Hyster J006 (H155FT) Forklift Service Repair Manual

General

Thissectionhasthedescriptionandrepairproceduresforthesteeringaxle.

Thesteeringaxleassemblyincludesanaxle frame,steeringcylinder,andtwospindleand

hubassemblies.SeeFigure1.Thesteeringaxleis articulatedandisconnectedtotheframebycenter pivotmounts.Thecenterpivotmountspermitthe steeringaxletomoveintheframemountwhenthe lifttrucktravelsoverroughsurfaces.

Figure1.SteeringAxle

Theendcapsofthesteeringcylinderarealsothe mountsforthecylinderandareheldtotheshellby themountcapscrews.ThereareO-rings,seals,and wipersintheendcapstosealthecapstotheshell androd.Theendsofthepistonrodextendfromboth endsofthecylinder.Asinglepistonandthesealare atthecenteroftherod.Oilpressureononesideof thepistonmovesthepistoninthebore.Thepiston pushesanequalamountofoilfromtheoppositeside ofthecylinder.

Whenthepistonreachestheendofthestroke,areliefvalveinthesteeringcircuitcontrolstheoilpressure.Thetierodsthatconnectthespindlearmsto thecylinderarenotadjustable.

Eachspindleturnsontwotaperedrollerbearingsin mountsintheaxleframe.Thepreloadonthebearingsiscontrolledbyshimsatthelowerbearingcap.

Thewheelsrotateontwotaperedrollerbearingsand areheldonthespindlesbyacastlenut.Thebearing preloadofthewheelsisadjustedbythecastlenut. Thegreasesealsprotectthebearingsfromdirtand water.Wearsleevesprotectthehubfromwearbythe seals.

WARNING PUTTINGTHELIFTTRUCKONBLOCKS

Thelifttruckmustbeputonblocksforsome typesofmaintenanceandrepair.Theremoval ofthemast,driveaxle,battery,orcounterweightassemblieswillcauselargechanges inthecenterofgravity.Whenthelifttruck isputonblocks,putadditionalblocksinthe followingpositions:

•Ifthemastanddriveaxleareremoved,put blocksunderthecounterweightsothelift truckcannotfallbackward.

•Ifthecounterweightisremoved,putblocks underthemastsothatthelifttruckcannot fallforward.

Putthelifttruckonblocksonasolid,even,and levelsurface.Verifytheblocksorstandshave enoughcapacitytoholdthelifttruck.Useadditionalblocksnexttothetiresasnecessaryto preventmovementofthelifttruck.Verifythe liftingdevicesusedduringrepairscanliftthe weightofthepartsandassemblies.

SeetheOperatingManualorPeriodicMaintenancesectionforyourlifttruckmodel,forthe procedurestoputthelifttruckonblocks.

Thesteeringaxlecanberemovedwithoutremoving thecounterweight.

1. Verifywheelsaresetforstraighttravel.Putlift truckonblockssothesteeringaxlewillhave enoughclearancetoberemoved.Thetopofthe axleframemusthaveclearanceunderthebottomoftheframeattherearofthelifttruck.

2. Disconnecthydrauliclinesatsteeringcylinder. Installplugfittingsincylinderandputcapson hydrauliclines.Plugfittingswillpreventspindlesfromturningasaxleisremovedfromunder thelifttruck.

NOTE: SteeringAxleAssemblymaybemountedto theframewithbracketsorplates.

3. Slidefloorjackorforksofanotherlifttruckunder steeringaxle.Raiseliftingdeviceuntilitholds theweightoftheaxleassembly.

a. Toremovebrackettypemounts,removefour capscrewsandnutsthatfastentwobrackets underrubbermounts.ForlifttruckmodelsS2.0-3.5FT(S40-70FT,S55FTS)(F187), seeFigure2,forlifttruckmodelsH2.0-3.5FT (H40-70FT)(L177),seeFigure3,forlifttruck modelsS4.0,4.5,5.5FT,S5.5FTS,(S80,100, 120FT;S80,100FTBCS;S120FTS;S120FTPRS)(G004),seeFigure5,andforH4.0FT5/ FT6;H4.5FTS5,H4.5FT6;H5.0-5.5FT(H80, 90,100,110,120FT)(N005,P005),seeFigure6.Removebracketsandslowlylower axleassemblyontowheels.Carefullyroll steeringaxleassemblyawayfromlifttruck.

SteeringAxleAssemblyRepair

b. ToRemoveplatetypemounts,removefour capscrewsandwashersfromtwoplates.For lifttruckmodelsS30FT,S35FT,S40FTS (E010)andH1.6FT,H1.8FT,H2.0FTS (H30FT,H35FT,H40FTS)(F001),seeFigure4,forlifttruckmodelsS6.0FT,S7.0FT, (S135FT,S155FT)(D024,E024),seeFigure7,andforlifttruckmodelsH6.0FT, H7.0FT(H135FT,H155FT)(H006,J006), seeFigure8.Removeplatesandslowly lowersteeringaxleassemblyontowheels. Carefullyrollsteeringaxleassemblyaway fromlifttruck.

DISASSEMBLE

1. ForlifttruckmodelH6.0FT,H7.0FT(H135FT, H155FT)(H006,J006),removeringseal,shims, flange,stubshaftandbushingfromsteeringaxle assembly.SeeFigure8.

2. Putaxleonblockssothewheelsjusttouchthe floor.Removehubcap.Removecotterpin, washer,andcastlenut.Removebearingcone anddiscardcotterpin.

NOTE: Identifyandtagtheouterandinnerbearing conessotheycanbereassembledintheiroriginal locations.

NOTE: Thewearsleevemaynotbepresentonall steeringaxles.

3. Slidewheelfromspindle.Removeinnerbearing cone,wearsleeve,andoilsealfromspindle.See Figure2forS2.0-3.5FT(S40-70FT,S55FTS) (F187)lifttrucks,Figure3forH2.0-3.5FT (H40-70FT)(L177)lifttrucks,Figure4for S30FT,S35FT,S40FTS(E010)andH1.6FT, H1.8FT,H2.0FTS(H30FT,H35FT,H40FTS) (F001)lifttrucks,Figure5forS4.0,4.5,5.5FT, S5.5FTS,(S80,100,120FT;S80,100FTBCS; S120FTS;S120FTPRS)(G004)lifttrucks,Figure6forH4.0FT5/FT6;H4.5FTS5,H4.5FT6; H5.0-5.5FT(H80,90,100,110,120FT)(N005, P005)lifttrucks,Figure7forS6.0FT,S7.0FT, (S135FT,S155FT)(D024,E024)lifttrucks,and Figure8forH6.0FT,H7.0FT(H135FT,H155FT) (H006,J006)lifttrucks.

NOTE: Ifthebearingisreplaced,thentheassociated bearingcupmustbereplacedalso.

4. Ifthebearingsmustbereplaced,useabrassdrift pintoremovethebearingcupsandwearsleeve.

5. Repeatprocedurefortheotherwheel.

CLEAN

WARNING

Cleaningsolventscanbeflammableandtoxic andcancauseskinirritation.Whenusing cleaningsolvents,alwaysfollowthesolvent manufacturer’srecommendedsafetyprocedures.

WARNING

Compressedairisusedforcleaningordrying purposes,orforclearingrestrictions.Wear protectiveclothing(goggles/shield,gloves, etc.)toavoidinjurytopersonnel.

1. Cleanbearingsbyplacingtheminawirebasket andimmersinginacontaineroffreshsolvent. Agitatethebearingsinthesolventtoremoveall tracesofoldlubricant.

2. Aftercleaningthebearings,drythemwithclean compressedair.Takecaretopreventspinning thebearingswhenusingacompressedairjet.

3. Immediatelywrapbearingsinalint-freeclothto protectthemfromdustandotherforeignmatter.

INSPECT

1. Inspectforloose,burned,missing,crackedor damagedhardware.

2. Inspectallpartsfordents,holes,bends,burrs, rust,corrosionormarredfinish.

NOTE: Ifthespindle,bearingsortierodsneedtobe repaired,gotoSpindles,Bearings,andTieRodsRepair.

Figure2.SpindletoTieRodAssemblyforLiftTruckModelsS2.0-3.5FT(S40-70FT,S55FTS)(F187)

Figure3.SpindletoTieRodAssemblyforLiftTruckModelsH2.0-3.5FT(H40-70FT)(L177)

Figure4.SpindletoTieRodAssemblyforLiftTruckModelsS30FT,S35FT,S40FTS(E010)and H1.6FT,H1.8FT,H2.0FTS(H30FT,H35FT,H40FTS)(F001)

5.BEARINGCONE(OUTER)

6.BEARINGCUP(OUTER)

7.BEARINGCONE(INNER)

Figure5.SpindletoTieRodAssemblyforLiftTruckModelsS4.0,4.5,5.5FT,S5.5FTS,(S80,100, 120FT;S80,100FTBCS;S120FTS;S120FTPRS)(G004)

Figure6.SpindletoTieRodAssemblyforLiftTruckModelsH4.0FT5/FT6;H4.5FTS5,H4.5FT6; H5.0-5.5FT(H80,90,100,110,120FT)(N005,P005)

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(D024,E024)

Figure7.SpindletoTieRodAssemblyforLiftTruckModelsS6.0FT,S7.0FT,(S135FT,S155FT)

22.BEARINGCONE(OUTER)

23.BEARINGCUP(INNER)

24.BEARINGCONE(INNER)

25.WEARSLEEVE 26.OILSEAL 27.SPINDLE

(H006,J006)

ASSEMBLE

NOTE: Refertothesection PeriodicMaintenance 8000SRM1150forS2.0-3.5FT(S40-70FT, S55FTS)(F187)andH2.0-3.5FT(H40-70FT)(L177) lifttrucks, PeriodicMaintenance 8000SRM1207 forS30FT,S35FT,S40FTS(E010)andH1.6FT, H1.8FT,H2.0FTS(H30FT,H35FT,H40FTS)(F001) lifttrucks, PeriodicMaintenance 8000SRM1248 forS4.0,4.5,5.5FT,S5.5FTS,(S80,100,120FT;

S80,100FTBCS;S120FTS;S120FTPRS)(G004) andH4.0FT5/FT6;H4.5FTS5,H4.5FT6;H5.0-5.5FT (H80,90,100,110,120FT)(N005,P005)lifttrucks, PeriodicMaintenance 8000SRM1319forS6.0FT, S7.0FT,(S135FT,S155FT)(D024,E024),and PeriodicMaintenance 8000SRM1322forH6.0FT, H7.0FT(H135FT,H155FT)(H006,J006)lifttrucks forspecifiedlubricant.

Figure8.SpindletoTieRodAssemblyforLiftTruckModelsH6.0FT,H7.0FT(H135FT,H155FT)

1. Ifnecessary,useapresstoinstallnewbearing cupsinwheelorhub.SeeFigure9forS2.0-3.5FT (S40-70FT,S55FTS)(F187)lifttrucks,Figure10 forH2.0-3.5FT(H40-70FT)(L177)lifttrucks, Figure11forH1.6FT,H1.8FT,H2.0FTS(H30FT, H35FT,H40FTS)(F001)lifttrucks,Figure12 forS30FT,S35FT,S40FTS(E010)lifttrucks, Figure13forS4.0,4.5,5.5FT,S5.5FTS,(S80, 100,120FT;S80,100FTBCS;S120FTS;S120FTPRS)(G004)lifttrucks,Figure15forS6.0FT, S7.0FT,(S135FT,S155FT)(D024,E024)lift trucks,Figure14forH4.0FT5/FT6;H4.5FTS5, H4.5FT6;H5.0-5.5FT(H80,90,100,110,120FT) (N005,P005),andFigure16forH6.0FT,H7.0FT (H135FT,H155FT)(H006,J006)lifttrucks.Lubricatebearingconeswithmultipurposegrease. Verifybearingsarefilledwithgrease.Installoil seal,wearsleeve(ifremoved)andinnerbearing coneonspindle.

Figure9.BearingArrangementforLiftTruck ModelsS2.0-3.5FT(S40-70FT,S55FTS)(F187)

Figure10.BearingArrangementforLiftTruck ModelsH2.0-3.5FT(H40-70FT)(L177)

Figure11.BearingArrangementforLiftTruck ModelsH1.6FT,H1.8FT,H2.0FTS(H30FT, H35FT,H40FTS)(F001)

Figure12.BearingArrangementforLiftTruck ModelsS30FT,S35FT,S40FTS(E010)

Figure13.BearingArrangementforLiftTruck ModelsS4.0,4.5,5.5FT,S5.5FTS,(S80,100, 120FT;S80,100FTBCS;S120FTS;S120FTPRS) (G004)

H5.0-5.5FT(H80,90,100,110,120FT)(N005, P005)

LegendforFigure14

NOTE: RIGHTSIDEISSHOWN

1.OILSLEEVE

2.OUTERBEARING

4.INNERBEARING

1.BEARINGCONE

2.BEARING

Figure15.BearingArrangementforLiftTruck ModelsS6.0FT,S7.0FT,(S135FT,S155FT)(D024, E024)

Figure14.BearingArrangementforLiftTruck ModelsH4.0FT5/FT6;H4.5FTS5,H4.5FT6;

(H006,J006)

CAUTION

Donotdamagethesealsduringinstallation.

2. Carefullyslidewheelontospindle.Installouter bearingconeandinstallwasher.

NOTE: Ensurethatthewasherisseatedproperly againstthebearingconeandnotagainsttheshaft shoulderbeforetighteningthecastlenut.

3. Installthecastlenutandtightenasfollowsfor yourlifttruck:

a. S2.0-3.5FT(S40-70FT,S55FTS)(F187)Tightenthecastlenutto68N•m(50lbfft) whilerotatingthewheelinbothdirections toproperlyseatthebearings.Loosenthe castlenut1/4turn.Tightennutto3N•m (27lbfin).Pullonthewheelaxiallytoensurethatthereisnoendplay.Ifthereis

excessiveendplay,reassemblewasherand repeatStep1throughStep3.

b. H2.0-3.5FT(H40-70FT)(L177)-Tightenthe castlenutto200N•m(147.5lbfft)whilerotatingthewheelinbothdirectionstoproperlyseatthebearings.Loosenthecastlenut untilwheelturnsfreelywithnoendplay. Tightennutto15N•m(133lbfin).

c. S30FT,S35FT,S40FTS(E010)andH1.6FT, H1.8FT,H2.0FTS(H30FT,H35FT,H40FTS) (F001)-Tightenthecastlenutto200N•m (147.5lbfft)whilerotatingthewheelin bothdirectionstoproperlyseatthebearings. Loosenthecastlenutuntilwheelturnsfreely withnoendplay.Tightennutto12N•m (106lbfin).

d. S4.0,4.5,5.5FT,S5.5FTS,(S80,100,120FT; S80,100FTBCS;S120FTS;S120FTPRS) (G004)-Tightenthecastlenutto203N•m (150lbfft)whilerotatingthewheelinboth directionstoproperlyseatthebearings. Loosenthecastlenutuntilwheelturns freelywithnoendplay.Tightennutto 34N•m(25lbfft).

e. H4.0FT5/FT6;H4.5FTS5,H4.5FT6; H5.0-5.5FT(H80,90,100,110,120FT) (N005,P005)-Tightencastlenutto200to 220N•m(148to162lbfft)whilerotating thewheelinbothdirectionstoproperlyseat thebearings.Loosenthecastlenutuntil wheelturnsfreelywithnoendplay.Tighten castlenutto35to40N•m(26to30lbfft).

f. ForlifttruckmodelsH6.0FT,H7.0FT (H135FT,H155FT)(H006,J006)andS6.0FT, S7.0FT,(S135FT,S155FT)(D024,E024)Tightencastlenutto203N•m(150lbfft) whilerotatingthewheelinbothdirectionsto properlyseatthebearings.Loosenthecastle nutuntilwheelturnsfreelywithnoendplay. Tightencastlenutto34N•m(25lbfft).

4. Installnewcotterpinincastlenut.Ifcotterpin cannotbeinstalled,tightencastlenuttothefirst alignmentpositionwherethecotterpincanbe installed.

Figure16. BearingArrangementforLiftTruck ModelsH6.0FT,H7.0FT(H135FT,H155FT)