Hyster G004 (S120FT) Forklift Service Manual

STEERING AXLE S30FT, S35FT, S40FTS [E010]; H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, H40FTS) [F001]; S2.0-3.5FT (S40-70FT, S55FTS ) [F187]; H2.0-3.5FT (H40-70FT) [L177]; S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; S80, 100FTBCS; S120FTS; S120FTPRS) [G004]; H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) [N005, P005]; S6.0FT, S7.0FT, (S135FT, S155FT) [D024, E024]; H6.0FT, H7.0FT (H135FT, H155FT) [H006, J006] PART NO. 1580512 1600 SRM 1133

Steering Axle Table of Contents TABLE OF CONTENTS General ............................................................................................................................................................... 1 Steering Axle Assembly Repair ......................................................................................................................... 2 Remove ........................................................................................................................................................... 2 Disassemble ................................................................................................................................................... 3 Clean .............................................................................................................................................................. 3 Inspect ............................................................................................................................................................ 3 Assemble ........................................................................................................................................................ 10 Install ............................................................................................................................................................. 15 Spindles, Bearings, and Tie Rods Repair ......................................................................................................... 16 Spindles and Bearings ................................................................................................................................... 16 S2.0-3.5FT (S40-70FT, S55FTS) (F187), S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT; S80, 100FTBCS; S120FTS; S120FTPRS) (G004), H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005, P005), S6.0FT, S7.0FT, (S135FT,S155FT) (D024, E024), and H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006).................................................................................. 16 Remove .................................................................................................................................................. 16 Disassemble ........................................................................................................................................... 17 Clean ...................................................................................................................................................... 18 Inspect ................................................................................................................................................... 18 Assemble ................................................................................................................................................ 18 Install..................................................................................................................................................... 19 Spindles and Bearings ................................................................................................................................... 22 S30FT, S35FT, S40FTS (E010), H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, H40FTS) (F001), and H2.0-3.5FT (H40-70FT) (L177) ......................................................................................................... 22 Remove and Disassemble ..................................................................................................................... 22 Assemble and Install ............................................................................................................................ 22 Tie Rods .......................................................................................................................................................... 23 S2.0-3.5FT (S40-70FT, S55FTS) (F187), and S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT; S80, 100FTBCS; S120FTS; S120FTPRS) (G004)............................................................................................. 23 Remove .................................................................................................................................................. 23 Install..................................................................................................................................................... 24 Tie Rods .......................................................................................................................................................... 25 S30FT, S35FT, S40FTS (E010), H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, H40FTS) (F001), H2.0-3.5FT (H40-70FT) (L177), H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005, P005), S6.0FT, S7.0FT, (S135FT,S155FT) (D024, E024) and H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006) ................................................................................................ 25 Remove .................................................................................................................................................. 25 Install..................................................................................................................................................... 25 Steering Cylinder Repair ................................................................................................................................... 28 Remove and Disassemble .............................................................................................................................. 28 Clean and Inspect .......................................................................................................................................... 29 Assemble and Install ..................................................................................................................................... 29 Torque Specifications ......................................................................................................................................... 30 ©2008 HYSTER COMPANY i

Table of Contents Steering Axle TABLE OF CONTENTS (Continued) This section is for the following models: S30FT, S35FT, S40FTS [E010]; H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, H40FTS) [F001]; S2.0-3.5FT (S40-70FT, S55FTS ) [F187]; H2.0-3.5FT (H40-70FT) [L177]; S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; S80, 100FTBCS; S120FTS; S120FTPRS) [G004]; H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) [N005, P005]; S6.0FT, S7.0FT, (S135FT, S155FT) [D024, E024]; H6.0FT, H7.0FT (H135FT, H155FT) [H006, J006] ii

1600 SRM 1133 General General This section has the description and repair procedures for the steering axle. 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 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. A. CUSHION TRUCKS ONLY B. PNEUMATIC TRUCKS ONLY 1. AXLE FRAME 2. MOUNT 3. BRACKET 4. STEERING CYLINDER 5. TIE ROD 6. SPINDLE 7. MOUNT 8. HUB ASSEMBLIES Figure 1. Steering Axle 1

Steering Axle Assembly Repair 1600 SRM 1133 The end caps of the steering cylinder are also the mounts for the cylinder and are held to the shell by the mount capscrews. There are O-rings, seals, and wipers in the end caps to seal the caps to the shell and rod. 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 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 re- lief valve in the steering circuit controls the oil pressure. 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 wheels rotate on two tapered roller bearings and are held on the spindles by a castle nut. The bearing preload of the wheels 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. Steering Axle Assembly Repair REMOVE WARNING PUTTING THE LIFT TRUCK ON BLOCKS The lift truck must be put on blocks for some types of maintenance and repair. The removal of the mast, drive axle, battery, or counterweight assemblies will cause large changes in the center of gravity. When the lift truck is put on blocks, put additional blocks in the following positions: • If the mast and drive axle are removed, put blocks under the counterweight so the lift truck cannot fall backward. • If the counterweight is removed, put blocks under the mast so that the lift truck cannot fall forward. Put the lift truck on blocks on a solid, even, and level surface. Verify the blocks or stands have enough capacity to hold the lift truck. Use additional blocks next to the tires as necessary to prevent movement of the lift truck. Verify the lifting devices used during repairs can lift the weight of the parts and assemblies. See the Operating Manual or Periodic Mainte- nance section for your lift truck model, for the procedures to put the lift truck on blocks. The steering axle can be removed without removing the counterweight. 1. Verify wheels are set for straight travel. Put lift truck on blocks so the steering axle will have enough clearance to be removed. The top of the axle frame must have clearance under the bot- tom of the frame at the rear of the lift truck. 2. Disconnect hydraulic lines at steering cylinder. Install plug fittings in cylinder and put caps on hydraulic lines. Plug fittings will prevent spindles from turning as axle is removed from under the lift truck. NOTE: Steering Axle Assembly may be mounted to the frame with brackets or plates. 3. Slide floor jack or forks of another lift truck under steering axle. Raise lifting device until it holds the weight of the axle assembly. a. To remove bracket type mounts, remove four capscrews and nuts that fasten two brackets under rubber mounts. For lift truck models S2.0-3.5FT (S40-70FT, S55FTS) (F187), see Figure 2, for lift truck modelsH2.0-3.5FT (H40-70FT) (L177), see Figure 3, for lift truck models S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT; S80, 100FTBCS; S120FTS; S120FT- PRS) (G004), see Figure 5, and for H4.0FT5/ FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005, P005), see Fig- ure 6. Remove brackets and slowly lower axle assembly onto wheels. Carefully roll steering axle assembly away from lift truck. 2

Hyster G004 (S120FT) Forklift Service Manual

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