SERVICE REPAIR

S30E S40E S50E S60ES Europe [D002]

General

Introduction

This section has the description and repair procedures for the steering axle. See the following sections for additional information of the steering system:

The Steering Control Unit

(1600 SRM 54)

THE HYDRAULIC PUMP (1900 SRM 97)

Description

The steering axle assembly includes an axle frame, steering cylinder, and two spindle and hub assemblies (See FIGURE 1.). The steering axle is articulated and is connected to the frame by a center pivot or mount. The center pivot or mount permits the steering axle to move in the frame mount when the lift truck travels over rough surfaces.

The steering axles and repair procedures described in this section are similar. Some parts are the same, but the axle frames are not the same. Different types of pivot mounts are welded to the axle frames for the different models of lift trucks. Procedures for the removal and installation of the steering axle with the different mounts are described in the first part of the Repair section.

The ends of the piston rod extend from both ends of the cylinder shell. A single piston and the seal are in the center of the 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.

When the piston reaches the end of the stroke, a relief valve controls the oil pressure. The relief valve is normally found in the steering hydraulic pump or in the supply line to the steering control unit. The tie rods that connect the spindle arms to the cylinder are not adjustable.

Each spindle turns on two tapered roller bearings in mounts in the axle frame. The preload on the bearings is controlled by shims at the lower bearing cap.

The wheel hubs rotate on two tapered roller bearings and are held on the spindles by a castle nut. A bearing preload of the wheel hubs is adjusted by the castle nut. The grease seals protect the bearings from dirt and water. Wear sleeves protect the hub from wear by the seals.

Repairs

Warning

PUTTING THE LIFT TRUCK ON BLOCKS OR STANDS

The lift truck must be put on blocks for some types of maintenance and repair. The removal of the following assemblies will cause large changes in the center of gravity: counterweight, mast, engine, drive axle and transmission. When the lift truck is put on blocks, put additional blocks in the following positions:

1. If the counterweight is not removed, put the blocks under the counterweight.

2. If the counterweight is removed, put blocks under the mast assembly. Make sure the lift truck will not fall from the blocks or stands. Make sure the lifting devices used during repairs can lift the weight of the parts and assemblies.

Steering Axles With Stub Shaft Mounts

The following lift trucks have a steering axle with a stub shaft mount. (See FIGURE 2.)

S40–50F

S30–50E, S60ES

S60–100E

P40–50A

J50AS, J60AS with step frame (Europe)

Except for the P40–50A, the counterweight must be removed before the steering axle is removed. See the section THE FRAME (100 SRM 27 for E30–50B, E60BS, E60–120B; 100 SRM 101 for the H60–110E; 100 SRM 164 for the S30–50E, S60ES, S60–120E; 100 SRM 176 for the J40–50A, J60AS) for information on removing the counterweight. The wheels, spindles, bearings and tie rods can be removed with the steering axle in the lift truck. The counterweight must be removed from the lift trucks with cushion tires if the steering cylinder must be removed for repairs.

Removal

1. If the lift truck is a J50AS or J60AS remove the battery. See PERIODIC MAINTENANCE (8000 SRM 201 for E30–50B, E60BS, E60–120B; 8000 SRM 114 for the H60–110E; 8000 SRM 191 for the S30–50E, S60ES, 8000 SRM 186 for the S60–120E; 8000 SRM 26 for the J40–50A, J60AS). Remove the counterweight. See THE FRAME (100 SRM 27 for E30–50B, E60BS, E60–120B; 100 SRM 101 for the H60–110E; 100 SRM 164 for the S30–50E, S60ES, S60–120E; 100 SRM 176 for the J40–50A, J60AS). Put the lift truck on stands so that the steering axle can be removed.

2. Disconnect the hydraulic lines to the steering cylinder and install caps on the cylinder fittings and open hydraulic lines. The caps will prevent the spindles from turning as the axle is removed from under the lift truck.

3. Put a lifting device under the steering axle assembly. Remove the capscrews from the end plate. Remove the end plate, shims and thrust washer. Remove the three capscrews and tapered sleeves from the thrust plate. (Some units use a capscrew with a tapered area under the head instead of a tapered sleeve.) Remove the thrust plate and the other thrust washer. Move the axle away from the lift truck.

4. Remove the O–ring, retainer, and bushings from the pivot housing.

Installation

1. Lubricate the stub shaft bushings with grease. Install the O–ring between the large bushing and the retainer.

2. Use a floor jack or another lift truck to lift the steering axle into position. Lubricate with grease and install one thrust washer and the thrust plate. Install the tapered sleeves and the capscrews. Tighten the capscrews to 160 N.m (120 lbf ft). [Some units use capscrews with a tapered area under the head. If capscrews with the tapered area are used instead of the sleeves, tighten the capscrews to 200 to 220 N.m (150 to 160 lbf ft)].

10100

1.PIVOT HOUSING

2.STUB SHAFT

3.TAPERED SLEEVE OR CAPSCREWS WITH TAPERED AREA

4.THRUST PLATE

5.SHIMS

6.THRUST WASHER

7.END PLATE

8.SMALL BUSHING

9.LARGE BUSHING

10.O–RING

11.RETAINER

3. Install the other thrust washer and end plate. Tighten the capscrews to 70 N.m (50 lbf ft). Measure the clearance between the end plate and the housing for the stub shaft. Remove the end plate and install shims 0.025 to 0.25 mm (0.001 to 0.010 in) thicker than the measured gap. Lubricate and install the end plate. Tighten the capscrews for the end plate to 70 N.m (50 lbf ft).

4. Connect the hydraulic lines to the steering cylinder. Make sure the hydraulic lines are connected to the correct ports.

5. Remove the air from the steering system as described in CHECKS AND ADJUSTMENTS in this section. Check for hydraulic leaks.

*E60–120B only

Electric Lift Truck With Rubber Mounts

Certain counterbalance electric lift trucks have steering axles with rubber mounts. Some units use two rubber mounts and others use three rubber mounts between the steering axle and the frame. If the axle has three mounts, the mount in the center of the axle has the face of the pad toward the axle. The other two rubber mounts have the face of the pad toward the frame.

The E30–50B, 60BS lift trucks before August 1981 use two rubber mounts between the steering axle and the frame. The E60–120B lift trucks use three rubber mounts. The rubber mount in the center of the axle mount has the face of the pad in the down direction. The other two rubber mounts have the face of the pad towards the frame.

Removal

1. Remove the battery (See PERIODIC MAINTENANCE (8000 SRM 201 for E30–50B, E60BS, E60–120B; 8000 SRM 114 for the H60–110E; 8000 SRM 191 for the S30–50E, S60ES, 8000 SRM 186 for the S60–120E; 8000 SRM 26 for the J40–50A, J60AS). Put the lift truck on stands so that the steering axle can be removed. The bottom of the counterweight must be at least 46 cm (18 in) from the floor so that the steering axle can be removed.

2. Disconnect the hydraulic lines at the steering cylinder. Install caps on the steering cylinder fittings and open hydraulic lines.

3. Slide a floor jack or the forks of another lift truck under the steering axle. Raise the lifting device until it holds the weight of the steering axle. Remove the four capscrews that hold the retainer plates to the frame.

4. Remove the two large capscrews in the center of each retaining plate. See FIGURE 5.) The capscrews are tightened to 475 N.m (150 lbf ft).

5. Lower the steering axle assembly and remove it from the lift truck.

Installation (See FIGURE 5.)

1. Install the rubber mounts on the steering axle. Tighten the capscrews to 160 N.m (115 lbf ft). The distance between the centers of the two outer rubber mounts must be adjusted so that the center capscrews will align with the frame:

J40–60A 280 mm (11.0 in)

E30–120 267 mm (10.5 in)

1.LIFT TRUCK FRAME

2.1 UNC X 5 1/2 in CAPSCREW

[TIGHTEN TO 475 N.m (350 lbf ft)]

3.RETAINER PLATE

4.5/8 UNC X 1 1/2 in CAPSCREWS

[TIGHTEN TO 160 N.m (115 lbf ft)]

[IF 5/8 UNC X 1 1/2 in PLACE

BOLT, TIGHTEN TO 215 N.m (160 lbf ft)]

5.STEERING AXLE ASSEMBLY

2. Use a floor jack or another lift truck to lift the steering axle into position. Install each 1 UNC x 5 1/2 inch center capscrew and lockwasher through the retainer plate and rubber mount to the frame.

3. Install the four 5/8 UNC x 1 1/2 inch capscrews through the retainer plates to the frame. Tighten the capscrews to 160 N.m (115 lbf ft). [If place bolts are used instead of capscrews (E30–60B), tighten the place bolts to 215 N.m (160 lbf ft)]. Tighten the 1 UNC x 5 1/2 in center capscrews to 475 N.m (350 lbf ft).

4. Connect the hydraulic lines to the steering cylinder. Make sure the hydraulic lines are connected to the correct ports.

5. Remove the air from the steering system as described in CHECKS AND ADJUSTMENTS in this section. Check for hydraulic leaks.

ELECTRIC LIFT TRUCKS WITH RUBBER MOUNTS (E30–50B, E60BS AFTER AUGUST 1981)

A new rubber mount was installed on this series of lift trucks beginning with serial number B108V–8114B made in Berea. Lift trucks made in Irvine and Toronto began installing the new mount in 1982. See FIGURE 6.

Removal

1. Remove the battery. See PERIODIC MAINTENANCE (8000 SRM 201). Put the lift truck on stands so that the steering axle can be removed. The bottom of the counter weight must be at least 46 cm (18 in) from the floor so that the steering axle can be removed.

2. Disconnect the hydraulic lines at the steering cylinder. Install caps on the steering cylinder fittings and open hydraulic lines.

3.RUBBER

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3. Slide a floor jack or the forks of another lift truck under the steering axle. Raise the lifting device until it holds the weight of the steering axle. Remove the four 5/8 UNC x 2 inch capscrews that hold the two retainer plates in position.

4. Lower the steering axle assembly and remove it from the lift truck.

Installation

1. Install the rubber mounts on the axle. Make sure the face of the rubber mount with the part number is away from the axle.

2. Apply a lubricant that is approved for use with rubber to the rubber mount. The lubricant is used where the mount and the frame join.

3. Use a floor jack or another lift truck to put the steering axle into the position in the frame. Make sure the rubber mounts fit inside the frame channels for the mounts.

4. Install the retainer plates. Tighten the four 5/8 UNC x 2 inch capscrews to 200 N.m (150 lbf ft).

5. Connect the hydraulic lines to the steering cylinder.

6. Remove the air from the steering system after the battery has been connected. Check for hydraulic leaks.

Wheels And Hubs

Removal and Disassembly

1. Put the axle on blocks so that the wheels just touch the floor. Remove the grease cap. Remove the cotter pin and the castle nut. Remove the outer cone. Slide the wheel from the hub. Remove the bearing and the seal from the spindle.

2. If the bearings must be replaced, use a brass drift to remove the bearing cups and the wear sleeve.

3. Repeat the procedure for the other wheel.

Cleaning

Clean all parts with solvent. Make sure there is no dirt is in the bearings. Do not turn the bearings with compressed air.

Assembly And Installation (See FIGURE 7.)

1. Install the grease seal on the spindle. Lubricate the bearing cones with grease. Install the cones on the spindle. Press the bearing cups into the hub. Install the wear sleeve into the hub.

2. Slide the wheel and hub onto the spindle.

Caution

Do not damage the seals during installation.

3. Install the washer and castle nut. Tighten to 200 N.m (150 lbf ft). Loosen the nut to less than 25 N.m (20 lbf ft). Tighten the nut to 35 N.m (25 lbf ft). Tighten the castle nut until the cotter pin can be installed. Install the cotter pin.

SPINDLES, BEARINGS AND TIE RODS

Removal And Disassembly

1. If the tie rod is to be replaced, remove the cotter pin and castle nut. Use a special puller to remove the tapered stud from the spindle arm. To loosen the stud, hit the spindle arm with a large hammer. Use another hammer behind the arm to hold the arm.

Caution

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

NOTE: To remove the spindle, the tie rod can be disconnected at the retaining pin.

2. Remove the grease cap from the spindle. Remove the capscrews from the bearing cap. Remove the cap and shims. Remove the bearing cup as shown in FIGURE 9.

3. Tilt the spindle and lift the spindle from the axle. Remove the bearings and seals from the spindle.

Cleaning

Clean all parts except the ends of the tie rods in solvent. Make sure there is no dirt is in the bearings.

Assembly And Installation (See FIGURE 7. and FIGURE 8.)

1. Install a new seal on the machined surface at the top of the spindle. Install the dust seal. On units that have a grease seal install the grease seal. Lubricate the seals with grease. Press the bearing cones on the spindles.

2. Lubricate the bearings with wheel bearing grease. Press the bearing cups into the steering axle and bearing cap. Install the wear sleeves in the steering axle.

3. Install the spindle in the steering axle. Install the bearing cap without the O–ring. Measure the clearance between the bearing cap and the axle. (See FIGURE 7.) Remove the bearing cap and install enough shims to give a preload of 0.00 to 0.12 mm (0.000 to 0.005 in).

NOTE: The spindle bearings must have no clearance. Install shims 0.00 mm to 0.12 mm (0.000 to 0.005 in) thicker than the measured gap.

Install the O–ring on the bearing cap. Install the bearing cap and capscrews. Tighten the 3/8 inch capscrews to 45 N.m (35 lbf ft). On the J40–60AS with the flat frame, tighten the 1/2 inch capscrews to 110 N.m (80 lbf ft).

4. Install the tie rod to the spindle arms. Tighten the castle nuts to 160 N.m (120 lbf ft). Tighten the castle nuts until the cotter pins can be installed.

5. Install the grease caps on the top of the steering axle.

Steering Cylinder

Removal And Disassembly (See FIGURE 9.)

NOTE: Loosen the two end retainers before removing the cylinder from the steering axle.

1. Disconnect the ends of the tie rods.

2. Remove the four capscrews that hold the cylinder to the axle.

Caution

Make a note of the shims on the bottom mount on the left side of the cylinder.

3. To disassemble the cylinder, remove both retainers. Pull the rod assembly from the shell. Remove all O–rings and seals.

Install the rod seals with the lips toward the center of the cylinder. Install the wipers in the retainers.

2. Lubricate the seal ring with O–ring lubricant. Install the back–up ring. Install the seal ring over the back–up ring. Install the piston in the shell.

3. Lubricate the retainer seals. Install the retainers on the rod.

Caution

Do not damage the seals during installation.

4. Tighten the retainers to 300 to 350 foot pounds (406 to 475 N.m). There is a tool available (Hyster Part Number 332495) to tighten the retainers.

NOTE: It is easier to tighten the retainers after the cylinder is installed in the steering axle.

Cleaning

Wash all parts except the tie rods in solvent. Use compressed air to dry the parts.

Caution

Do not turn the bearings with compressed air.

Assembly And Installation (See FIGURE 11.)

1. Put the O–rings, seals and wipers in warm hydraulic oil. Install the O–ring between the lips of the seal.

Install the dowel sleeve (except H60–110E) on the upper left mount. (See FIGURE 10.). Install bolts on the two right–hand side and upper left mounts. Tighten the bolts to 120 N.m (90 lbf ft). [165 N.m (120 lbf ft) on H60–110E].

On the lower left–hand mount install as many shims as possible between the cylinder and the axle. (See FIGURE 10.). Install the bolt and tighten.

6. Connect the cylinder rod to the tie rods with the pins and snap rings. Pull the rubber dust cover toward the cylinder. Install and tighten the clamps.

NOTE: Make sure to tighten the cylinder retainers.

CAUTION: Do not damage the seals during installation.