8.00-12.00XM (H170-280HD) (F007, G007, H007), H13.00-14.00XM (H300-330HD) (E019, F019, G019), H16.00XM-6 (H360HD) (E019, F019, G019), H10.00-12.00XM-12EC (H360HD-EC) (E019, F019, G019)

14

1600 SRM 326

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 prevent 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.

goggles 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. Remove small scratches with fine emery cloth. Inspect cylinder bore for damage. Inspect mounts for cracks.

2. Disconnect tie rods as described in the Tie Rods Repair (All Units) procedures.

ASSEMBLE AND INSTALL

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 position of the mounting place.

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

4. Move the shell to one side of the assembly, to cap one side of the shell.

5. Remove capscrews and washers that fasten cylinder to axle frame. Hold end caps on shell and remove steering cylinder.

6. 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 procedure for other end.

7. Remove one end cap from shell. Carefully pull rod from shell. Keep rod in center of shell during removal. Remove end cap from rod. Remove 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 recommendations 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 away from all personnel. Wear protective

CAUTION

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), S3.505.50XL (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/E098) 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 H8.00-12.00XM (H170-280HD) (F007, G007, H007), H13.00-14.00XM (H300-330HD) (E019, F019, G019), H16.00XM-6 (H360HD) (E019, F019, G019), H10.00-12.00XM-12EC (H360HD-EC) (E019, F019, G019) units.

Tighten capscrews to 435 N•m (320 lbf ft).

15

Troubleshooting

1600 SRM 326 operate steering system to remove air from cylinders and system. Turn steering wheel several times from one wheel stop to the other wheel stop.

4. Install tie rods as described in the Tie Rods Repair (All Units) procedures.

5. Remove plugs and caps, and connect hydraulic lines to steering cylinder. Start engine, and

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SHELL END CAP PISTON ROD PISTON SEAL

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O-RING BACKUP RING ROD SEAL WIPER SEAL

Figure 9. Steering Cylinder

Troubleshooting PROBLEM The steering wheels do not move when the steering wheel is turned.

16

POSSIBLE CAUSE

PROCEDURE OR ACTION

The hydraulic oil level is low or there is no hydraulic oil in the tank.

Fill tank. Check for leaks.

The steering control unit is damaged.

Repair or install new control unit.

No oil flow from the steering control unit to the steering cylinder.

Repair or install new components.

Check for leaks.

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