Hyster h165-280xl h300-360xl Forklift Repair Manual
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STEERING AXLE
S3.50-5.50XL (S70-120XL) [D004];
S3.50-5.50XM (S70-120XM) [E004, F004];
E3.50-5.50XL (E70-120XL, E70-120XL
3
) [C098];
H3.50-5.00XL (H70-110XL) [G005];
H6.00-7.00XL (H135-155XL, H135-155XL
2
) [F006, G006];
H8.00-16.00XL (H165-360XL) [D019, E007];
H8.00-16.00XM (H170-360HD) [E019, F007, F019, G007]
PART NO. 897108 1600 SRM 326
SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly
fastened, and that the load being lifted is balanced. Make sure the crane, cables, and
chains have the capacity to support the weight of the load.
• Do not lift heavy parts by hand, use a lifting mechanism.
• Wear safety glasses.
• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair
on electric lift trucks.
• Disconnect the battery ground cable on internal combustion lift trucks.
• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT
THE LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Mainte-
nance section.
• Keep the unit clean and the working area clean and orderly.
• Use the correct tools for the job.
• Keep the tools clean and in good condition.
• Always use HYSTER APPROVED parts when making repairs. Replacement parts
must meet or exceed the specifications of the original equipment manufacturer.
• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before
using force to remove parts.
• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs,
or if the unit needs repairs.
• Be sure to follow the WARNING and CAUTION notes in the instructions.
• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel
are flammable. Be sure to follow the necessary safety precautions when handling these
fuels and when working on these fuel systems.
• Batteries generate flammable gas when they are being charged. Keep fire and sparks
away from the area. Make sure the area is well ventilated.
NOTE: The following symbols and words indicate safety information in this
manual:
WARNING
Indicates a condition that can cause immediate death or injury!
CAUTION
Indicates a condition that can cause property damage!
Steering Axle Table of Contents
TABLE OF CONTENTS
General ............................................................................................................................................................... 1
Description ......................................................................................................................................................... 1
Steering Axle Assembly Repair ......................................................................................................................... 5
Steering Axle H3.50-5.00XL (H70-110XL) (G005), S3.50-5.50XL (S70-120XL) (D004),
S3.50-5.50XM (S70-120XM) (E004, F004), and E3.50-5.50XL (E70-120XL, E70-120XL
3
) (C098) ........... 5
Remove ....................................................................................................................................................... 5
Install ......................................................................................................................................................... 6
Steering Axle H6.00-7.00XL (H135-155XL, H135-155XL
2
) (F006, G006), H8.00-16.00XL
(H165-360XL) (D019, E007), and H8.00-16.00XM (H170-360HD) (E019, F007, F019, G007).................. 6
Remove ....................................................................................................................................................... 6
Install ......................................................................................................................................................... 7
Wheels and Hubs Repair (All Units) ................................................................................................................ 7
Remove and Disassemble .............................................................................................................................. 7
Clean .............................................................................................................................................................. 7
Inspect ............................................................................................................................................................ 7
Assemble and Install ..................................................................................................................................... 8
Spindles and Bearings Repair (All Units) ........................................................................................................ 9
Remove ........................................................................................................................................................... 9
Clean .............................................................................................................................................................. 9
Assemble and Install ..................................................................................................................................... 9
Tie Rods Repair (All Units) ............................................................................................................................... 10
Remove ........................................................................................................................................................... 10
Clean .............................................................................................................................................................. 10
Install ............................................................................................................................................................. 10
Steering Cylinder Repair ................................................................................................................................... 13
Remove and Disassemble .............................................................................................................................. 13
Clean and Inspect .......................................................................................................................................... 13
Assemble and Install ..................................................................................................................................... 13
Troubleshooting.................................................................................................................................................. 14
This section is for the following models:
S3.50-5.50XL (S70-120XL) [D004];
S3.50-5.50XM (S70-120XM) [E004, F004];
E3.50-5.50XL (E70-120XL, E70-120XL
3
) [C098];
H3.50-5.00XL (H70-110XL) [G005];
H6.00-7.00XL (H135-155XL, H135-155XL
2
) [F006, G006];
H8.00-16.00XL (H165-360XL) [D019, E007];
H8.00-16.00XM (H170-360HD) [E019, F007, F019, G007]
©2003 HYSTER COMPANY i
"THE
QUALITY
KEEPERS"
HYSTER
APPROVED
PARTS
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.
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.
1. STEERING AXLE
2. COVER
3. CLAMP
4. COTTER PIN
5. SNAP RING
6. TIE ROD AND BUSHING
7. NUT
8. CAPSCREW
9. CAP
10. BEARING CONE
11. BEARING CUP
12. SEAL
13. WEAR SLEEVE
14. SPINDLE (RH)
15. SPINDLE (LH)
16. O-RING
17. SHIM
18. BEARING CAP
19. LUBE FITTING
20. SCREW
21. SEALANT
22. STEER CYLINDER
23. OIL SEAL
24. CAP (HUB)
25. WASHER
26. MOUNT
27. PLATE
28. LOCKWASHER
29. WHEEL
30. GREASE FITTING
Figure 1. Steering Axle E3.50-5.50XL (E70-120XL, E70-120XL
3
) (C098), S3.50-5.50XL (S70-120XL)
(D004), and S3.50-5.50XM (S70-120XM) (E004, F004)
1
Description 1600 SRM 326
Figure 2. Steering Axle H8.00-16.00XL (H165-360XL) (D019, E007) and H8.00-16XM (H170-360HD)
(E019, F007, F019, G007)
2
1600 SRM 326 Description
Legend for Figure 2
1. HUB ASSEMBLY
2. STUD
3. BEARING CUP
4. WEAR SLEEVE
5. HUB CAP
6. COTTER PIN
7. NUT
8. WASHER
9. LOCKWASHER
10. CAPSCREW
11. BEARING CONE
12. BEARING CAP
13. SHIM
14. OIL SEAL
15. LUBE FITTING
16. PIN
17. PLUG
18. SPINDLE
19. FRAME
20. SHAFT
21. TIE ROD
22. BUSHING
23. ANCHOR
24. STEERING CYLINDER
25. FITTING
26. O-RING
27. FLANGE
28. LUG NUT
29. HANGER CUP
1. STEERING AXLE
2. STEER CYLINDER
3. SPINDLE (LH)
4. SEAL
5. BEARING CONE
6. SPINDLE (RH)
7. HUB
8. BEARING CUP
9. STUD (WHEEL)
10. WEAR SLEEVE
11. TIE ROD
12. CAPSCREW
13. NUT (SPINDLE)
14. CAP (HUB)
15. SHIM
16. CAP ASSEMBLY
17. PIN
18. SNAP RING
19. O-RING
20. GREASE FITTING
21. COTTER PIN
22. MOUNT
23. PLATE
24. WASHER
25. NUT
26. LUG NUT
27. PIN
28. PLUG AND SEALANT
29. CLAMP
30. OIL SEAL
31. BEARING CAP
32. CAPSCREW
33. 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 Steering Axle Assembly Repair
Legend for Figure 4
1. STEERING AXLE
2. SHAFT
3. SEAL
4. PIN
5. SNAP RING
6. TIE ROD
7. CAPSCREW
8. LOCKWASHER
9. PLUG
10. BEARING CONE
11. BEARING CUP
12. WEAR SLEEVE
13. SPINDLE
14. O-RING
15. SHIM
16. SCREW
17. OIL SEAL
18. HUB
19. STUD
20. WHEEL NUT
21. WASHER
22. COTTER PIN
23. CAP
24. GREASE FITTING
25. BUSHING
26. BEARING CAP
27. STEER CYLINDER
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)
The center pivots for the axle are installed in the
frame of the lift truck and rotate in fiber bushings
on the following units:
H6.00-7.00XL (H135-155XL, H135-155XL
2
) (F006,
G006)
H8.00-16.00XL (H165-360XL) (D019, E007)
H8.00-16.00XM (H170-360HD) (E019, F007, F019,
G007)
The end caps of the steering cylinder are also the
mounts for the cylinder and are held to the axle by
capscrews. The ends of the piston rod extend from
both ends of the cylinder. A single piston and the
seal are at the center of the piston rod. Oil pressure
on one side of the piston moves the piston in the bore.
The piston pushes an equal amount of oil from the
opposite side of the cylinder. The oil returns to the
steering control unit.
When the piston in the steering cylinder reaches the
end of the stroke, a relief valve controls the oil pres-
sure. The relief valve for the steering system is in
the manifold block that is installed on the steering
control unit.
Each spindle turns on two tapered roller bearings in
the axle frame. The preload on the bearings is con-
trolled by shims at the lower bearing cap. The tie
rods that connect the spindle arms to the cylinder do
not have an adjustment.
The wheel hubs rotate on two tapered roller bear-
ings and are held on the spindles by a castle nut.
The bearing preload of the wheel hubs is adjusted by
the castle nut. The grease seals protect the bearings
from dirt and water. Wear sleeves prevent the seals
from causing wear on the hub.
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), AND
E3.50-5.50XL (E70-120XL, E70-120XL
3
)
(C098)
Remove
WARNING
Put the lift truck on blocks. Follow the proce-
dures for raising the lift truck described in the
Operating Manual for this lift truck. The sur-
face must be solid, even, and level. Make sure
the blocks are solid, one-piece units. Make sure
the lifting devices used during repairs can lift
the weight of the parts.
The steering axle can be removed without removing
the counterweight.
1. Make sure wheels are set for straight travel. Put
blocks under frame in front of steer wheels and
under counterweight so steering axle can be re-
moved. The top of the axle frame must have
clearance under the counterweight so that the
steering axle can be removed.
2. It is not required, but it can make removal of the
axle easier if wheels are removed. See Wheels
and Hubs Repair (All Units) for wheel removal.
Disconnect hydraulic lines at steering cylinder.
5
Steering Axle Assembly Repair 1600 SRM 326
Install caps on cylinder and put plugs in hy-
draulic lines. Caps will prevent spindles from
turning when axle is removed from the lift truck.
3. Slide a floor jack or forks of another lift truck
under steering axle. Raise lifting device until it
holds the weight of the axle assembly. Remove
four capscrews and nuts that fasten two brack-
ets under rubber mounts. Remove brackets and
slowly lower axle assembly. Carefully remove
axle assembly from under lift truck.
Install
1. Install rubber mounts on axle. Make sure part
number is away from axle frame and tapered
edge of rubber mount is at the top. See Fig-
ure 1and Figure 3.
2. Apply a lubricant that is approved for use with
rubber (tire lubricant) to the rubber mounts.
Lubricant is used where rubber mount fits into
frame brackets.
3. Use a floor jack or another lift truck to put steer-
ing axle into position in the frame. Make sure
rubber mounts fit inside frame brackets for the
mounts. If necessary, lower weight of the lift
truck onto axle to make sure rubber mounts fit
completely in frame brackets.
4. Install bottom brackets for rubber mounts.
H3.50-5.00XL (H70-110XL) (G005) units.
Tighten four bolts for brackets to 72 N•m
(53 lbf ft).
S3.50-5.50XL (S70-120XL) (D004), S3.50-
5.50XM (S70-120XM) (E004, F004), and
E3.50-5.50XL (E70-120XL, E70-120XL
3
)
(C098) units. Tighten four bolts to 110 N•m
(81 lbf ft).
5. Remove plugs and caps and connect hydraulic
lines to steering cylinder. Install wheels if they
were removed.
6. Operate steering system to remove air from sys-
tem. Turn steering wheel several times from one
wheel stop to other wheel stop. Check for hy-
draulic leaks.
STEERING AXLE H6.00-7.00XL
(H135-155XL, H135-155XL
2
) (F006,
G006), H8.00-16.00XL (H165-360XL) (D019,
E007), AND H8.00-16.00XM (H170-360HD)
(E019, F007, F019, G007)
Remove
WARNING
Put the lift truck on blocks. Follow the proce-
dures for raising the lift truck described in the
Operating Manual for this lift truck. The sur-
face must be solid, even, and level. Make sure
the blocks are solid, one-piece units. Make sure
the lifting devices used during repairs can lift
the weight of the parts.
The steering axle can be removed without removing
the counterweight.
1. Make sure wheels are set for straight travel. Put
blocks under frame in front of steer wheels, so
steering axle can be removed. Top of axle frame
must have clearance under counterweight so
steering axle can be removed.
2. It is not required, but it can make removal of
the axle easier if the wheels are removed. Dis-
connect hydraulic lines at steering cylinder. In-
stall caps on cylinder and put plugs in hydraulic
lines. Caps will prevent spindles from turning
when axle is removed from under the lift truck.
3. Remove two dust covers from openings of bearing
caps.
4. Slide a floor jack or forks of another lift truck
under steering axle. Raise lifting device until it
holds weight of axle assembly. Remove four cap-
screws and washers that fasten two bearing caps
to frame. Remove bearing caps and slowly lower
axle assembly. Carefully remove axle assembly
from under lift truck.
6
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$49.99
The Service workshop repair manual provides detailed servicing instructions for your Hyster Fork Lift. It offers complete step-by-step information on repair, servicing, preventative maintenance, and troubleshooting procedures. This comprehensive manual features photos, illustrations, and detailed instructions to guide you through the entire repair process. It contains all the necessary information to keep your Hyster Fork Lift working correctly, making it an indispensable source of maintenance and repair information for both professional mechanics and DIY enthusiasts.
This manual covers the following:
- h165-280xl (d007 / e007) h300-360xl (c019 / d019)
- Frame
- Perkins diesel engine-1000 series
- GM V8-366 engine
- Perkins diesel engine-1000 series (ar, yg, yh)
- Cooling system
- LPG fuel system
- Three-speed ps trans - descr / oper
- Three-speed ps trans - repair
- Three-speed ps trans - descr / oper (hyster-t50)
- Three-speed ps trans - repair (hyster-t50)
- Autoshift transmission controller
- Differential
- Planetary gear axle
- Steering axle
- Steering system
- Brake system
- Air compressor
- Tu-flo air compressor (GM V8-366 eng)
- Hydraulic system
- Main control valve
- Tilt control valve
- Tilt cylinders
- Alternator
- Starter
- High energy ignition system
- Instrument panel indicators and senders
- Masts
- Empty container handling attachment
- Inch (SAE) and metric fasteners
- Periodic maintenance
- Capacities and specifications
- Diagrams
Whether you are a professional mechanic or a DIY enthusiast, this manual will help you better understand, care for, and service your Hyster Fork Lift, ultimately lowering the repair and maintenance costs.
