1600SRM1479 (11 2019) Us en PDF

STEERING SYSTEM
PART NO. 4034071 1600 SRM 1479

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 Maintenance 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 hazardous situation which, if not avoided, could result in death
or serious injury.
CAUTION
Indicates a hazardous situation which, if not avoided, could result in minor
or moderate injury and property damage.
On the lift truck, the WARNING symbol and word are on orange back-
ground. The CAUTION symbol and word are on yellow background.
Table of Contents
TABLE OF CONTENTS
Series Code / Model Designation Reference Table...............................................................................................1
General................................................................................................................................................................... 1
Steering System Main Component Identification................................................................................................1
Description and Operation.................................................................................................................................... 5
Steering System.................................................................................................................................................. 5
Introduction...................................................................................................................................................... 5
Description........................................................................................................................................................5
Hydraulic Oil Flow Path.................................................................................................................................. 5
Priority Valve...................................................................................................................................................... 5
Fundamentals...................................................................................................................................................5
Description........................................................................................................................................................5
Operation.......................................................................................................................................................... 5
Component Validation for Correct Operation.................................................................................................6
Steering Control Unit......................................................................................................................................... 6
Description........................................................................................................................................................6
Steering Control Valve..................................................................................................................................... 7
Fundamentals................................................................................................................................................ 7
Operation........................................................................................................................................................7
Component Validation for Correct Operation.............................................................................................. 7
Hand Pump....................................................................................................................................................... 7
Fundamentals................................................................................................................................................ 7
Operation........................................................................................................................................................7
Component Validation for Correct Operation.............................................................................................. 7
LS Relief Valve....................................................................................................................................................7
Fundamental.....................................................................................................................................................7
Operation.......................................................................................................................................................... 7
Shock Valve......................................................................................................................................................... 7
Fundamental.....................................................................................................................................................7
Operation.......................................................................................................................................................... 7
Steering Axle....................................................................................................................................................... 7
Hydraulic Troubleshooting Flowcharts................................................................................................................ 8
Hydraulic Pressure Checks Preparation........................................................................................................... 8
Steering Relief Pressure Check..........................................................................................................................9
Pressure Check, Port MLS1 and MLS2 on the Main Control Valve.............................................................. 10
Steering Wheel Lock to Lock Check.................................................................................................................10
Flowchart...........................................................................................................................................................11
Hydraulic Pressure Checks for Troubleshooting Flowcharts............................................................................12
Hydraulic Pressure Checks Preparation......................................................................................................... 12
Condition Check, Shuttle Valve L and M in the Main Control Valve............................................................12
Condition Check, Logic Element N in the Main Control Valve......................................................................13
Condition Check, Priority Valve on the Main Control Valve......................................................................... 13
Remove and Replace ...........................................................................................................................................14
Steering Control Unit....................................................................................................................................... 14
Remove............................................................................................................................................................ 14
Install.............................................................................................................................................................. 15
Wheels (A238, K007/J007 and H019/J019)..................................................................................................... 16
Remove............................................................................................................................................................ 16
Install.............................................................................................................................................................. 16
Wheels (C236, D214 and E214)........................................................................................................................16
Remove............................................................................................................................................................ 16
©2019 HYSTER COMPANY i

Table of Contents
TABLE OF CONTENTS (Continued)

Install.............................................................................................................................................................. 17
Steer Axle (K007/J007) (H019/J019)................................................................................................................17
Remove............................................................................................................................................................ 17
Install.............................................................................................................................................................. 18
Tie Rod (K007/J007) (H019/J019).................................................................................................................... 20
Remove............................................................................................................................................................ 20
Clean and Inspect...........................................................................................................................................20
Install.............................................................................................................................................................. 20
Steering Cylinder (K007/J007) (H019/J019)....................................................................................................20
Remove............................................................................................................................................................ 20
Assemble and Install...................................................................................................................................... 23
Hubs (K007/J007) (H019/J019)........................................................................................................................ 23
Remove and Disassemble...............................................................................................................................23
Spindle (K007/J007) (H019/J019).................................................................................................................... 24
Remove............................................................................................................................................................ 24
Clean............................................................................................................................................................... 25
Steer Axle (A238) ............................................................................................................................................. 25
Remove............................................................................................................................................................ 25
Install.............................................................................................................................................................. 26
Tie Rod (A238) ..................................................................................................................................................28
Remove............................................................................................................................................................ 28
Install.............................................................................................................................................................. 28
Steering Cylinder (A238) ................................................................................................................................. 28
Remove............................................................................................................................................................ 28
Hubs (A238) ......................................................................................................................................................32
Spindle (A238) .................................................................................................................................................. 34
Remove............................................................................................................................................................ 34
Steer Axle (D214 and C236 until C236E01652R)........................................................................................... 35
Remove............................................................................................................................................................ 35
Install.............................................................................................................................................................. 36
Tie Rod (D214 and C236 until C236E01652R)................................................................................................ 37
Remove............................................................................................................................................................ 37
Install.............................................................................................................................................................. 38
Steering Cylinder (D214 and C236 until C236E01652R)............................................................................... 38
Remove............................................................................................................................................................ 38
Hubs (D214 and C236 until C236E01652R)....................................................................................................41
ii
Table of Contents
TABLE OF CONTENTS (Continued)

Spindle (D214 and C236 until C236E01652R)................................................................................................ 42
Remove............................................................................................................................................................ 42
Steer Axle (E214 and C236 starting C236E01653R)...................................................................................... 43
Remove............................................................................................................................................................ 43
Install.............................................................................................................................................................. 44
Tie Rod (E214 and C236 starting C236E01653R)...........................................................................................46
Remove............................................................................................................................................................ 46
Install.............................................................................................................................................................. 46
Steering Cylinder (E214 and C236 starting C236E01653R).......................................................................... 46
Remove............................................................................................................................................................ 46
Hubs (E214 and C236 starting C236E01653R)...............................................................................................49
Spindle(E214 and C236 starting C236E01653R)............................................................................................ 51
Remove............................................................................................................................................................ 51
Checks and Adjustments.....................................................................................................................................52
Maximum Steering Angle Adjustment (K007/J007) (H019/J019)..................................................................52
Maximum Steering Angle Adjustment (A238)................................................................................................ 52
Torque Specifications...........................................................................................................................................53
iii
"THE
QUALITY
KEEPERS"
HYSTER
APPROVED
PARTS
1600 SRM 1479 Series Code / Model Designation Reference Table
Series Code / Model Designation Reference Table

This section is for the following models:
Series European Model Americas Model

Code
J007 H8.0-12.0XM-6 H190-280HD2
K007 H8-12XM-6, H10XMS-6 H190-280HD2, H230HDS
H019 H13.0-14.0XM-6, H16.0XM-6, H10.0-12.0XM-12EC H300-330HD2, H360HD2,
H360HD2-EC
J019 H13-16XM-6, H10-12XM-12EC H300-360HD2, H360HD2-EC
A238 H16XM-9, H16XM-12, H18XM-7.5, H18XM-9 H360-36HD, H360-48HD
C236 H18-20XM-9, H18-20XMS-9 H400HD, H450HD, H400HDS,
H450HDS
D214 H18XM-12EC, H22XM-12EC, H23XM-12EC H450HD-EC, H500HD-EC
E214 H8XM-EC6, H8XM-EC7, H9XM-EC7, H9XM-EC8, H9XM- H180HD-EC6 H180HD-EC7
ECD7, H9XM-ECD8, H10XM-ECD8, H11XM-ECD8, H200HD-EC7 H200HD-EC8
H11XM-ECD9 H200HD-ECD7 H190HD-ECD8
H210HD-ECD8 H230HD-ECD8
H230HD-ECD9
A3C0 H9XM-EC7
General
This section has the description, repair procedures, the most recent schematics and values, refer to the
and troubleshooting for the components of the manual
steering system.
Diagrams 8000SRM1655 (for A238).
Repair information for the steering column is in the
Diagrams 8000SRM1591 (for K007/J007 and H019/
manual Operator's Cab 0100SRM1390.
J019).
Repair information for the hydraulic pumps is in the
Diagrams 8000SRM1730 (for D214).
manual Hydraulic System 1900SRM1478.
Diagrams 8000SRM2071 (for E214).
The partial schematics and values shown in this
manual may vary from the complete schematics. For
Steering System Main Component Identification
Figure 1 and Figure 2 show the relation and locations of the steering system main components between the
schematic and the lift truck.
1
Steering System Main Component Identification 1600 SRM 1479
Figure 1. Steering System Schematic
2
1600 SRM 1479 Steering System Main Component Identification
Legend for Figure 1.
1. PRIORITY VALVE 6. VARIABLE DISPLACEMENT PUMP (SECONDARY)

2. STEERING CONTROL UNIT 7. MAIN CONTROL VALVE
3. STEERING CYLINDER 8. LOGIC ELEMENT (N)
4. HYDRAULIC TANK 9. ORIFICE (R)
5. VARIABLE DISPLACEMENT PUMP (PRIMARY)
3
Steering System Main Component Identification 1600 SRM 1479
Figure 2. Steering System Main Component Identification (K007 Shown)
4
1600 SRM 1479 Description and Operation
1. PRIORITY VALVE 6. MAIN CONTROL VALVE

2. STEERING CONTROL UNIT 7. STEER AXLE
3. STEERING CYLINDER 8. LOGIC ELEMENT (N)
4. HYDRAULIC TANK 9. ORIFICE (R)
5. VARIABLE DISPLACEMENT PUMP
Description and Operation

STEERING SYSTEM Hydraulic Oil Flow Path
Introduction Orifice (R), located in the Main Control Valve,
supplies a pilot flow that is flushed, via Logic
Steering is accomplished in this lift truck by the use Element (N) and the Steer Control Unit, to the tank
of an LS hydraulic steering system. The steering through the LS lines. The Pressure inside the LS
system includes a Priority Valve located in the Main circuit is limited, due to an internal restriction.
Control Valve and a Steering Control Unit. See
Steering System Main Component Identification, When the Steering Wheel is rotated, the flow
Figure 1, and Figure 2, item 1. supplied by Orifice (R) is connected to the Steer
Cylinder and it pressurizes the LS circuit to the
The Primary Variable Displacement Pump supplies required steering pressure. The LS pressure signal
flow via Priority Valve (A) to the Steering Control will activate the Variable Displacement Pump and
Unit. Priority Valve (A) to supply the demanded flow to
The Steering Control Unit supplies flow to the Steer the Steering Control Unit.
Cylinder in direct relation to the rotation of the The Steering Control Unit supplies flow to one side
Steering Wheel. of the Steer Cylinder in direct relation to the
rotation of the Steering Wheel and will direct flow
Description coming from the opposite side of the steer cylinder
The steering system, with the use of a priority valve back to tank.
(Steering System Main Component Identification,
Figure 1 and Figure 2, item 1), will supply the PRIORITY VALVE
required hydraulic oil flow to the steering cylinder
(Steering System Main Component Identification,
Fundamentals
Figure 1 and Figure 2, item 3) as demanded by the Priority valves are based on pressure compensated
operation of the steering wheel. flow control valves.
The steering system shares the priority valve with
the brake system. Description
One function of the priority valve is to supply The priority valve prioritizes the required flow to
hydraulic oil flow to the steering system, which is the steering system and brake accumulator
accomplished by sending an LS pressure signal to charging system over the flow requirements of other
the priority valve. functions.
Another function of the priority valve is to supply Operation

hydraulic oil flow to the brake accumulator charging
system, which is also accomplished by sending an The primary variable displacement pump will
LS pressure signal to the priority valve. supply the flow that is required by the hydraulic
system. The priority valve will divide the flow
When both functions are active at the same time, between the priority functions and other hydraulic
the function with the highest demanded function functions. The priority valve will guarantee that the
pressure will control the pressure of the LS pressure required flow is supplied to the priority functions.
signal.
5
Description and Operation 1600 SRM 1479
The selection (position) of the priority spool is There are four internal components in the steering
directly related with the output flow to the priority control unit. Refer to Figure 3 and Table 1 for the
functions. This spool selection is controlled by the schematic view and list of the internal components
pressure differential between the pressure directly and their basic functions.
behind the priority spool and the LS signal (function
pressure of the priority function that is active), to
the priority valve.
When more flow is supplied by the variable
displacement pump to the priority valve than
required for the priority function, the pressure
differential will not be in balance with the priority
valve setting (spring) and the priority spool will
shift to relieve the excessive flow to the pressure
gallery of the main control valve. For additional
information on the main control valve, refer to the
manual Hydraulic System 1900SRM1478.
Component Validation for Correct

Operation
Remove the priority valve from the main control
valve. With a clean suitable tool, press the priority
spool into the cartridge. If the priority spool moves
smoothly against the spring, the priority valve is
functioning properly and may be reinstalled. When
installing the priority valve, DO NOT exceed the
maximum torque of NOTE: FOR FIGURE LEGEND SEE TABLE 1
217 to 231 N•m (160 to 170 lbf ft).
Figure 3. Internal Components of the Steering
STEERING CONTROL UNIT Control Unit
Description
The steering control unit supplies flow to the
steering cylinder in direct relation to the rotation of
the steering wheel.
Table 1. Internal Components of the Steering Control Unit

Component Item Basic Function
Number
Steering Control Valve 1 Controls flow to and from the hand pump.
Hand Pump 2 Displaces flow to the steering cylinder/flow amplifier valve based
solely on the movement of the steering wheel.
LS Relief Valve 3 Will protect the steering system against excessive pressures by
opening to relieve excessive pressure to the hydraulic tank.
Shock Valves 4 When there is an external impact to the steering system, the shock
valves open, allowing the operator some controlled movement of the
steering system to help relieve the effects of impact.
6
1600 SRM 1479 Description and Operation
Steering Control Valve (active), the flow from the variable displacement
pump will also be affected.
Fundamentals
By relieving the LS pressure to the hydraulic tank,
The steering control valve is a mechanically required flow for the steering system will be
operated directional control valve. returned to zero and if no other hydraulic functions
are being operated, the variable displacement pump
Operation will return to zero output flow.
When the steering wheel is turned, the steering
control valve will mechanically shift to the required Component Validation for Correct
position based on the direction the steering wheel is Operation
turned. The setting of the LS relief valve can be measured
on measurement port MLS1. Refer to the section
Component Validation for Correct Hydraulic Pressure Checks for Troubleshooting
Operation Flowcharts.
Refer to the section Hydraulic Pressure Checks for
Troubleshooting Flowcharts. SHOCK VALVE
Fundamental
Hand Pump
The shock valve is a direct-acting relief valve based
Fundamentals on a pressure control valve.
The hand pump is based on a fixed displacement
pump. Operation
The shock valve has two pressure relief valves, one
Operation positioned at each of the steering cylinder lines.
The steering control valve provides flow to the hand When an external impact creates a pressure greater
pump. The hand pump displaces flow at a fixed rate than the relief valve settings, the relief valves will
through the steering control valve, based on the open to relieve the pressure and the flow will be
movement and direction of the steering wheel. The directed to the opposite side of the steering cylinder.
rotation speed of the hand pump is limited by the Check valves are positioned in the steering cylinder
flow supplied by the priority valve. lines to prevent the flow through these lines when
the relief valves are closed.
Component Validation for Correct
Operation Component Validation for Correct
Refer to the section Hydraulic Pressure Checks for Operation
Troubleshooting Flowcharts. Refer to the section Hydraulic Pressure Checks for
Troubleshooting Flowcharts.
LS RELIEF VALVE
STEERING AXLE
Fundamental
The steering axle includes a steering axle frame,
The LS relief valve is a direct-acting relief valve
steering cylinder, tie rods, pivot pin, two spindles,
based on a pressure control valve.
and wheel hub assemblies. See Figure 4.
Operation The pivot pin secures the steering axle assembly to
the lift truck frame and supports the weight of the
When the Steer Control Unit is selected, the LS line lift truck. When the steer tires are lifted from the
is connected to the steering function pressure and if ground or surface, the pivot pin will support the
the pressure is greater than the LS relief valve weight of the steer axle. The maximum load is on
setting, the LS relief valve will open a line to the the steer axle when the lift truck is not lifting a
hydraulic tank and control the maximum steering load. When the lift truck travels over rough or
pressure. When the LS relief valve is opening uneven surfaces, the pivot pin permits the steering
7
Hydraulic Troubleshooting Flowcharts 1600 SRM 1479
axle to articulate without stressing the frame or The position of the steering wheel and steering
shifting the load. cylinder also controls the turning radius of the lift
truck.
The spindle and wheel hub assemblies are
connected to the steering cylinder with the tie rods. To minimize tire wear and to optimize the turning
When the steering wheel is turned by the operator, radius, it is critical that all steering axle
the hydraulic system will supply flow to one side of components are in good condition and have minimal
the steering cylinder to force the steer wheels to free play.
turn in the direction the steering wheel is turned.
1. WHEEL HUB ASSEMBLY 4. TIE ROD

2. STEERING AXLE FRAME 5. PIVOT PIN
3. SPINDLE 6. STEERING CYLINDER
Figure 4. Steer Axle
Hydraulic Troubleshooting Flowcharts

HYDRAULIC PRESSURE CHECKS 1. Place the lift truck on a solid, level surface.
PREPARATION
2. Apply the parking brake.
WARNING 3. Lower the carriage until the lift cylinders are
The engine must be at room temperature before approximately 25 cm (10 in.) before the
starting disassembly or personal injury may occur. completely retracted position.
8
1600 SRM 1479 Hydraulic Troubleshooting Flowcharts
4. Tilt the mast to the maximum forward position.
5. Shut down the engine.
6. Place blocks on both sides (front and back) of

the tires to prevent movement of the lift truck.
7. Turn the key switch to the ON position. DO

NOT START THE ENGINE.
WARNING
Step 8, Step 9, and Step 10 must be performed to
relieve the trapped or stored hydraulic pressure
from the hydraulic system, or serious personal
injury may occur.
8. Apply brake pedal 10 to 20 times until

accumulated hydraulic brake pressure is
released. 1. CHECK PORT MLS1
2. CHECK PORT MLS2
9. Use the emergency lowering button and 3. PRIORITY VALVE
operate the tilt function fully backward to
remove the hydraulic pressure from the tilt Figure 5. Priority Valve, Check Port MLS1, and
system. Check Port MLS2
10. Use the emergency lowering button and 2. Connect a 0 to 30 MPa (0 to 4,351 psi)
operate the lowering function to remove the hydraulic pressure gauge at port MLS1.
hydraulic pressure from the lift system. Make
sure the lift cylinders are completely retracted. 3. Start the engine and check the pressure with
the engine at idle speed and steering wheel
11. Turn the key switch to the OFF position. positioned at the end of stroke.
STEERING RELIEF PRESSURE CHECK 4. If the pressure is lower than 15 MPa (2176 psi),
the Steer Control Unit must be replaced. Refer
to the section Remove and Replace .
WARNING
Before performing the following procedure, the 5. Shut down the engine.
Hydraulic Pressure Checks Preparation procedure
must be performed or serious personal injury may
occur. WARNING
Before performing the following procedure, Step 7
1. Remove the cap from check port MLS1 on the through Step 11 in the Hydraulic Pressure Checks
main control valve. See Figure 5. Preparation procedure must be performed or
serious personal injury may occur.
6. Remove the pressure gauge from port MLS1.
7. Install the cap on check port MLS1 on the main

control valve.
9
Hydraulic Troubleshooting Flowcharts 1600 SRM 1479
PRESSURE CHECK, PORT MLS1 AND 7. Remove the pressure gauges from port MLS1
MLS2 ON THE MAIN CONTROL VALVE and port MLS2.
8. Install the caps on check ports MLS1 and

WARNING MLS2 on the main control valve.
Before performing the following procedure, the
Hydraulic Pressure Checks Preparation procedure STEERING WHEEL LOCK TO LOCK
CHECK
occur.
1. Start the engine and turn the steering wheel in
1. Remove the caps from check ports MLS1 and one direction until the lock in that direction has
MLS2 on the main control valve. See Figure 5. been reached.
2. Connect a 0 to 30 MPa (0 to 4,351 psi) 2. Turn the steering wheel at a pace greater than
hydraulic pressure gauge at port MLS1. 1 turn per second in the opposite direction
while counting the number of turns until the
3. Connect a 0 to 30 MPa (0 to 4,351 psi) lock in that direction is reached.
hydraulic pressure gauge at port MLS2.
3. Compare the number of turns from lock to lock
4. Start the engine and check the pressures with with the number of turns stated in the
the engine at idle speed. flowchart that referred to this procedure. See
Table 2.
5. Compare the pressures with the pressures
stated in the flowchart step that referred to 4. Shut down the engine.
this procedure. See Table 2.
WARNING
Before performing the following procedure, Step 7
through Step 11 Page 9 in the Hydraulic Pressure
Checks Preparation procedure must be performed
or serious personal injury may occur.
10
1600 SRM 1479 Hydraulic Troubleshooting Flowcharts
FLOWCHART Pressure Checks for Troubleshooting Flowcharts in

this manual unless the flowchart specifies to refer to
For check and adjustment procedures referred to another manual.
the flowchart, refer to the section Hydraulic
Table 2. Flowchart
'START
PROCED
Steering
URE
response is
HERE' Check/Clean
―YES―▸ slow (Hard ―YES―▸
Steering is Orifice (R).
point at start of
hard or
steering).|
not
possible.
|
NO
|
▾
Steering is
Replace
hard during
―YES―▸ Steering
unloaded
Control Unit.
conditions only.
|
NO
|
▾
Measure
pressure
Measure
at MLS1.
pressure at
Check position When the
MLS1 and
of Steering
MLS2 when
Transmission Wheel is Clean/
operating
Calibration operated, Replace
―YES―▸ the Steering ―YES―▸ ―YES―▸
Switch. Is is the Priority
Wheel. Are
switch in pressure Valve (A).
the
proper at MLS1
measured
position? higher
pressures
than
equal?
50 bar
(725 psi)?
| | |
NO NO NO
| | |
▾ ▾ ▾
Place the Replace
switch in Replace Steering
correct shuttle (L). Control
position. Unit.
11
Hydraulic Pressure Checks for Troubleshooting Flowcharts 1600 SRM 1479
Hydraulic Pressure Checks for Troubleshooting Flowcharts

HYDRAULIC PRESSURE CHECKS CONDITION CHECK, SHUTTLE VALVE L
PREPARATION AND M IN THE MAIN CONTROL VALVE
WARNING WARNING
The engine must be at room temperature before Before performing the following procedure, the
starting disassembly or personal injury may occur. Hydraulic Pressure Checks Preparation procedure
1. Place the lift truck on a solid, level surface. occur.
2. Apply the parking brake. 1. Remove the shuttle valve at port L and M on
the main control valve. See Figure 6.
3. Lower the carriage until the lift cylinders are
approximately 25 cm (10 in.) before the
completely retracted position.
4. Tilt the mast to the maximum forward position.


WARNING
relieve the trapped or stored hydraulic pressure
from the hydraulic system, or serious personal 1. SHUTTLE VALVE L
injury may occur. 2. LOGIC ELEMENT N
3. SHUTTLE VALVE M
8. Apply brake pedal 10 to 20 times until
accumulated hydraulic brake pressure is Figure 6. Shuttle Valve L, M,and Logic Element N in
released. the Main Control Valve
9. Use the emergency lowering button and 2. Check the condition of the shuttle valve for
operate the tilt function fully backward to signs of wear, grooves, and damage. If any
remove the hydraulic pressure from the tilt signs of wear, grooves, or damage are present,
system. replace the shuttle valve.
10. Use the emergency lowering button and 3. Install new O-rings on the shuttle valve.
operate the lowering function to remove the
hydraulic pressure from the lift system. Make 4. Install the shuttle valve at port L and M on the
sure the lift cylinders are completely retracted. main control valve and tighten to
34 to 40 N•m (25 to 30 lbf ft).
11. Turn the key switch to the OFF position.
12
1600 SRM 1479 Hydraulic Pressure Checks for Troubleshooting Flowcharts
CONDITION CHECK, LOGIC ELEMENT N

IN THE MAIN CONTROL VALVE
WARNING
Before performing the following procedure, the
Hydraulic Pressure Checks Preparation procedure
occur.
1. Remove the logic element at port N on the main

control valve. See Figure 6.
2. Check the condition of the logic element for

signs of wear, grooves, and damage. If any
signs of wear, grooves, or damage are present,
replace the logic element.
3. Install new O-rings on the logic element.

1. CHECK PORT MLS1
4. Install the logic element in port N on the main 2. CHECK PORT MLS2
control valve and tighten to 3. PRIORITY VALVE
34 to 40 N•m (25 to 30 lbf ft).
Figure 7. Priority Valve, Check Port MLS1, and
CONDITION CHECK, PRIORITY VALVE ON Check Port MLS2
THE MAIN CONTROL VALVE 2. With a clean suitable tool, press the spool into
the cartridge. If the spool moves smoothly
WARNING against the spring, the priority valve is
Before performing the following procedure, the functioning properly and may be reinstalled. If
Hydraulic Pressure Checks Preparation procedure the spool does not move smoothly, replace the
must be performed or serious personal injury may priority valve.
occur.
3. Install a new seal kit on the priority valve.
1. Remove the priority valve from the main
control valve. See Figure 7.
CAUTION
DO NOT exceed the maximum torque when
installing the priority valve, as component damage
may occur.
4. Install the priority valve into the main control

valve. Tighten the priority valve to
217 to 231 N•m (160 to 170 lbf ft).
13
Remove and Replace 1600 SRM 1479
Remove and Replace

STEERING CONTROL UNIT
Remove
1. Place the lift truck on a solid, level surface.
2. Lower the carriage until the lift cylinders are

approximately 25 cm (10 in.) from the fully
retracted position.
3. Tilt the mast completely forward.
4. Shut down the engine and turn the key switch

to the OFF position.


WARNING
relieve the trapped or stored hydraulic pressure 1. HOSE (L) 4. HOSE (T)
from the hydraulic system, or serious personal 2. HOSE (R) 5. STEERING CONTROL
injury may occur. 3. HOSE (P) UNIT
6. HOSE (LS)
7. Apply brake pedal 10 to 20 times until Figure 8. Steering Control Unit
accumulated hydraulic brake pressure is
released.
8. Use the emergency lowering button and

WARNING
operate the tilt function fully backward to The steering control unit weighs approximately
remove the hydraulic pressure from the tilt 6 kg (13.2 lb) and can cause serious injury if the
system. steering control unit is not lifted properly or falls.
Make sure the steering control unit is properly
9. Use the emergency lowering button and supported before removing the capscrews and
operate the lowering function to remove the washers.
hydraulic pressure from the lift system. Make
sure the lift cylinders are completely retracted. 13. Remove the four capscrews and washers that
retain the steering control unit to the underside
10. Turn the key switch to the OFF position. of the operator’s cab. See Figure 9.
11. Raise the cab to the fully open position to gain 14. Remove the steering control unit from the
access to the steering control unit. Refer to the steering column at the underside of the
manual Operator's Cab 0100SRM1390. operator’s cab and place the steering control
unit on a clean and level surface.
12. Tag and disconnect the five hydraulic hoses
from the steering control unit. Place caps and
plugs on the five hydraulic hoses and the open
ports of the steering control unit. See Figure 8.
14
1600 SRM 1479 Remove and Replace
3. Remove the plugs and caps from hydraulic

hoses and the ports on the steering control
unit.
4. Connect the hydraulic hoses to the steering

control unit according to the identification tags.
Tighten the hoses to the correct torque as
described in the section Torque Specifications.
5. Check the fluid level in the hydraulic tank. Add

hydraulic fluid if necessary, as specified in the
maintenance table in the manual.
Periodic Maintenance 8000SRM1475 (for
H019/J007).
K007/J019).
A238).
C236).
D214).
E214).
6. Start the engine and operate the steering

system. Make sure the steering control unit
operates correctly.
1. OPERATOR'S CAB
2. STEERING CONTROL UNIT
3. WASHER
4. CAPSCREW WARNING
DO NOT try to locate hydraulic leaks by placing
Figure 9. Steering Control Unit, View Under hands on pressurized hydraulic components.
Operator's Cab Hydraulic oil can be injected into the body by
pressure.
Install
7. Check for leaks.
CAUTION 8. Lower the cab until it is in the fully lowered
DO NOT force the steering control unit onto the and latched position. Refer to the manual
steering column shaft, as damage can occur. Operator's Cab 0100SRM1390.
1. Place the steering control unit in position
under the cab while aligning the steering
column shaft with the slot in the steering
control unit.
2. Install the four capscrews and washers that

retain the steering control unit to the underside
of the operator’s cab.
15
WHEELS (A238, K007/J007 AND H019/

J019) WARNING
When the wheels have been installed, check all
Remove wheel nuts after 2 to 5 hours of operation. Tighten
the nuts to the correct torque. When the nuts stay
WARNING tight after an 8-hour check, the interval for
checking can be extended to time specified in the
Completely remove the air from the tire before
Periodic Maintenance section.
removing the tire and wheel from lift truck. Air
pressure in the tires can cause the tire and wheel 5. Repeat procedure for other wheel.
parts to explode, causing serious injury or death.
1. Raise axle to remove weight from tires, but

have tires still touching the floor. Loosen wheel
nuts just enough so they can be easily removed.
Raise axle so tires can be removed. Use a tire
jack to remove tires and wheels.
2. If a tire jack is not available, raise axle only

enough so tires are just touching the floor.
Slide tires from axle while they are still on the
floor.
Install
1. If bearings in hubs must be replaced, use a
press to install new inner and outer bearing
cups in hub. Install a new wear sleeve in wheel
hub.
Figure 10. Wheel Nut Tightening Sequence
2. Install grease seal on spindle. Lubricate
bearing cones and seal surfaces with grease. WHEELS (C236, D214 AND E214)
Make sure bearings are filled with grease.
Install inner bearing cone on spindle. Remove
WARNING WARNING
Completely remove the air from the tire before
Add air to the tires only in a safety cage. Inspect
removing the tire and wheel from lift truck. Air
safety cage for damage before use. When adding
pressure in the tires can cause the tire and wheel
air, use a clip on chuck with enough hose to let the
operator stand clear of the cage.
1. Raise axle to remove weight from tires, but
3. Install wheel on hub. Be careful not to damage
have tires still touching the floor. Loosen wheel
threads on studs.
nuts just enough so they can be easily removed.
4. Start with wheel nut at the top and tighten Raise axle so tires can be removed. Use a tire
nuts to 65 to 130 N•m (48 to 96 lbf ft) in jack to remove tires and wheels.
sequence shown. Make sure there is no dirt
between wheel and hub. The wheel must fit
over the pilot surface and be tight against the
hub. Tighten nuts to
floor.
615 to 710 N•m (454 to 524 lbf ft). See
Figure 10.
16
Install
1. If bearings in hubs must be replaced, use a
press to install new inner and outer bearing
cups in hub. Install a new wear sleeve in wheel
hub.
2. Install grease seal on spindle. Lubricate

bearing cones and seal surfaces with grease.
Make sure bearings are filled with grease.
Install inner bearing cone on spindle.
WARNING
air, use a clip on chuck with enough hose to let the Figure 11. Nut Tightening Sequence for Steering
operator stand clear of the cage. Axle and Standard Drive Axle
3. Install wheel on hub. Be careful not to damage STEER AXLE (K007/J007) (H019/J019)
threads on studs.
Remove
4. Start with the wheel nut at the top and tighten
the nuts to 25 to 75 N•m (20 to 55 lbf ft) in the
sequence shown in Figure 11. Check to make WARNING
sure that the wheel is tight against the hub, Put the lift truck on blocks. Follow the procedures
then tighten the nuts to for raising the lift truck described in the Operating
640 to 680 N•m (472 to 502 lbf ft). Manual for this lift truck. The surface must be
solid, even, and level. Make sure the blocks are
solid, one-piece units. Make sure the lifting
WARNING devices used during repairs can lift the weight of
the parts.
When the wheels have been installed, check all
wheel nuts after 2 to 5 hours of operation. Tighten
the nuts to the correct torque. When the nuts stay
tight after an 8-hour check, the interval for WARNING
checking can be extended to time specified in the Completely remove the air from the tire before
Periodic Maintenance section. removing the tire and wheel from lift truck. Air
pressure in the tires can cause the tire and wheel
5. Repeat procedure for other wheel. parts to explode, causing serious injury or death.
NOTE: The steering axle can be removed without

removing the counterweight.
1. Remove the steer wheels. Raise axle to remove
weight from tires, but have tires still touching
the floor. Loosen wheel nuts just enough so
they can be easily removed. Raise axle so tires
can be removed. Use a tire jack to remove tires
and wheels.

floor.
17
3. Put blocks under frame in front of steer axle, so 6. Remove bushing, shim and flange from steering
steering axle can be removed. Top of steering axle mounting shaft. Remove and discard seal
axle must have clearance under counterweight ring from shaft.
so the steering axle can be removed.
Install
4. Disconnect hydraulic hoses at steering cylinder.
Install caps on cylinder fittings at the end caps
and put plugs in hydraulic hoses. Caps will WARNING
prevent spindles from turning when axle is Excessive play in the shaft bushings will result in
removed from under the lift truck. increased shock loadings to the shafts and
increased movement of the axle, and may affect
5. Slide a floor jack or forks of another lift truck steering responsiveness. If movement in the shaft
under steering axle. Raise lifting device until it bushings is more than 4 mm (0.16 in.), or damage
holds weight of axle assembly. Remove four to the seals ring exists, replace the bushings,
capscrews and washers that fasten two hanger flanges, and seal ring.
cups to frame. Remove hanger cups and slowly
lower axle assembly. Carefully remove axle 1. Install seal ring, flange, and shims on each
assembly from under lift truck. shaft. Lubricate shafts with multipurpose
grease and install bushing. See Figure 12.
18
1. HUB ASSEMBLY 10. CAPSCREW 20. SHAFT

2. STUD 11. BEARING CONE 21. TIE ROD
3. BEARING CUP 12. BEARING CAP 22. BUSHING
4. WEAR SLEEVE 13. SHIM 23. ANCHOR
5. HUB CAP 14. OIL SEAL 24. STEERING CYLINDER
6. COTTER PIN 15. LUBE FITTING 25. FITTING
7. CASTLE NUT 16. PIN 26. O-RING
8. WASHER 17. PLATE 27. FLANGE
9. LOCKWASHER 18. SPINDLE 28. HANGER CUP
19. FRAME
Figure 12. Steer Axle (K007/J007) (H019/J019)
19
2. Use a floor jack or another lift truck to put Install

steering axle into position in frame. Make sure
bushings fit into mounts of frame. 1. Install seals on the greased tie rod ball bearing
and insert with the tie rod in the spindle. Use
3. Install hanger cups. Tighten capscrews to an alignment pin to align tie rod and seals with
270 N•m (199 lbf ft). After installation, make the mounting bore in the spindle.
sure there is zero clearance between shims and
frame. Add or remove shims as necessary to get 2. Install tie rod pin at the spindle and at the
zero clearance. cylinder with the grease fitting facing
downward and insert the anchor pin.
4. Remove plugs and caps, and connect hydraulic
lines to steering cylinder. 3. Install the cap screw to secure the anchor pin
and tighten the cap screw to 30 N•m (22 lbf ft).
WARNING 4. Apply EP2/3 grease to the grease nipples on the

tie rod pins until grease escapes from the seals.
NOTE: Tie rods do not have an adjustment for
wheel alignment.
operator stand clear of the cage.
STEERING CYLINDER (K007/J007) (H019/
5. Install wheel on hub. See Wheels, Install. J019)
TIE ROD (K007/J007) (H019/J019) Remove

1. Disconnect tie rods at the steering cylinder by
Remove removing cap screw, anchor pin and tie rod pin.
1. Remove wheel as described in Wheels, Remove
procedures. 2. Rotate tie rods backward, out of slot in steering
cylinder. See Figure 13.
2. Remove cap screw from anchor pin and remove
anchor pins at cylinder and at spindle. 3. Disconnect hydraulic hoses on steering cylinder
at end caps. Install plastic caps on cylinder
3. Remove tie rod, with seals. fittings and put plugs in hydraulic hoses. Caps
will prevent piston rod from moving when
Clean and Inspect steering cylinder is removed from steering axle.
4. Support the cylinder under the tie rods. The

WARNING cylinder weighs 48 kg (106 lbs). Remove nuts
Cleaning solvents can be flammable and toxic and and washers from the hex head bolts that hold
can cause skin irritation. When using cleaning the steering cylinder to the axle frame.
solvents, always follow the recommendations of
the manufacturer. 5. Hold end caps in the cylinder and remove
steering cylinder.
1. Make sure bearings are clean and not worn.
6. Hold end of steering cylinder over a drain pan.
2. Verify tie rod does not show cracks. Remove plastic cap from cylinder fitting at each
end cap. Push piston rod towards end of
3. Re-lubricate bearings before re-installing tie cylinder shell that is over drain pan. Oil will
rod. drain from steering cylinder. See Figure 14.
7. Remove end cap on one side of cylinder.
8. Remove piston rod by pulling it out of the

cylinder shell. Keep piston rod in center of
cylinder shell during removal.
20
9. Remove opposite cylinder end cap. 10. Remove the seals, wipers, O-rings, backup
rings and wear rings from piston and end caps.
See Figure 14.
1. HEX HEAD BOLT 5. CAPSCREW

2. WASHER 6. ANCHOR
3. TIE ROD PIN 7. STEERING CYLINDER
4. TIE ROD 8. AXLE FRAME
Figure 13. Steering Cylinder Mounting
21
1. SHELL 6. ROD WIPER

2. O-RING 7. WEAR RING
3. BACKUP RING 8. PISTON SEAL
4. END CAP 9. PISTON ROD
5. ROD SEAL
Figure 14. Steering Cylinder
Clean and Inspect 1. Clean all parts in solvent. Use compressed air
to dry parts.
WARNING 2. Inspect piston rod for grooves or damage.

Cleaning solvents can be flammable and toxic and Remove small scratches with fine emery cloth.
can cause skin irritation. When using cleaning
solvents, always follow the recommendations of 3. Verify distance rings are not damaged and the
the manufacturer. Compressed air can move installed O-ring prevents the distance ring
particles so they cause injury to the user or to from sliding on the rod.
other personnel. Make sure the path of the
compressed air is away from all personnel. Wear 4. Inspect cylinder shell for damage. Inspect for
protective goggles or a face shield to prevent wear between the shell and the end caps.
injury to the eyes.
5. Inspect end caps for cracks and wear.
22
6. Replace damaged components as necessary. 10. Start engine, and operate steering system to
remove air from steering cylinder and system.
Assemble and Install Turn steering wheel several times from one
wheel stop to the other wheel stop.
CAUTION 11. Check for hydraulic leaks.

DO NOT damage the seals, O-rings, wipers, or
backup rings during installation. HUBS (K007/J007) (H019/J019)
NOTE: Always use new seals, O-rings, rod wipers, Remove and Disassemble
wear rings, and backup rings. Make sure all parts 1. Remove the wheel. See Wheels, Remove.
are clean.
1. Lubricate the piston seal and two guide rings 2. Remove grease cap from hub.
with clean hydraulic oil and install onto the
piston. See Figure 14. 3. Remove cotter pin, castle nut and washer from
spindle.
2. Lubricate the seals, wipers, O-rings, and
backup rings with clean hydraulic and install NOTE: The hub assemblies for this truck model
onto the end caps. weigh 58 to 63 kg (128 to 139 lb). Use a lifting
device when removing the hub assembly.
4. Remove outer bearing cone and hub from
CAUTION spindle and put on a flat clean surface.
Use caution when installing the piston rod into the
cylinder shell or damage to the cylinder shell may 5. Remove seal and inner bearing cone from hub.
occur.
Clean and Inspect
3. Slide piston rod into cylinder shell. Keep piston
rod in center of cylinder shell during
installation. WARNING
Cleaning solvents can be flammable and toxic and
4. Slide end caps over piston rod, into cylinder can cause skin irritation. When using cleaning
shell. Slide other end cap over piston rod and solvents, always follow the recommendations of
into cylinder shell. the manufacturer.
5. Move and install steering cylinder to steering 1. Clean all parts with solvent. Make sure
axle frame and install washers and cap screw. bearings are clean and dry.
Tighten cap screws to 435 N•m (321 lbf ft).
2. Inspect the bearings, bearing cups and seal.
6. Remove plastic caps from fittings on steering Replace as necessary. Use appropriate pushers
cylinder at end caps. Also remove plugs from when replacing cups with a press.
hydraulic hoses.
3. Inspect spindle and hub for cracks and damage.
7. Connect hydraulic hoses to steering cylinder. Ensure spindle and hub do not have any rough
or sharp areas that would prevent the bearings
8. Rotate the tie rods with seals and spacers to from being correctly installed. If necessary,
align with the steering cylinder tie rod pin smoothen any rough or sharp areas before
holes. installing the bearings.
9. Install tie rod pins with grease fitting facing 4. Inspect the contact surface between spindle
downward, install anchor pins and secure with and seal. Smoothen as necessary.
cap screws. Tighten cap screws to
30 N•m (22 lbf ft).
23
Assemble and Install

1. Apply EP2/3 grease and install inner bearing
cone and seal on hub. Install the seal in the
hub until it almost touches the face of the inner
bearing cone.
2. Fill the cavity inside the hub with EP2/3

grease.
NOTE: The hub assembly for this truck model

weighs 58 to 63 kg (128 to 139 lb). Use a lifting
device when installing the hub assembly on the
spindle.
3. Use a lifting device to position the hub on the
spindle.
4. Install the outer bearing cone, washer and

castle nut. Figure 15. Wheel Nut Tightening Sequence
5. Install washer and castle nut. Tighten castle

nut to 203 N•m (150 lbf ft) while rotating SPINDLE (K007/J007) (H019/J019)
wheel hub in both directions to properly seat Remove
the bearings. Loosen castle until wheel hub
turns freely with no end play. 1. Remove wheel, tie rod and hub as described in
Wheel, Remove, Tie Rod, Remove and Wheel
6. Tighten castle nut to 34 N•m (25 lbf ft) and Hub, Remove.
lock in place, with cotter pin, at first alignment
position that occurs at or above 34 N•m (25 lbf 2. Remove three cap screws, three washers,
ft). If cotter pin cannot be installed tighten grease plate and O-ring from upper steering
castle nut to first alignment position where the frame. Discard O-ring. See Figure 12.
cotter pin can be installed.
3. Remove three cap screws and three washers
7. Completely fill hub cap with grease and install from bearing cap and shims located on the
in hub. lower steering frame. See Figure 12. If
necessary, remove bearing cup from bearing
cap. See Figure 16.
WARNING
NOTE: The spindle weighs 26.7 kg (58.9 lb) Use a
lifting device when removing or installing the
spindle.
operator stand clear of the cage. 4. Tilt spindle and lift spindle from axle.
8. Install wheel on hub. Be careful not to damage

threads on studs.
9. Start with wheel nut at the top and tighten

nuts to 65 to 130 N•m (48 to 96 lbf ft) in
sequence shown. Make sure there is no dirt
between wheel and hub. The wheel must fit
over the pilot surface and be tight against the
hub. Tighten nuts to
615 to 710 N•m (454 to 524 lbf ft). See
Figure 15.
24
3. Install spindle in steering axle and make the

following bearing adjustment:
NOTE: Spindle bearings must have no clearance.

Install shims 0.00 to 0.13 mm (0.000 to 0.005 in.)
less than measured clearance.
a. Install bearing cap without shims. Tighten
three capscrews to 20 N•m (15 lbf ft). Rotate
spindle, then tighten capscrews to 20 N•m
(15 lbf ft) again. Loosen capscrews and
tighten again to 14 N•m (10 lbf ft). Measure
gap. Install correct amount of shims to equal
the gap. Tighten capscrews to 77 N•m (56.8
lbf ft).
4. Install new O-ring, grease plate and three

capscrews to top of steering frame. See
Figure 12.
5. Install tie rod as described in Tie Rods

procedures.
6. Repeat procedure for other spindle.
7. Install hubs and wheels as described in Wheels

and Hubs, Assemble and Install.
1. PRY BAR
2. BEARING CUP
3. BEARING CAP STEER AXLE (A238)
Figure 16. Bearing Cup Removal Remove
Clean WARNING
Put the lift truck on blocks. Follow the procedures
WARNING for raising the lift truck described in the Operating
Cleaning solvents can be flammable and toxic and Manual for this lift truck. The surface must be
can cause skin irritation. When using cleaning solid, even, and level. Make sure the blocks are
solvents, always follow the recommendations of solid, one-piece units. Make sure the lifting
the manufacturer. devices used during repairs can lift the weight of
the parts.
1. Clean all parts in solvent. Make sure bearings
are clean and dry.
WARNING
Assemble and Install Completely remove the air from the tire before
1. Install new seals on spindle. Lubricate seals removing the tire and wheel from lift truck. Air
with grease. See Figure 12. pressure in the tires can cause the tire and wheel
2. Lubricate bearings with wheel bearing grease.
Make sure bearings are filled with grease. If NOTE: The steering axle can be removed without
necessary, press new bearing cups into steering removing the counterweight.
axle frame and bearing cap. Install wear sleeve
in steering axle frame.
25
1. Remove the steer wheels. Raise axle to remove steering responsiveness. If movement in the shaft
weight from tires, but have tires still touching bushings is more than 4 mm (0.16 in.), or damage
the floor. Loosen wheel nuts just enough so to the seals ring exists, replace the bushings,
they can be easily removed. Raise axle further flanges, and seal ring.
so tires can be removed. Use a tire jack to
remove tires and wheels. 1. Lubricate shafts with multipurpose grease,
install bushing and thrust washer. See
2. If a tire jack is not available, raise axle only Figure 17.
Slide tires from axle while they are still on the 2. Use a floor jack or another lift truck to put
floor. steering axle into position in frame. Make sure
bushings fit into mounts of frame.
3. Put blocks under frame in front of steer axle, so
steering axle can be removed. Top of steering 3. Install hanger cups. Tighten cap screws to 550
axle must have clearance under counterweight N•m (405 lbf ft).
so the steering axle can be removed.
4. After installation, make sure there is zero
4. Disconnect hydraulic hoses at steering cylinder. clearance between shims and frame. Add or
Install caps on cylinder fittings at the end caps remove shims as necessary to get zero
and put plugs in hydraulic hoses. Caps will clearance.
prevent spindles from turning when axle is
removed from under the lift truck. 5. Remove plugs and caps, and connect hydraulic
lines to steering cylinder.
5. Slide a floor jack or forks of another lift truck
under steering axle. Raise lifting device until it
holds weight of axle assembly. WARNING
6. Remove four cap screws and washers that safety cage for damage before use. When adding
fasten two hanger cups to frame. Remove air, use a clip on chuck with enough hose to let the
hanger cups and slowly lower axle assembly. operator stand clear of the cage.
Carefully remove axle assembly from under lift
truck. 6. Install wheel on hub. See Wheels, Install.
7. Remove thrust washer and bushing from 7. Start engine and operate steering system to
steering axle mounting shaft. remove air from steering cylinder and system.
Turn steering wheel several times from one
Install wheel stop to other wheel stop. Check for
hydraulic leaks.
WARNING
Excessive play in the shaft bushings will result in
increased shock loadings to the shafts and
increased movement of the axle, and may affect
26
1. WHEEL HUB 4. TIE ROD

2. STEERING AXLE HOUSING 5. PIVOT PIN
3. SPINDLE 6. STEERING CYLINDER
Figure 17. Steer Axle Assembly (A238)
27
TIE ROD (A238) 1. Make sure bearings are clean and not worn.
Remove
2. Verify tie rod does not show cracks.
procedures. 3. Re-lubricate bearings before re-installing tie
rod.
2. At the cylinder side, remove cotter pin, castle
nut and tie rod pin from the tie rod. See Install
Figure 18.
1. Install seals and spacers on the tie rod ball
3. At the spindle side, loosen set screws and bearing and insert with the tie rod in the
remove tie rod pin. spindle. Use an alignment pin to align tie rod
and spacers with the mounting bore in the
4. Remove tie rod, spacers and seals. spindle. See Figure 18.
2. Install tie rod pin at the spindle with the

grease fitting facing upward and tighten the set
screws to 19 N•m (14 lbf ft).
3. At cylinder side, install the tie rod pin also with

the grease fitting facing upward and install
castle nut. Tighten castle nut to
200 N•m (148 lbf ft) and lock in place, with
cotter pin, at first alignment position that
occurs between
190 and 210 N•m (140 and 155 lbf ft).
4. Apply EP2/3 grease to the grease nipples on the

tie rod pins until grease escapes from the
bearings.

wheel alignment.
STEERING CYLINDER (A238)

Remove
1. Disconnect tie rods at the steering cylinder by
1. GREASE FITTING 6. SPACER removing cotter pin, castle nut and tie rod pin.
2. TIE ROD PIN 7. SEAL
3. COTTER PIN 8. SNAP RING
4. CASTLE NUT 9. BALL BEARING 2. Rotate tie rods backward, out of slot in steering
5. SET SCREW 10. TIE ROD cylinder.
Figure 18. Tie Rod Assembly 3. Disconnect hydraulic hoses on steering cylinder
at end caps. Install plastic caps on cylinder
Clean and Inspect fittings and put plugs in hydraulic hoses. Caps
will prevent piston rod from moving when
steering cylinder is removed from steering axle.
WARNING See Figure 19.
the manufacturer.
28
1. HEX HEAD BOLTS 7. CASTLE NUT

2. GREASE FITTING 8. WASHERS
3. TIE ROD PIN 9. NUTS
4. BUSHING 10. STEERING CYLINDER
5. TIE ROD 11. AXLE FRAME
6. COTTER PIN
Figure 19. Steering Cylinder Mounting
4. Support the cylinder under the tie rods. The 8. Remove cylinder tie rods.
cylinder weighs 110 kg (240 lb). Remove nuts
and washers from the hex head bolts that hold 9. Remove end cap on one side of cylinder.
the steering cylinder to the axle frame.
10. Remove piston rod by pulling it out of the
5. Remove steering cylinder. cylinder shell. Keep piston rod in center of
cylinder shell during removal.
6. Hold end of steering cylinder over a drain pan.
Remove plastic cap from cylinder fitting at each 11. Remove opposite cylinder end cap.
end cap. Push piston rod towards end of
cylinder shell that is over drain pan. Oil will 12. Remove the seals, wipers, O-rings, backup
drain from steering cylinder. rings and wear rings from piston and end caps.
See Figure 20 and Figure 21.
7. Remove nuts and washers at one of the end
caps.
29
1. CYLINDER SHELL
2. CYLINDER TIE ROD
3. CYLINDER END CAP
4. WASHER
5. NUTS
Figure 20. Steering Cylinder Assembly
30
1. PISTON 8. GUIDE RING

2. CYLINDER SHELL 9. BACKUP RING
3. END CAP 10. O-RING
4. ROD 11. O-RING
5. WIPER 12. GUIDE RING
6. SEAL 13. SEAL
7. SEAL
Clean and Inspect 4. Inspect cylinder shell for damage. Inspect for
wear between the shell and the end caps.
WARNING 5. Inspect end caps for cracks and wear.

can cause skin irritation. When using cleaning 6. Replace damaged components as necessary.
the manufacturer. Compressed air can move Assemble and Install
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
CAUTION
protective goggles or a face shield to prevent DO NOT damage the seals, O-rings, wipers, or
injury to the eyes. backup rings during installation.
1. Clean all parts in solvent. Use compressed air NOTE: Always use new seals, O-rings, rod wipers,
to dry parts. wear rings, and backup rings. Make sure all parts
are clean.
2. Inspect piston rod for grooves or damage. 1. Lubricate the seals, wipers, O-rings, and
Remove small scratches with fine emery cloth. backup rings with clean hydraulic and install
onto the end caps. See Figure 21.
3. Verify distance rings are not damaged and the
installed O-ring prevents the distance ring 2. Lubricate the seals, wipers, O-rings, and
from sliding on the rod. backup rings with clean hydraulic and install
onto the end caps.
31
13. Apply EP2/3 grease to the grease nipples on the

CAUTION tie rod pins until grease escapes from the
Use caution when installing the piston rod into the bearings.
cylinder shell or damage to the cylinder shell may
occur. 14. Start engine, and operate steering system to
remove air from steering cylinder and system.
3. Slide piston rod into cylinder shell. Keep piston Turn steering wheel several times from one
rod in center of cylinder shell during wheel stop to the other wheel stop.
installation.
15. Check for hydraulic leaks.
4. Slide end caps over piston rod, into cylinder
shell. Slide other end cap over piston rod and HUBS (A238)
into cylinder shell.
Remove and Disassemble
5. Install tie-rods to the end caps. 1. Remove the wheel. See Wheels, Remove.
6. Install washers and nuts to the tie rods and 2. Remove tie rod pin and tie rod at the spindle.
tighten to 165 N•m (122 lbf ft). The tie rod will See Tie Rod, Remove.
protrude approximately 5 mm (0.2 in.) out of
the nut. 3. Remove magnetic plug and collect draining oil
in a container.
7. Install steering cylinder to hex head bolts on
axle frame using washers and nuts. Tighten 4. Remove cap screws and washers from cover
nuts to 550 N•m (405 lbf ft). plate, remove cover plate.
8. Remove plastic caps from fittings on steering 5. Remove cap screws from mounting plate,
cylinder at end caps. Also remove plugs from remove mounting plate and shims.
hydraulic hoses.
6. The hub weighs 55 kg (120 lb). Use a lifting
9. Connect hydraulic hoses to steering cylinder. device to remove hub.
10. Rotate the tie rods with seals and spacers to 7. Catch the outer bearing cone as the hub is
align with the steering cylinder pin holes. See moved from the spindle. See Figure 22.
Figure 18.
8. Remove hub from spindle and put on a flat
11. Install tie rod pin, castle nut, and cotter pin to clean surface.
connect steering cylinder to tie rod.
12. Tighten castle nut to 200 N•m (148 lbf ft). and
lock in place, with cotter pin, at first alignment
position that occurs between
190 and 210 N•m (140 and 155 lbf ft).
32
1. WHEEL HUB HOUSING 7. CAP SCREWS

2. WHEEL STUD 8. O-RING
3. OIL SEAL 9. COVER PLATE
4. BEARING SET (CUP & CONE) 10. WASHERS
5. SHIMS 11. CAP SCREWS
6. MOUNTING PLATE 12. MAGNETIC PLUG WITH O-RING
Figure 22. Hub Assembly
Clean and Inspect 4. Inspect the contact surface between spindle

and seal. Smoothen as necessary.
WARNING Assemble and Install

solvents, always follow the recommendations of CAUTION
the manufacturer. DO NOT damage the seals during installation.
1. Clean all parts with solvent. Make sure 1. Apply oil and install inner bearing cone and
bearings are clean and dry. seal on hub.
2. Inspect the bearings, bearing cups and seal. NOTE: The hub assembly for this truck model
Replace as necessary. Use appropriate pushers weighs 55 kg (120 lb). Use a lifting device when
when replacing cups with a press. installing the hub assemblies on Steering Axle.
2. Use a lifting device to position the hub on the
spindle.
Ensure spindle and hub do not have any rough
or sharp areas that would prevent the bearings 3. Apply oil and install the outer bearing cone.
from being correctly installed. If necessary,
smoothen any rough or sharp areas before 4. Measure and record thickness A of the
installing the bearings. mounting plate with an accuracy of
0.1 mm (0.003 in.). See Figure 23.
33
5. Install mounting plate without any shim.

Tighten cap screws to 15 N•m (11 lbf ft) while
rotating wheel hub in both directions to
properly seat the bearings.
6. Loosen all cap screws to almost zero N•m and

retighten to 2.5 N•m (1.85 lbf ft).
7. Measure distance B between mounting plate

surface and face of the spindle. Deduct the
distance as measured at step 4. The value
found represents the total thickness of the
required shims which are available in different
sizes.
8. Remove the cap screws and the mounting plate

and reinstall together with the required shims.
9. Apply Loctite 270 to the cap screws and torque

to 40 N•m (29.5 lbf ft).
10. Check rotating torque of the hub by a spring

scale with the use of a rope wrapped around 1. WHEEL HUB 2. PLATE
the wheel studs.
Figure 23. Mounting Plate Shimming
11. Re-shim the hub if rotating torque is lower
than SPINDLE (A238)
37 or higher than 47 N•m
Remove
(27.2 or higher than 34.6 lbf ft).
NOTE: The spindle weighs 26.7 kg (58.9 lb). Use a
12. Install the cover plate and torque cap screws to lifting device when removing or installing the
25 N•m (18 lbf ft). spindle.
1. Remove wheel, tie rod and hub as described in
13. Rotate the hub until the two fill plugs are at
Wheel, Remove, Tie Rod, Remove and Wheel
the same height, remove both magnetic fill
Hub, Remove.
plugs and fill the hub with gear oil until level
reaches bottom of both filling holes. Required
2. Remove the cap screws, washers and caps at
oil quantity is about 0.8 liter (27 oz) for each
the top and the bottom of the king pin.
hub.
3. Loosen the nut and subsequently the setscrew,
14. Clean the magnetic plugs and install with
which secures the king pin in the steering axle.
proper O-rings.
4. Push the king pin out of the steering axle.
5. Support the spindle by a lifting device and

remove the spindle from the steering axle. See
Figure 24.
34
Assemble and Install

1. Lubricate bearings with grease.
2. Install spindle in steering axle and make the

following bearing adjustment.
3. Install bearing cap without shims.
NOTE: Spindle bearings must have no clearance.

Install shims 0.00 to 0.13 mm (0.000 to 0.005 in.)
less than measured clearance.
4. Tighten three cap screws to 20 N•m (15 lbf ft).
Rotate spindle, then tighten cap screws to
20 N•m (15 lbf ft) again. Loosen cap screws and
tighten again to 14 N•m (10 lbf ft).
5. Measure gap. Install correct amount of shims

to equal the gap. Tighten cap screws to
77 N•m (56.8 lbf ft).
6. Install new O-ring, grease plate and three cap

screws to top of steering frame. See Figure 24.
1. STEERING AXLE 8. SPINDLE
2. CAP SCREW 9. SET SCREW 7. Install tie rod as described in Tie Rods, Install.
3. WASHER 10. LOCK NUT
4. CAP 11. THRUST BEARING
5. O-RING 12. O-RING 8. Repeat procedure for other spindle.
6. BUSHING 13. BEARING
7. KING PIN 9. Install hubs and wheels as described in Wheels,
Install and Wheel Hubs, Install.
Figure 24. Spindle Assembly (A238)
STEER AXLE (D214 AND C236 UNTIL
Clean and Inspect C236E01652R)
Remove
WARNING
can cause skin irritation. When using cleaning WARNING
solvents, always follow the recommendations of Put the lift truck on blocks. Follow the procedures
the manufacturer. for raising the lift truck described in the Operating
Manual for this lift truck. The surface must be
1. Clean all parts in solvent. Inspect contact solid, even, and level. Make sure the blocks are
surface and play between king pin and solid one-piece units. Make sure the lifting devices
bushings. Replace if worn or if play can be felt used during repairs can lift the weight of the parts.
when dry. Replace as necessary.
The steering axle can be removed without removing
2. Use appropriate pushers when replacing cups the counterweight. See Figure 25.
with a press.
1. Make sure the wheels are set for straight
3. Inspect spindle for cracks and damage. travel. Put blocks under the frame in front of
Smoothen the contact surface between spindle the steer wheels, so that the steering axle can
and hub seal as necessary. be removed. The top of the axle frame must
have clearance under the counterweight so that
the steering axle can be removed.
35
2. It is not required, but it can make removal of 4. Install the seal ring in the groove around the
the axle easier if the wheels are removed. pivot shafts.
Disconnect the hydraulic lines at the steering
cylinder. Install caps on the cylinder and put 5. Use a lifting device to position the steering axle
plugs in the hydraulic lines. The caps will pivots in the mounts in the frame.
prevent the spindles from turning when the
axle is removed from under the lift truck. 6. Verify correct positioning of the bushings and
zero clearance between steering axle and
3. Slide a floor jack or the forks of another lift frame.
truck under the steering axle. Raise the lifting
device until it holds the weight of the axle 7. Install the bearing caps and tighten the cap
assembly. Remove the four capscrews and screws to 320 N•m (236 lbf ft).
washers that fasten the two bearing caps to the
frame. Remove the bearing caps and slowly 8. Use a tool to move the seal rings out of the
lower the axle assembly. Carefully remove the groove and onto the shims and thrust rings.
axle assembly from under the lift truck.
NOTE: Tighten the capscrews for the bearing caps
again after eight hours of service.
Install
1. Determine the required shims on the pivot 9. Remove the plugs and caps and connect the
shafts to obtain zero clearance between hydraulic lines to the steering cylinder. Install
steering axle and frame. the wheels if they were removed.
2. Apply grease to the shims and thrust rings. 10. Operate the steering system to remove the air
First install the shims. Divide the shims from the system. Turn the steering wheel
equally over the two pivots. Install the thrust several times from one stop to the other stop.
ring last. Check for hydraulic leaks.
3. Lubricate the pivot shafts with grease and

install the bushings.
36
1. AXLE FRAME 10. THRUST WASHER 19. HUB

2. GREASE FITTING 11. SHIM 20. CAPSCREW
3. SPINDLE 12. DUST SEAL 21. HUB COVER
4. ANCHOR PIN 13. GREASE SEAL 22. O-RING
5. PIN 14. WEAR RING 23. SPINDLE NUT
6. BEARING AND SEAL 15. BEARING CONE 24. TONGUED WASHER
7. TIE ROD 16. BEARING CUP 25. SEAL RING
8. STEERING CYLINDER 17. SHIM 26. FIBER BUSHING
9. SHIM 18. BEARING CAP 27. GROOVE
Figure 25. Steer Axle (C236 until S/N C236E01652R and D214)
TIE ROD (D214 AND C236 UNTIL Clean and Inspect

C236E01652R)
Remove WARNING
procedures.
the manufacturer.
2. Remove cap screw from anchor pin and remove
anchor pins at cylinder and at spindle. Make sure bearings are clean and not worn.
1.
3. Remove tie rod, with seals. Verify tie rod does not show cracks.
2.
3. Re-lubricate bearings before re-installing tie

rod.
37
Install 2. Disconnect the tie rods as described in the

procedures for the Spindles and Bearings
1. Install seals on the greased tie rod ball bearing Repair Remove, in this section.
and insert with the tie rod in the spindle. Use
an alignment pin to align tie rod and seals with 3. Remove the capscrews and washers that fasten
the mounting bore in the spindle. the cylinder to the axle frame. Remove the
steering cylinder from the axle.
2. Install tie rod pin at the spindle and at the
cylinder with the grease fitting facing 4. Remove the nuts from the through bolts. Hold
downward and insert the anchor pin. the end of the steering cylinder over a drain
pan. Remove the end cap from the shell. Oil
3. Install the cap screw to secure the anchor pin will drain from the cylinder. Repeat the
and tighten the cap screw to 30 N•m (22 lbf ft). procedure for the other end.
4. Apply EP2/3 grease to the grease nipples on the 5. Carefully slide one end cap from the rod.
tie rod pins until grease escapes from the seals. Carefully pull the rod from the shell. Remove
the other end cap from the shell. Remove all
seals, wipers, and O-rings.
wheel alignment.
STEERING CYLINDER (D214 AND C236

UNTIL C236E01652R)
Remove
1. Disconnect the hydraulic lines at the steering
cylinder. Install caps in the fittings on the
cylinder and put fittings on the hydraulic lines.
See Figure 26.
38
1. ROD AND PISTON 6. ROD SEAL

2. WEAR RING 7. END CAP
3. O-RING 8. BACKUP RING
4. PISTON SEAL 9. SHELL
5. WIPER 10. THROUGH BOLT
39
Clean and Inspect 5. Carefully slide the rod into the shell. Keep the
rod in the center of the shell during
installation. Carefully slide the end cap onto
WARNING the shell. Install the other end cap on the rod
Cleaning solvents can be flammable and toxic and and shell.
solvents, always follow the recommendations of 6. Install the through bolts and fasten the nuts
the manufacturer. hand tight to hold the end caps in position. Do
not yet torque.
1. Clean all parts in solvent. Use compressed air
to dry the parts. 7. Install the cylinder on the axle frame. Loosen
the nuts at one end of the through bolts for one
2. Inspect the piston rod for grooves or damage. complete turn. Rotate one or both end caps to
Remove small scratches with fine emery cloth. make sure that both end caps completely touch
Inspect the cylinder bore for damage. Inspect the axle frame. Install the cap screws on the
the mounts for cracks. cylinder end cap, but do not yet tighten.
Assemble and Install 8. Tighten the nuts on the through bolts to 320
N•m (235 lbf ft).
1. Put the O-rings, seals, and wipers in warm
hydraulic oil.
9. Tighten the cap screws on the cylinder end cap
to 755 N•m (557 lbf ft).
CAUTION 10. Install the tie rods as described in the
Do not damage the O-rings, seals, or wipers during procedures for the Spindles and Bearings
installation. Repair Assemble and Install, in this section.
2. Install the wipers and rod seals in the end caps. 11. Remove the plugs and caps and connect the
Install the O-ring and backup ring in each end hydraulic lines to the steering cylinder. Start
cap. See Figure 27 and Figure 26. the engine and operate the steering system to
remove the air from the cylinders and the
3. Install the O-ring and piston seal on the piston. system. Turn the steering wheel several times
Install the wear rings on the piston. from one stop to the other.
4. Install one end cap on the rod.
40
1. END CAP 6. SHELL

2. WIPER 7. PISTON
3. ROD SEAL 8. THROUGH BOLT
4. O-RING 9. NUT
5. BACKUP RING
Figure 27. Steering Cylinder Seals
HUBS (D214 AND C236 UNTIL 7. If the wheel bearings must be replaced, use a
C236E01652R) brass drift to remove the bearing cups.
Remove and Disassemble 8. Remove the wear sleeve from the spindle.
1. Remove the wheel. See Wheels, Remove. 9. Repeat the procedure for the other hub.
2. Remove the hub cover and O-ring. See
Figure 25.
Clean and Inspect
3. Release the four capscrews of the spindle nut WARNING

and remove the spindle nut and tongued Cleaning solvents can be flammable and toxic and
washer. can cause skin irritation. When using cleaning
4. Remove the bearing cone.
the manufacturer.
5. Slide the hub from the spindle. Clean all parts with solvent. Make sure
1.
bearings are clean and dry.
6. Remove the seal and the inner bearing cone.
41
2. Inspect the bearings, bearing cups and seal.

Replace as necessary. Use appropriate pushers WARNING
when replacing cups with a press. Add air to the tires only in a safety cage. Inspect
3. Inspect spindle and hub for cracks and damage. air, use a clip on chuck with enough hose to let the
Ensure spindle and hub do not have any rough operator stand clear of the cage.
or sharp areas that would prevent the bearings
from being correctly installed. If necessary, 9. Install the wheel on the hub. Be careful not to
smoothen any rough or sharp areas before damage the threads on the studs. Tighten the
installing the bearings. wheel nuts to 640 to 680 N•m (470 to 500 lbf
ft). See Figure 28.
4. Inspect the contact surface between spindle
and seal. Smoothen as necessary.
WARNING
Assemble and Install When the wheels have been installed, check all
1. If the bearings in the hubs must be replaced, wheel nuts after 2-5 hours of operation. Tighten
use a press to install the new bearing cups in the nuts to the correct torque. When the nuts stay
the hub. See Figure 25. tight after an 8-hour check, the interval for
2. Lubricate and install the inner bearing cone in Periodic Maintenance section.
the hub.
10. Repeat the procedure for the other wheel.
3. Install a new seal in the hub.
4. Install the wear sleeve on the spindle.

Lubricate the bearing cones and seal surfaces
with grease.
CAUTION
Do not damage the seals during installation.
5. Carefully slide the hub onto the spindle. It can

be necessary to use a lifting device during
installation. Lubricate and install the outer
bearing cone.
6. Install the tongued washer. Install the spindle

nut. Tighten the spindle nut to 190 to 210 N•m
(140 to 155 lbf ft) while rotating the hub in both Figure 28. Wheel Nut Tightening Sequence
directions to seat the bearings. Verify the wear
ring is against the shoulder of the spindle and SPINDLE (D214 AND C236 UNTIL
that the inner bearing cone is fully seated C236E01652R)
against the wear ring. Loosen the spindle nut,
then tighten again to 5 to 10 N•m (3.7 to 7.4 lbf Remove
ft). 1. Remove the capscrew, anchor pin, and tie rod
pin from each end of the tie rod. Remove the tie
7. Apply more torque to eliminate end play. rod. See Figure 25.
Tighten spindle nut from this position 57 to 73°
more. Torque capscrews on the spindle nut 2. Remove the capscrews from the bearing cap.
evenly to 32 to 36 N•m (23.7 to 26.6 lbf ft). Remove the bearing cap and shims. If
necessary, remove the bearing cup from the
8. Install O-ring and hub cover. bearing cap. See Figure 16.
42
3. Tilt the spindle and lift the spindle from the 4. Lubricate the bearings in the tie rods. Install
axle. If the bearing must be replaced, remove the seals on the tie rod bearings. Use an
the bearing and seals from the spindle. If the alignment pin to align the seals with the
wear sleeve and the bearing cup must be bushings.
replaced, remove them from the axle frame.
5. Lubricate the tie rod pin with antiseize
4. Repeat the procedure for the other spindle. compound and install the tie rod pins, anchor
pins and cap screws. Make sure the grease
Clean and Inspect fittings on the tie rod pins are on the bottom
and toward the rear of the lift truck. Tighten
the cap screws for the anchor pins to 66 N•m
WARNING (40.5 lbf ft).
can cause skin irritation. When using cleaning 6. Repeat the procedure for the other spindle.
the manufacturer. STEER AXLE (E214 AND C236 STARTING
C236E01653R)
1. Clean all parts in solvent. Inspect contact
surface and play between king pin and Remove
bushings. Replace if worn or if play can be felt
when dry. Replace as necessary.
WARNING
2. Use appropriate pushers when replacing cups Put the lift truck on blocks. Follow the procedures
with a press. for raising the lift truck described in the Operating
Manual for this lift truck. The surface must be
3. Inspect spindle for cracks and damage. solid, even, and level. Make sure the blocks are
Smoothen the contact surface between spindle solid one-piece units. Make sure the lifting devices
and hub seal as necessary. used during repairs can lift the weight of the parts.
Assemble and Install The steering axle can be removed without removing
1. If necessary, install the wear sleeves in the the counterweight. See Figure 29.
bearing cap and axle frame. Install new seals
1. Make sure the wheels are set for straight
on the spindle. Lubricate the seals with grease.
travel. Put blocks under the frame in front of
2. Lubricate the bearing cones with wheel bearing the steer wheels, so that the steering axle can
grease. If necessary, press the new bearing be removed. The top of the axle frame must
cups into the steering axle frame and bearing have clearance under the counterweight so that
cap. the steering axle can be removed.
3. Install the spindle in the steering axle and 2. It is not required, but it can make removal of
make the following bearing adjustment: the axle easier if the wheels are removed.
Disconnect the hydraulic lines at the steering
a. Install the bearing cap without the shims. cylinder. Install caps on the cylinder and put
Tighten the capscrews to 30 N•m (20 lbf ft) plugs in the hydraulic lines. The caps will
while rotating the spindle. prevent the spindles from turning when the
axle is removed from under the lift truck.
b. Loosen the capscrews and tighten again
until there is no clearance in the spindle.
Measure the gap for the shims and install a
shim pack equal to the gap. There must be
zero clearance for the bearings. Tighten the
capscrews to 66 N•m (50 lbf ft).
43
3. Slide a floor jack or the forks of another lift 5. Use a lifting device to position the steering axle
truck under the steering axle. Raise the lifting pivots in the mounts in the frame.
device until it holds the weight of the axle
assembly. Remove the four capscrews and 6. Verify correct positioning of the bushings and
washers that fasten the two bearing caps to the zero clearance between steering axle and
frame. Remove the bearing caps and slowly frame.
lower the axle assembly. Carefully remove the
axle assembly from under the lift truck. 7. Install the bearing caps and tighten the cap
screws to 320 N•m (236 lbf ft).
Install
8. Use a tool to move the seal rings out of the
1. Determine the required shims on the pivot groove and onto the shims and thrust rings.
shafts to obtain zero clearance between
steering axle and frame. NOTE: Tighten the capscrews for the bearing caps
again after eight hours of service.
2. Apply grease to the shims and thrust rings.
First install the shims. Divide the shims 9. Remove the plugs and caps and connect the
equally over the two pivots. Install the thrust hydraulic lines to the steering cylinder. Install
ring last. the wheels if they were removed.
3. Lubricate the pivot shafts with grease and 10. Operate the steering system to remove the air
install the bushings. from the system. Turn the steering wheel
several times from one stop to the other stop.
4. Install the seal ring in the groove around the Check for hydraulic leaks.
pivot shafts.
44
Figure 29. Steer Axle (E214 and C236 starting C236E01653R)
45
1. FRAME 21. TIE ROD 41. BEARING CONE

2. STEER AXLE 22. LOCK NUT 42. BEARING CUP
3. SEAL 23. WASHER 43. WHEEL STUD
4. THRUST WASHER 24. WASHER 44. WHEEL HUB
5. SHIM 25. CAP SCREW 45. WHEEL NUT
6. SHIM 26. CAP SCREW 46. BEARING CUP
7. BUSHING 27. SHIM (0,508 MM) 47. BEARING CONE
8. SHAFT 28. SHIM (0,178 MM) 48. THRUST WASHER
9. GREASE FITTING 29. SHIM (0,127 MM) 49. THICK SPINDLE NUT
10. CAP SCREW 30. BEARING CAP PLATE 50. THIN SPINDLE NUT
11. WASHER 31. WASHER 51. WHEEL NUT
12. COVER 32. CAP SCREW 52. O-RING
13. O-RING 33. GREASE FITTING 53. PLATE
14. STEERING CYLINDER 34. BEARING CUP 54. WASHER
15. CAP SCREW 35. BEARING CONE 55. CAP SCREW
16. WASHER 36. WEAR SLEEVE 56. PIN
17. GREASE FITTING 37. SEAL 57. DUST SEAL
18. LOCKPLATE 38. SPINDLE 58. BEARING CONE
19. PIN 39. SPACER 59. BEARING CUP
20. BUSHING 40. SEAL
TIE ROD (E214 AND C236 STARTING Install

C236E01653R) 1. Install the tie rod with the threaded pins at the
Remove spindle and at the cylinder with the threaded
end facing downward.
procedures. 2. Install the lock plates and the cap screws and
tighten to 30 N•m (22 lbf ft).
2. Remove the nut from the threaded pin, remove
the cap screw from the lock plate and remove 3. Install the nuts on the pins and tighten to
the lock plate. 550 N•m (406 lbf ft).
3. Remove the pin from the spindle. 4. Apply EP2/3 grease to the grease nipples on the
tie rod pins until grease escapes from the seals.
4. Repeat step Step 2 and Step 4 to remove the
other pin. NOTE: Tie rods do not have an adjustment for
wheel alignment.
5. Remove tie rod.
STEERING CYLINDER (E214 AND C236
Clean and Inspect STARTING C236E01653R)
Remove
WARNING
Cleaning solvents can be flammable and toxic and 1. Disconnect the hydraulic lines at the steering
can cause skin irritation. When using cleaning cylinder. Install caps in the fittings on the
solvents, always follow the recommendations of cylinder and put fittings on the hydraulic lines.
the manufacturer. See Figure 30.
1. Make sure bearings are clean and not worn. 2. Disconnect the tie rods as described in the
procedures for the Spindles and Bearings
2. Verify tie rod does not show cracks. Repair Remove, in this section.
3. Re-lubricate bearings before re-installing tie 3. Remove the capscrews and washers that fasten
rod. the cylinder to the axle frame. Remove the
steering cylinder from the axle.
46
4. Remove the nuts from the through bolts. Hold 5. Carefully slide one end cap from the rod.
the end of the steering cylinder over a drain Carefully pull the rod from the shell. Remove
pan. Remove the end cap from the shell. Oil the other end cap from the shell. Remove all
will drain from the cylinder. Repeat the seals, wipers, and O-rings.
procedure for the other end.
1. ROD AND PISTON 6. ROD SEAL

2. WEAR RING 7. END CAP
3. O-RING 8. BACKUP RING
4. PISTON SEAL 9. SHELL
5. WIPER 10. THROUGH BOLT
Clean and Inspect 1. Clean all parts in solvent. Use compressed air
to dry the parts.
WARNING
2. Inspect the piston rod for grooves or damage.
Cleaning solvents can be flammable and toxic and Remove small scratches with fine emery cloth.
can cause skin irritation. When using cleaning Inspect the cylinder bore for damage. Inspect
solvents, always follow the recommendations of the mounts for cracks.
the manufacturer.
47
Assemble and Install 7. Install the cylinder on the axle frame. Loosen
the nuts at one end of the through bolts for one
1. Put the O-rings, seals, and wipers in warm complete turn. Rotate one or both end caps to
hydraulic oil. make sure that both end caps completely touch
the axle frame. Install the cap screws on the
cylinder end cap, but do not yet tighten.
CAUTION
Do not damage the O-rings, seals, or wipers during 8. Tighten the nuts on the through bolts to 320
installation. N•m (235 lbf ft).
2. Install the wipers and rod seals in the end caps. 9. Tighten the cap screws on the cylinder end cap
Install the O-ring and backup ring in each end to 755 N•m (557 lbf ft).
cap. See Figure 30 and Figure 31.
10. Install the tie rods as described in the
3. Install the O-ring and piston seal on the piston. procedures for the Spindles and Bearings
Install the wear rings on the piston. Repair Assemble and Install, in this section.
4. Install one end cap on the rod. 11. Remove the plugs and caps and connect the
hydraulic lines to the steering cylinder. Start
5. Carefully slide the rod into the shell. Keep the the engine and operate the steering system to
rod in the center of the shell during remove the air from the cylinders and the
installation. Carefully slide the end cap onto system. Turn the steering wheel several times
the shell. Install the other end cap on the rod from one stop to the other.
and shell.
6. Install the through bolts and fasten the nuts

handtight to hold the end caps in position. Do
not yet torque.
48
1. END CAP 6. SHELL

2. WIPER 7. PISTON
3. ROD SEAL 8. THROUGH BOLT
4. O-RING 9. NUT
5. BACKUP RING
Figure 31. Steering Cylinder Seals
HUBS (E214 AND C236 STARTING 7. If the wheel bearings must be replaced, use a
C236E01653R) brass drift to remove the bearing cups.
Remove and Disassemble 8. Remove the wear sleeve from the spindle.
1. Remove the wheel. See Wheels, Remove. 9. Repeat the procedure for the other hub.
2. Remove the hub cover and O-ring. See
Figure 29.
Clean and Inspect
3. Release the six capscrews of the spindle nut WARNING

and remove the spindle nut and tongued Cleaning solvents can be flammable and toxic and
washer. can cause skin irritation. When using cleaning
4. Remove the bearing cone.
the manufacturer.
5. Slide the hub from the spindle. Clean all parts with solvent. Make sure
1.
bearings are clean and dry.
6. Remove the seal and the inner bearing cone.
49
2. Inspect the bearings, bearing cups and seal. NOTE: There must be approx. 1 mm clearance
Replace as necessary. Use appropriate pushers between thick nut and thin nut otherwise there is
when replacing cups with a press. no retention of the nuts when the six screws in the
next step are tightened.
Ensure spindle and hub do not have any rough 9. Install the six cap screws and torque evenly to
or sharp areas that would prevent the bearings 12 – 16 N•m (8.8 – 11.8 lb ft).
from being correctly installed. If necessary,
smoothen any rough or sharp areas before 10. Install O-ring and hub cover.
installing the bearings.
4. Inspect the contact surface between spindle WARNING

and seal. Smoothen as necessary. Add air to the tires only in a safety cage. Inspect
Assemble and Install air, use a clip on chuck with enough hose to let the
1. If the bearings in the hubs must be replaced, operator stand clear of the cage.
use a press to install the new bearing cups in
11. Install the wheel on the hub. Be careful not to
the hub. See Figure 29.
damage the threads on the studs. Tighten the
2. Lubricate and install the inner bearing cone in wheel nuts to 640 to 680 N•m (470 to 500 lbf
the hub. ft). See Figure 32.
3. Install a new seal in the hub.

WARNING
4. Install the wear sleeve on the spindle. When the wheels have been installed, check all
Lubricate the bearing cones and seal surfaces wheel nuts after 2-5 hours of operation. Tighten
with grease. the nuts to the correct torque. When the nuts stay
tight after an 8-hour check, the interval for
CAUTION Periodic Maintenance section.
Do not damage the seals during installation.
12. Repeat the procedure for the other wheel.
5. Carefully slide the hub onto the spindle. It can
be necessary to use a lifting device during
installation. Lubricate and install the outer
bearing cone.
6. Install the tongued washer and install the thick

spindle nut.
7. Tighten the thick spindle nut to 190 to 210

N•m (140 to 155 lbf ft) while rotating the hub
in both directions to seat the bearings. Verify
the wear ring is against the shoulder of the
spindle and the inner bearing cone is fully
seated against the wear ring. Loosen the thick
spindle nut, then tighten again to 5 to 10 N•m
(3.7 to 7.4 lbf ft). From this position, tighten the
thick spindle nut 26 – 30° more.
Figure 32. Wheel Nut Tightening Sequence
8. Install the thin spindle nut by hand until it
seats against the thick nut, then loosen the
thin spindle nut 150 – 210° until the holes
align with the holes of the thick nut.
50
SPINDLE(E214 AND C236 STARTING Assemble and Install

C236E01653R) 1. If necessary, install the wear sleeves in the
Remove bearing cap and axle frame. Install new seals
on the spindle. Lubricate the seals with grease.
1. Remove the tie rods, see chapter Tie Rods.
2. Lubricate the bearing cones with wheel bearing
2. Remove the hubs, see chapter Hubs. grease. If necessary, press the new bearing
cups into the steering axle frame and bearing
3. Remove the nut, lock plate, screw, and tie rod cap.
pin from each end of the tie rod. Remove the tie
rod. See Figure 29. 3. Install the spindle in the steering axle and
make the following bearing adjustment:
4. Remove the capscrews from the bearing cap.
Remove the bearing cap and shims. If a. Install the bearing cap without the shims.
necessary, remove the bearing cup from the Tighten the capscrews to 30 N•m (22 lbf ft)
bearing cap. See Figure 16. while rotating the spindle.
5. Tilt the spindle and lift the spindle from the b. Loosen the capscrews and tighten again
axle. If the bearing must be replaced, remove until there is no clearance in the spindle.
the bearing and seals from the spindle. If the Measure the gap for the shims and install a
wear sleeve and the bearing cup must be shim pack equal to the gap. There must be
replaced, remove them from the axle frame. zero clearance for the bearings. Tighten the
capscrews to 66 N•m (49 lbf ft).
6. Repeat the procedure for the other spindle.
4. Install the tie rod with the threaded pins at the
Clean and Inspect spindle and at the cylinder with the threaded
end facing downward.
WARNING 5. Install the lock plates and the cap screws and
Cleaning solvents can be flammable and toxic and tighten to 30 N•m (22 lbf ft).
solvents, always follow the recommendations of 6. Install the nuts on the pins and tighten to
the manufacturer. 550 N•m (406 lbf ft).
1. Clean all parts in solvent. Inspect contact 7. Apply EP2/3 grease to the grease nipples on the
surface and play between king pin and tie rod pins until grease escapes from the seals.
bushings. Replace if worn or if play can be felt
when dry. Replace as necessary. 8. Repeat the procedure for the other spindle.
2. Use appropriate pushers when replacing cups NOTE: Tie rods do not have an adjustment for
with a press. wheel alignment.
3. Inspect spindle for cracks and damage.

Smoothen the contact surface between spindle
and hub seal as necessary.
51
Checks and Adjustments 1600 SRM 1479
Checks and Adjustments

MAXIMUM STEERING ANGLE MAXIMUM STEERING ANGLE
ADJUSTMENT (K007/J007) (H019/J019) ADJUSTMENT (A238)
NOTE: Steering Angle can not be adjusted on steer 1. The turning radius of the truck can be changed
axles for C236, D214 and E214. by differently positioning the washers which
support the adjusting bolt. See Figure 34.
1. The turning radius of the truck can be changed
by adjusting the bolts, which protrude at the 2. A shorter turning radius is obtained by moving
side of the spindles. See Figure 33. more washers from the front side to the rear
side of the spindle. The maximum allowable
a. Both for (K007/J007) and (H019/J019) number of washers at the rear side is 7.
trucks the standard adjustment is
21.5 mm (0.85 in.). The adjustment
providing the shortest allowable turning
radius is 17.5 mm (0.70 in.).
1. ADJUSTING BOLT
2. WASHERS
Figure 34. Steering Angle Adjustment (A238)

A. ADJUSTMENT
1. TIE ROD
2. SPINDLE
3. WHEEL HUB
4. STEERING AXLE
Figure 33. Steering Angle Adjustment (K007/J007)

(H019/J019)
52
1600 SRM 1479 Torque Specifications
Torque Specifications
Part Item Torque Value

Priority Valve Cap Screw 217 to 231 N•m (160 to 170 lbf ft)
Shuttle Valve (Port L and M) --- 34 to 40 N•m (25 to 30 lbf ft)
Logic Element (Port N) --- 34 to 40 N•m (25 to 30 lbf ft)
Steering Control Unit Cap Screw 77 N•m (56.8 lbf ft)
For K007/J007 and H019/J019 trucks:
Steer Axle, Hanger Cup Cap Screw 270 N•m (199 lbf ft)
Tie Rod, Anchor Pin Cap Screw 30 N•m (22 lbf ft)
Steering Cylinder, Install Cap Screw 435 N•m (321 lbf ft)
Hub (Bearing Install) Castle Nut 203 N•m (150 lbf in)
Hub (Final Torque) Castle Nut 34 N•m (25 lbf in)
Spindle, Bearing Cap (Final Cap Screw 77 N•m (56.8 lbf in)
Torque)
Drive Wheels (Final Torque) Wheel Nut 615 to 710 N•m (454 to 524 lbf ft)
Steer Wheels (Final Torque) Wheel Nut 615 to 710 N•m (454 to 524 lbf ft)
For A238 trucks:
Steer Axle, Hanger Cup Cap Screw 550 N•m (405 lbf ft)
Tie Rod, Anchor Pin at Spindle Set Screw 19 N•m (14 lbf ft)
Tie Rod, Cylinder Side Castle Nut 200 N•m (148 lbf ft)
Steering Cylinder, Mount Nut 550 N•m (405 lbf ft)
Hub (Final Torque) Cap Screw 25 N•m (18 lbf in)
Spindle, Bearing Cap (Final Cap Screw 77 N•m (56.8 lbf in)
Torque)
Drive Wheels (Final Torque) Nut 615 to 710 N•m (454 to 524 lbf ft)
Steer Wheels (Final Torque) Nut 615 to 710 N•m (454 to 524 lbf ft)
For C236, D214 and E214 trucks:
Steer Axle, Bearing Cap (Final Cap Screw 580 N•m (430 lbf ft)
Torque)
Steering Cylinder (Final Torque) Cap Screw 755 N•m (557 lbf ft)
Spindle, Bearing Cap (Final Cap Screw 66 N•m (50 lbf in)
Torque)
Drive Wheels (Final Torque) Nut 640 to 680 N•m (470 to 500 lbf ft)
Steer Wheels (Final Torque) Nut 640 to 680 N•m (470 to 500 lbf ft)
53
Torque Specifications 1600 SRM 1479
Part Item Torque Value

For D214 and C236 (Until E1652R) trucks:
Hub – Step 1: Torque Spindle Nut 190 to 210 N•m (140 to 155 lbf ft)
Hub – Step 2: Loosen Spindle Nut ---
Hub – Step 3: Re-torque Spindle Nut 5 to 10 N•m (3.7 to 7.4 lbf ft)
Hub – Step 4: Turn Spindle Nut 57 – 73°
Spindle Nut Lock Screw 32 to 36 N•m (23.7 to 26.6 lbf in)
Anchor Pins (both sides) Cap Screw 30 N•m (22 lbf ft)
For E214 and C236 (Starting E1653R) trucks:
Tie Rod, Threaded Pin Nut 550 N•m (405 lbf ft)
Tie Rod, Lock Plate Cap Screw 30 N•m (22 lbf ft)
Hub – Step 1: Torque Spindle Nut 190 to 210 N•m (140 to 155 lbf ft)
Hub – Step 2: Loosen Spindle Nut ---
Hub – Step 3: Re-torque Spindle Nut 5 to 10 N•m (3.7 to 7.4 lbf ft)
Hub – Step 4: Turn Spindle Nut 26 – 30°
Spindle Nut Lock Screw 12 to 16 N•m (8.8 to 11.8 lbf in)
54
TECHNICAL PUBLICATIONS
1600 SRM 1479 11/19 (1/18)(6/16)(8/14)(9/14)(11/13)

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STEERING SYSTEM

PART NO. 4034071 1600 SRM 1479

©2019 HYSTER COMPANY i

TABLE OF CONTENTS (Continued)

TABLE OF CONTENTS (Continued)

Series Code / Model Designation Reference Table

Series European Model Americas Model

Steering System Main Component Identification

Figure 1. Steering System Schematic

Legend for Figure 1.

1. PRIORITY VALVE 6. VARIABLE DISPLACEMENT PUMP (SECONDARY)

Figure 2. Steering System Main Component Identification (K007 Shown)

Legend for Figure 2.

1. PRIORITY VALVE 6. MAIN CONTROL VALVE

Description and Operation

Another function of the priority valve is to supply Operation

Component Validation for Correct

Table 1. Internal Components of the Steering Control Unit

1. WHEEL HUB ASSEMBLY 4. TIE ROD

Figure 4. Steer Axle

Hydraulic Troubleshooting Flowcharts

4. Tilt the mast to the maximum forward position.

5. Shut down the engine.

6. Place blocks on both sides (front and back) of

7. Turn the key switch to the ON position. DO

8. Apply brake pedal 10 to 20 times until

6. Remove the pressure gauge from port MLS1.

7. Install the cap on check port MLS1 on the main

8. Install the caps on check ports MLS1 and

6. Shut down the engine.

FLOWCHART Pressure Checks for Troubleshooting Flowcharts in

Hydraulic Pressure Checks for Troubleshooting Flowcharts

4. Tilt the mast to the maximum forward position.

5. Shut down the engine.

6. Place blocks on both sides (front and back) of

7. Turn the key switch to the ON position. DO

CONDITION CHECK, LOGIC ELEMENT N

1. Remove the logic element at port N on the main

2. Check the condition of the logic element for

3. Install new O-rings on the logic element.

4. Install the priority valve into the main control

Remove and Replace

2. Lower the carriage until the lift cylinders are

3. Tilt the mast completely forward.

4. Shut down the engine and turn the key switch

5. Place blocks on both sides (front and back) of

6. Turn the key switch to the ON position. DO

8. Use the emergency lowering button and

3. Remove the plugs and caps from hydraulic

4. Connect the hydraulic hoses to the steering

5. Check the fluid level in the hydraulic tank. Add

6. Start the engine and operate the steering

2. Install the four capscrews and washers that

WHEELS (A238, K007/J007 AND H019/

1. Raise axle to remove weight from tires, but

2. If a tire jack is not available, raise axle only

2. Install grease seal on spindle. Lubricate

NOTE: The steering axle can be removed without

2. If a tire jack is not available, raise axle only

1. HUB ASSEMBLY 10. CAPSCREW 20. SHAFT

Figure 12. Steer Axle (K007/J007) (H019/J019)

2. Use a floor jack or another lift truck to put Install

WARNING 4. Apply EP2/3 grease to the grease nipples on the