YALE B810 GLP030-040AF LIFT TRUCK Service Repair Manual

GLP/GDP16-20AF (GP/GLP/GDP030-040AF) (B810) SERVICE MANUAL CONTENTS SECTION

PART NUMBER

YRM NUMBER

REV DATE

FRAME............................................................................................................................

MAZDA FE AND F2 ENGINE.........................................................................................

MAZDA HA/XA DIESEL ENGINES................................................................................

COOLING SYSTEM........................................................................................................

LPG FUEL SYSTEM (AISAN OPEN LOOP)..................................................................

LPG FUEL SYSTEM (AISAN CLOSED LOOP).............................................................

SINGLE-SPEED POWERSHIFT TRANSMISSION-DESCRIPTION AND REPAIR.......

DRIVE AXLE...................................................................................................................

STEERING AXLE............................................................................................................

STEERING CONTROL UNIT..........................................................................................

BRAKE SYSTEM............................................................................................................

HYDRAULIC SYSTEM AND GEAR PUMP....................................................................

MAIN CONTROL VALVE................................................................................................

TILT CYLINDERS...........................................................................................................

INSTRUMENT CLUSTER...............................................................................................

ELECTRICAL SYSTEM (MAZDA FE AND F2 ENGINES).............................................

ELECTRICAL SYSTEM (MAZDA 2.5 DIESEL ENGINE)...............................................

MAST - DESCRIPTION...................................................................................................

MAST - REPAIR..............................................................................................................

METRIC AND INCH (SAE) FASTENERS.......................................................................

DIAGRAMS.....................................................................................................................

CAPACITIES AND SPECIFICATIONS...........................................................................

PERIODIC MAINTENANCE............................................................................................

524168415 524158742 524162461 524150775 524158747 524158748 524168417 524168418 524168419 524158753 524168420 524168421 524168422 524150790 524158757 524158758 524168423 524158890 524158891 524150797 524168426 524168425 524175034

0100 YRM 0545 0600 YRM 0496 0600 YRM 1019 0700 YRM 0626 0900 YRM 0925 0900 YRM 0948 1300 YRM 0543 1400 YRM 0542 1600 YRM 0532 1600 YRM 0720 1800 YRM 0540 1900 YRM 0539 2000 YRM 0541 2100 YRM 0103 2200 YRM 0514 2200 YRM 0524 2200 YRM 0550 4000 YRM 0521 4000 YRM 0522 8000 YRM 0231 8000 YRM 0544 8000 YRM 0546 8000 YRM 0959

01/05 01/11 01/11 03/03 12/03 10/06 12/03 12/03 10/04 11/06 05/02 05/02 05/02 03/07 01/04 12/03 05/02 03/06 07/10 10/13 06/04 01/11 06/09

Service information for Cummins diesel engines can be ordered through the Hyster Literature Distribution Center.

PART NO. 524175029 (10/13)

700 YRM 626

General

General This section has the description and the checks for some parts of the cooling system. Prodecures for cleaning the radiator and troubleshooting are also included in this section.

The cooling system has the following parts: radiator, auxiliary coolant reservoir, water pump, thermostat, fan, and fan shroud. See Figure 1.

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AUXILIARY COOLANT RESERVOIR RADIATOR CAP RADIATOR RADIATOR DRAIN VALVE

TOP RADIATOR HOSE FAN SHROUD BOTTOM RADIATOR HOSE PORTS FOR TRANSMISSION OIL COOLER

Figure 1. Typical Radiator Arrangement

1

Description

700 YRM 626

Description The purpose of the cooling system is to control the operating temperature of the engine (and in some units, the transmission, brakes, and hydraulic system).

A centrifugal water pump circulates coolant through passages in the engine block and the radiator. A thermostat is installed in the water outlet fitting on the engine. As the coolant flows through the radiator, the fan moves air through the radiator to help cool the system.

The coolant is a mixture of water and antifreeze. The antifreeze prevents the coolant from freezing in cold weather, and thereby preventing damage to the engine and radiator. The antifreeze also prevents rust and lubricates the water pump.

RADIATOR The radiator is the heat exchanger for the cooling system. The fan causes air to flow through the radiator and reduces the temperature of the coolant. The auxiliary coolant reservoir is connected to the radiator by a hose. As the engine gets hot, the coolant expands.

During expansion, coolant moves from the radiator to the reservoir. When the engine stops, the coolant becomes cool and contracts. The coolant in the reservoir flows back into the radiator. In this way, the radiator is kept filled with coolant during normal operation.

The vacuum valve opens to relieve the vacuum created when the coolant temperature decreases. In certain conditions this vacuum can cause the radiator or top hose to collapse.

THERMOSTAT The thermostat is a device that controls coolant flow by opening and closing to regulate coolant temperature.

The thermostat uses a wax pellet to control its operation. The wax pellet expands when it is heated and contracts when it is cold. When heated, the wax pellet pushes on the piston, causing the valve in the thermostat to open. As the wax pellet cools, it contracts and lets a spring close the valve. When the engine is first started and the coolant is cold, the thermostat remains closed. During this time the coolant circulates through the engine, letting it warm quickly. As the engine becomes warm the thermostat opens, letting coolant circulate through the radiator.

The opening and closing of the thermostat helps keep the coolant within the operating limits of the system.

The same thermostat is used for summer and winter seasons. Do not operate the engine without a thermostat. The engine will take longer to get warm and may run improperly. See Figure 2.

On units with a powershift transmission, an oil cooler is built into the radiator. Oil from the transmission flows through coils in the radiator tank to help control the oil temperature.

RADIATOR CAP The radiator cap is a pressure-vent type that lets the pressure in the cooling system increase to 103 kPa (15 psi). The pressure in the system prevents vapor from forming in the coolant flowing to the water pump.

This action maintains the efficiency of the water pump and the performance of the cooling system. The increase in pressure also raises the boiling point of the coolant mixture to approximately 125 C (257 F) at sea level.

The radiator cap has a pressure valve and a vacuum valve. The pressure valve is held against its seat by a spring. The pressure valve opens when the pressure in the cooling system exceeds 103 kPa (15 psi). The vacuum valve is held against its seat by another spring.

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PISTON VALVE SEAT SPRING DIAPHRAGM

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WAX PELLET FRAME FLANGE VENT HOLE

Figure 2. Typical Thermostat

700 YRM 626

Cooling System Checks

WATER PUMP

FAN AND FAN SHROUD

The centrifugal-type water pump is installed at the front of the engine block. The inlet for the pump is connected to the bottom of the radiator by a hose. From the pump, coolant passes through the passages in the engine block to the top of the radiator. The thermostat controls the flow of coolant through the engine and radiator.

The fan is used to provide airflow through the radiator at all engine speeds. The fan is a pusher-type or pullertype and can be installed on the water pump or on a separate hub. The fan is driven by a drive belt from the engine crankshaft.

The fan shroud ensures the airflow from the fan goes through the core of the radiator.

Cooling System Checks RADIATOR WARNING During engine operation, be careful not to touch the fan, pulleys, or drive belts. Contact with these parts can cause serious injury.

3. Hold thermostat with wire and put it in solution.

Stir solution. If operating correctly, thermostat will open.

4. Remove thermostat and put in same solution at 12 C (10 F) below temperature on thermostat.

Valve must close completely.

NOTE: The Repair procedures for the radiator are in the Frame section of the Service Manual.

To check for water flow restrictions in the radiator, run the engine until it is warm. Shut the engine OFF and feel the radiator. The temperature must be even across the radiator. (The radiator will be hotter near the top radiator hose.) Cold spots on the radiator indicate restrictions.

If the radiator has leaks, have it repaired by trained personnel.

THERMOSTAT WARNING During engine operation, be careful not to touch the fan, pulleys, or drive belts. Contact with these parts can cause serious injury.

CAUTION DO NOT operate the engine without a thermostat.

The engine and cooling system can be damaged.

NOTE: Repair procedures for the thermostat are in the Engine section of the Service Manual.

1. Remove thermostat from cooling system. See Figure 3.

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FAN SPACER HUB/PULLEY WATER PUMP

5. THERMOSTAT 6. THERMOSTAT HOUSING

Figure 3. Cooling System Components Typical Arrangement

2. Mix solution of water with 33% antifreeze. Heat solution to 14 C (57 F) above temperature on thermostat.

3

Radiator Cleaning

700 YRM 626

WATER PUMP

FAN AND FAN SHROUD

WARNING

WARNING

During engine operation, be careful not to touch the fan, pulleys, or drive belts. Contact with these parts can cause serious injury.

NOTE: Repair procedures for the water pump are in the Engine section of the Service Manual.

Run the engine until it is warm. Check the operation of the water pump by holding the top radiator hose. If the pump is operating, there will be pressure surges in the hose. See Figure 3.

During engine operation, be careful not to touch the fan, pulleys, or drive belts. Contact with these parts can cause serious injury.

WARNING DO NOT try to repair a damaged fan. If a fan has a bent blade or is cracked, install a new fan. A damaged fan can break during use and cause damage or serious injury.

NOTE: Repair procedures for the fan and shroud are in the Frame section of the Service Manual.

EXHAUST LEAKS WARNING During engine operation, be careful not to touch the fan, pulleys, or drive belts. Contact with these parts can cause serious injury.

To check for exhaust leaks into the cooling system, use a kit for this purpose. Follow the manufacturer’s instructions when doing the test.

1. When installing fan, make sure correct spacers are installed and mounting capscrews are tight. See Figure 1 and Figure 3.

2. When installing fan shroud, make sure correct seals are on shroud. Before tightening capscrews, make sure clearance around circumference of fan is even with shroud. Also make sure 1/3 to 1/2 of crosssection of fan blade extends into fan shroud.

3. Make sure WARNING labels are installed on shroud.

Radiator Cleaning DRAIN WARNING DO NOT remove the radiator cap from the radiator when the engine is hot. When the radiator cap is removed, the pressure is released from the system.

If the system is hot, the steam and boiling coolant can cause burns.

CAUTION Disposal of lubricants and fluids must meet local environmental regulations.

1. Let coolant cool to room temperature. Put drain pan under radiator. Remove radiator cap. See Figure 1.

2. Open drain valve or remove bottom radiator hose.

Remove drain plug from engine block to drain engine.

CLEAN CAUTION Disposal of lubricants and fluids must meet local environmental regulations.

1. Drain cooling system. Fill cooling system with clean water.

2. Install radiator cap. Run engine until top radiator hose is hot. Stop engine and let engine cool.

3. Drain water from radiator. If water is dirty, fill system with water and repeat procedure until water is clean.

CAUTION Follow the manufacturer’s instructions when using a chemical radiator cleaner.

4. If water does not clean system, use chemical radiator cleaner.

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700 YRM 626

Radiator Cleaning The 50/50 mixture will protect the cooling system to 37 C ( 35 F).

CAUTION Follow the manufacturer’s instructions when using special equipment to reverse clean the radiator.

NOTE: On lift truck models GC070-120LJ/MJ (C818), the cooling system may be equipped with an optional radiator screen.

5. If radiator or cooling system is very dirty or has restriction, use reverse cleaning method. This method uses air pressure to force water through radiator in opposite direction of normal flow.

3. Use same coolant mixture to fill auxiliary coolant reservoir to FULL mark. See Figure 4.

4. Start and run engine until thermostat opens. (Top radiator hose will be warm.)

5. Check coolant level at auxiliary coolant reservoir.

Add coolant as necessary to keep level between FULL and ADD marks.

WARNING 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 goggles or a face shield to prevent injury to the eyes.

6. Check radiator fins. Clean exterior of radiator with compressed air or water as needed.

FILL 1. Install drain plug in engine block. Close drain valve or install bottom radiator hose as needed.

WARNING Do not use an alcohol or methanol-base antifreeze.

They are flammable and can cause personal injury or damage to the lift truck.

NOTE: Units with a Mazda engine must use a boronfree type of antifreeze.

2. Fill cooling system with mixture of 50% water and 50% ethylene glycol antifreeze. Install radiator cap.

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ADD MARK FULL MARK AUXILIARY COOLANT RESERVOIR FILL CAP RADIATOR CAP Figure 4. Auxiliary Coolant Reservoir

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Troubleshooting

700 YRM 626

Troubleshooting PROBLEM Coolant leaks.

The engine is too hot during operation.

Exhaust leaks into coolant.

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POSSIBLE CAUSE

PROCEDURE OR ACTION

There is a leak in the radiator.

Repair radiator.

There is a leak in a radiator hose or coolant hose.

Install new hoses.

There is a leak from a plug or sensor in the engine block.

Check sensors and plugs, and repair leaks.

Water pump leaks.

Install new water pump.

Thermostat housing leaks.

Install new thermostat housing. Check for correct installation of thermostat.

Cylinder head gasket is damaged.

Install new head gasket.

Cylinder head is cracked.

Install new cylinder head.

Engine block is cracked.

Install new cylinder block.

There is not enough coolant in the cooling system.

Check coolant level in radiator and coolant recovery bottle. Add coolant to correct level.

The radiator is dirty.

Drain and clean radiator. Clean radiator fins with low pressure air or water in reverse direction of normal airflow.

Be careful not to bend fins. Refill with clean coolant.

The drive belt for water pump is not adjusted correctly, worn, or broken.

Check water pump drive belt. Adjust or install new belt as required.

The thermostat is wrong heat range or does not operate correctly.

Check heat range. Install new thermostat.

The cooling system has restrictions.

Drain and back-flush engine and radiator. Refill with clean coolant.

The water pump is worn or damaged.

Install new water pump.

The exhaust system has restrictions.

Check exhaust system. Remove restrictions.

Ignition timing is not correct.

Check and adjust timing.

Head gasket(s) leaks.

Install new gasket(s).

Cylinder head is damaged.

Install new cylinder head.

1600 YRM 532

Description

General This section has the description and repair procedures for the steering axle. For additional information on the parts of the steering system, see the sections Steering Housing and Control Unit 1600 YRM 720 and Hydraulic System and Gear Pump Assembly 1900 YRM 539.

Description The steering axle assembly includes an axle frame, steering cylinder, and two spindle and hub assemblies. See Figure 1. The steering axle is connected to the frame with center pivot mounts. The center pivot mounts on the axle frame are fastened to the lift truck frame with rubber mounts. The steering axle can make an articulated motion, which gives the lift truck smoother travel over rough surfaces.

There are two plates welded to the steering cylinder that allow the cylinder to be mounted to the axle frame.

The oil is kept inside the cylinder by O-rings, seals, and wipers in the end caps. The piston rod extends from both ends of the cylinder. A single piston and seal are at the center of the rod. Oil pressure on one side of the piston moves the piston in the bore, pushing an equal amount of oil from the opposite end of the cylinder. This oil returns to the steering control unit. When the piston reaches the end of the stroke, a relief valve controls the oil pressure so the components are not damaged.

NOTE: GP/GLP/GDP16-20AF/BF (GP/GLP/GDP030-040AF/BF) AND GLP/GDP16-20AF (GP/GLP/GDP030040AF) ARE SHOWN HERE. GC/GLC030-040AF IS SIMILAR. 1.

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SPINDLE AND HUB ASSEMBLY AXLE FRAME BRACKET RUBBER MOUNT STEERING CYLINDER

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CYLINDER MOUNTING CAPSCREW AXLE MOUNTING CAPSCREW PIN LINK

Figure 1. Steering Axle

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Wheels and Hubs Repair

1600 YRM 532

Links connect the spindle arms to the cylinder. Each spindle turns on two tapered roller bearings. The spindle and bearings are held in the axle frame by a kingpin. A roll pin and lock nut assembly hold each kingpin in the axle frame. The wheel or hub rotates on two tapered-roller bearings and is held on the spindle by a

castle nut. The castle nut adjusts the preload on the bearings. Grease seals in the inner hub and a hub cap protect the bearings from dirt and water.

Steering Axle Assembly Repair REMOVE WARNING The steering axle assembly without the wheels weighs approximately 115 kg (253.5 lb). To avoid possible injury, use a lifting device if the steering axle assembly must be lifted.

NOTE: The steering axle can be removed without removing the counterweight.

1. Make sure the wheels are set for straight travel. Put the lift truck on blocks so the steering axle can be removed. See How to Put Lift Truck on Blocks in the Periodic Maintenance section for your lift truck.

The top of the axle frame must have clearance under the counterweight so the steering axle can be removed. See Figure 1.

2. Disconnect hydraulic lines at steering cylinder. Install caps on cylinder and put plugs in hydraulic lines. The caps will prevent the spindles from turning when the axle is removed from under the lift truck.

3. Slide a floor jack or the forks of another lift truck under the steering axle. Raise lifting device until it holds the weight of axle assembly. Remove four capscrews that fasten two brackets under rubber mounts. Remove brackets and slowly lower axle assembly onto wheels. Carefully roll axle assembly from under lift truck.

INSTALL NOTE: The mounts of the steering axle have TOP moulded into the rubber. Verify TOP is up when installing the mounts.

1. Install rubber mounts onto axle. See Figure 1.

2. Install bottom brackets. Tighten four bracket capscrews and nuts to 41 to 49 N•m (30 to 36 lbf ft).

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

4. Operate steering system to remove air from system. Turn steering wheel several times from one stop to other stop. Check for hydraulic leaks.

Wheels and Hubs Repair PNEUMATIC TIRES, REMOVE AND DISASSEMBLE WARNING Completely remove the air from the tires before removing them from the lift truck. Air pressure in the tires can cause the tire and rim parts to explode which can cause serious injury or death.

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

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1. Put axle onto blocks so tires are raised from floor.

Completely remove air from tires.

2. Remove wheels, grease cap, cotter pin, castle nut, and outer bearing cone. Slide hub from spindle.

Remove inner bearing cone and seal from spindle.

See Figure 2.

3. If new wheel bearings must be installed, use a brass drift to remove bearing cups.

4. Repeat the procedure for the other wheel.

1600 YRM 532

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AXLE FRAME KNUCKLE KINGPIN UPPER SLEEVE LOWER SLEEVE BEARING O-RING GROOVE PIN OIL SEAL COTTER PIN CASTLE NUT GREASE FITTING LINK PIN

Wheels and Hubs Repair

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BUSHING SCREW LOCK NUT GREASE FITTING STEERING CYLINDER SPACER BOLT WASHER HUB (PNEUMATIC TIRES) BOLT (PNEUMATIC TIRES) WHEEL NUT (PNEUMATIC TIRES) 26. HUB CAP 27. WASHER

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BEARING BEARING OIL SEAL FITTING FITTING LOCK NUT RUBBER CUSHION CUSHION COVER WASHER LOCKWASHER BOLT TIRE/WHEEL (CUSHION)

Figure 2. Steering Axle

3

Wheels and Hubs Repair

CUSHION TIRES, REMOVE AND DISASSEMBLE WARNING The steer wheel and tire assembly weighs approximately 41 kg (90 lb). To avoid possible injury, use a lifting device if the steer wheel and tire assembly must be lifted.

NOTE: The steer axle does not have to be removed from the truck to remove the wheel/hub assembly.

1. Apply a coat of axle grease to bottom surface of tire.

Put axle onto blocks so side of tire with the grease just touches the floor.

2. Remove grease cap, cotter pin, castle nut, and outer bearing cone. Slide wheel/hub assembly from spindle. Remove inner bearing cone and seal from spindle. See Figure 2.

3. If new wheel bearings must be installed, use a brass drift to remove bearing cups.

4. Repeat the procedure for the other wheel.

PNEUMATIC TIRES, ASSEMBLE AND INSTALL WARNING Cleaning solvents can be flammable and toxic and can cause skin irritation. When using cleaning solvents, always follow the solvent manufacturer’s safety procedures.

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

CAUTION Do not damage the seals during installation.

2. If new wheel bearings are installed, use a press to install new bearing cups in wheel or hub. See Figure 2. Install grease seal on spindle. Lubricate bearing cones and seal lips with grease. Make sure bearings are filled with grease. Install bearing cone onto spindle.

3. Carefully slide hub onto spindle. Install outer bearing cone.

4. Install castle nut. Tighten castle nut to 200 N•m (150 lbf ft) while hub is rotated.

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1600 YRM 532 5. Loosen castle nut to less than 27 N•m (20 lbf ft).

Tighten castle nut to at least 34 N•m (25 lbf ft).

6. Install cotter pin. If the hole for the cotter pin is blocked, tighten castle nut until the cotter pin can be installed.

WARNING Add air pressure to the tires only in a safety cage.

Inspect the safety cage for damage before use.

When air pressure is added, use a chuck that fastens onto the valve stem of the inner tube. Make sure there is enough hose to permit the operator to stand away from the safety cage when air pressure is added to the tire. Do not sit or stand by the safety cage.

7. Inflate the tire to 698 kPa (101 psi). Mount wheel and torque wheel nuts to 114 to 136 N•m (84 to 100 lbf ft).

8. Repeat the procedure for the other wheel.

CUSHION TIRES, ASSEMBLE AND INSTALL WARNING Cleaning solvents can be flammable and toxic and can cause skin irritation. When using cleaning solvents, always follow the solvent manufacturer’s safety procedures.

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

WARNING The steer wheel and tire assembly weighs approximately 41 kg (90 lb). To avoid possible injury, use a lifting device if the steer wheel and tire assembly must be lifted.

CAUTION Do not damage the seals during installation.

2. If new wheel bearings are installed, use a press to install new bearing cups in hub. See Figure 2.

Install grease seal on spindle. Lubricate bearing cones and seal lips with grease. Make sure bearings are filled with grease. Install bearing cone onto spindle.

1600 YRM 532

Spindles, Bearings, and Tie Rods Repair

3. Apply a coat of axle grease to bottom surface of tire.

Carefully slide wheel/hub assembly onto spindle.

Install outer bearing cone.

4. Install castle nut. Tighten castle nut to 200 N•m (150 lbf ft) while tire and wheel assembly is rotated.

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

Tighten castle nut to at least 34 N•m (25 lbf ft).

6. Install cotter pin. If the hole for the cotter pin is blocked, tighten castle nut until cotter pin can be installed.

7. Repeat the procedure for the other wheel.

Spindles, Bearings, and Tie Rods Repair PNEUMATIC TIRES, REMOVE WARNING Completely remove the air from the tires before removing them from the lift truck. Air pressure in the tires can cause the tire and rim parts to explode, which can cause serious injury or death.

4. Remove kingpin lock nuts. Use a driver to remove kingpin.

5. Use a driver to remove bearings and seals from axle.

PNEUMATIC TIRES, INSTALL

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

1. If new spindle bearings are installed, use a press to install new bearing cups into spindle. See Figure 2.

Lubricate bearing cones and seal lips with grease.

Lubricate O-rings with O-ring lubricant.

1. Put the lift truck onto blocks so the tires are raised from the floor. See How to Put Lift Truck on Blocks in the Periodic Maintenance section for your lift truck. Completely remove air from tires.

2. Install bearings, seals, sleeves, and O-rings into spindle. If groove pin was removed from kingpin, install new groove pin. Apply grease to kingpin.

Position spindle in axle and install king pin.

2. Remove wheels. See the section Wheels and Hubs Repair for the procedure.

3. Install first lock nut onto kingpin and tighten lock nut to 121 N•m (89 lbf ft). Completely loosen lock nut, then tighten lock nut to 30 N•m (22 lbf ft).

3. Remove hub from steering axle spindle.

4. Remove pin to disconnect link from spindle.

5. Remove kingpin lock nuts. Use a driver to remove kingpin.

6. Use a driver to remove bearings and seals from axle.

CUSHION TIRES, REMOVE 1. Put the lift truck onto blocks so the tires are raised from the floor. See How to Put Lift Truck on Blocks in the Periodic Maintenance section for your lift truck.

2. Remove steer wheel and tire assembly from steering axle spindle. See the section Wheels and Hubs Repair for the procedure.

3. Remove pin to disconnect link from spindle.

4. Install second lock nut onto kingpin. While holding first lock nut so it does not turn, tighten second lock nut to 81.5 to 98 N•m (60 to 72 lbf ft).

5. Connect links. Align setscrews with setscrew holes in pins. Tighten setscrews and lock nuts.

WARNING Add air pressure to the tires only in a safety cage.

Inspect the safety cage for damage before use.

When air pressure is added, use a chuck that fastens onto the valve stem of the inner tube. Make sure there is enough hose to permit the operator to stand away from the safety cage when air pressure is added to the tire. Do not sit or stand by the safety cage.

6. Inflate tires to 689 kPa (100 psi). Mount wheels and tighten wheel nuts to 114 to 136 N•m (84 to 100 lbf ft).

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Steering Cylinder Repair

1600 YRM 532

CUSHION TIRES, INSTALL 1. If new spindle bearings are installed, use a press to install new bearing cups into spindle. See Figure 2.

Lubricate bearing cones and seal lips with grease.

Lubricate O-rings with O-ring lubricant.

2. Install bearings, seals, sleeves, and O-rings into spindle. If the groove pin was removed from the kingpin, install new groove pin. Apply grease to kingpin. Position spindle in axle and install kingpin.

3. Install first lock nut onto kingpin and tighten lock nut to 121 N•m (89 lbf ft). Completely loosen lock nut, then tighten lock nut to 30 N•m (22 lbf ft).

4. Install second lock nut onto kingpin. While holding first lock nut so that it does not turn, tighten second lock nut to 81.5 to 98 N•m (60 to 72 lbf ft).

5. Connect links. Align setscrews with setscrew holes in pins. Tighten setscrews and lock nuts.

6. Install steer wheel and tire assembly. See the section Wheels and Hubs Repair for the procedure.

Steering Cylinder Repair REMOVE AND DISASSEMBLE

ASSEMBLE AND INSTALL

1. Disconnect hydraulic lines at steering cylinder. See Figure 3. Mark the locations of the hydraulic lines to make sure of correct assembly. Install caps in fittings on cylinders and put caps on hydraulic lines.

1. Put dust seals, U-packings, O-rings, and piston seals into warm hydraulic oil.

2. Remove setscrews from links. Remove pins.

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

3. Remove capscrews that fasten cylinder to axle frame. Remove steering cylinder.

4. Hold end of steering cylinder over a drain pan. Remove cap for hydraulic fitting from each end cap.

Push rod toward end of shell that is over drain pan.

Oil will drain from cylinder. Repeat the procedure for the other end.

5. Carefully remove one guide assembly from shell.

Carefully pull cylinder rod and piston from shell.

Keep cylinder rod aligned in center of shell during removal so the parts are not damaged. Remove guide assembly from rod. Remove other guide assembly 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 solvent manufacturer’s safety procedures.

1. Clean all parts in solvent.

2. Inspect piston rod for grooves or damage. Remove small scratches with fine emery cloth. Inspect cylinder bore for damage. Inspect mounts for cracks.

6

CAUTION

2. Lubricate dust seals and U-packings with O-ring lubricant and install them into guide assemblies. Lubricate piston seals and install them onto piston.

Install one guide assembly onto cylinder rod. See Figure 3.

3. Carefully slide cylinder rod and piston into shell.

Keep cylinder rod aligned in center of shell during installation so the parts are not damaged. Carefully slide guide assembly into shell. Carefully install other guide assembly onto rod and shell. Put caps on hydraulic fittings of end caps.

4. Install cylinder onto axle frame using capscrews.

Install spacers between cylinder mounts and axle frame. Tighten capscrews to 294 to 353 N•m (217 to 260 lbf ft).

5. Install links between cylinder and spindles. Install pins. Align setscrews with setscrew holes in pins.

Tighten setscrews and lock nuts.

6. Remove caps and connect hydraulic lines to steering cylinder. Operate steering system to remove air from cylinder and hydraulic system. Turn steering wheel several times from one stop to the other.

1600 YRM 532

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ROD ASSEMBLY GUIDE ASSEMBLY DUST SEAL U-PACKING O-RING

Torque Specifications

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O-RING PISTON SEAL SNAP RING ROD BUSHING PIN BUSHING

Figure 3. Steering Cylinder

Torque Specifications Steering Axle Mounting Bolts 41 to 49 N•m (30 to 36 lbf ft)

Spindle Nut (Final) 30 N•m (22 lbf ft)

Castle Nut (Initial) 200 N•m (148 lbf ft)

Spindle Lock Nut (Initial) 81 to 98 N•m (60 to 72 lbf ft)

Castle Nut (Final) 34 N•m (25 lbf ft)

Steering Cylinder Mounting Bolts 294 to 353 N•m (217 to 260 lbf ft)

Spindle Nut (Initial) 121 N•m (89 lbf ft)

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