STEERING SYSTEM

H8-12XM-6, H10XMS-6 (H190-280HD2,

H230HDS2) [L007];H13.00-16.00XM-6,
H10.00-12.00XM-12EC (H300-360HD2, H360HD2-
EC) [K019];H16XM-9, H16XM-12, H18XM-7.5,
H18XM-9 (H360-36HD, H360-48HD) [B238]

PART NO. 4133474 1600 SRM 1932

 SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• The Service Manuals are updated on a regular basis, but may not reflect recent design changes to the
product. Updated technical service information may be available from your local authorized Hyster®
dealer. Service Manuals provide general guidelines for maintenance and service and are intended for
use by trained and experienced technicians. Failure to properly maintain equipment or to follow
instructions contained in the Service Manual could result in damage to the products, personal injury,
property damage or death.
• 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
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
Component Validation for Correct Operation.................................................................................................7
Shock Valve......................................................................................................................................................... 7
Fundamental.....................................................................................................................................................7
Operation.......................................................................................................................................................... 7
Component Validation for Correct 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................................................................................................................................................................16
Remove Wheels From Lift Truck...................................................................................................................16
Install Wheels on Lift Truck.......................................................................................................................... 17
Steer Axle (L007/K019).....................................................................................................................................17
Remove............................................................................................................................................................ 17
Install.............................................................................................................................................................. 18

©2019 HYSTER COMPANY i

Table of Contents

TABLE OF CONTENTS (Continued)

Tie Rod (L007/K019)......................................................................................................................................... 20
Remove............................................................................................................................................................ 20
Clean and Inspect...........................................................................................................................................20
Install.............................................................................................................................................................. 20
Steering Cylinder (L007/K019).........................................................................................................................20
Remove............................................................................................................................................................ 20
Clean and Inspect...........................................................................................................................................22
Assemble and Install...................................................................................................................................... 23
Hubs (L007/K019)............................................................................................................................................. 23
Remove and Disassemble...............................................................................................................................23
Clean and Inspect...........................................................................................................................................23
Assemble and Install...................................................................................................................................... 24
Spindle (L007/K019)......................................................................................................................................... 24
Remove............................................................................................................................................................ 24
Clean............................................................................................................................................................... 25
Assemble and Install...................................................................................................................................... 25
Steering Axle (B238) ........................................................................................................................................ 25
Remove............................................................................................................................................................ 25
Install.............................................................................................................................................................. 26
Tie Rod (B238) ..................................................................................................................................................27
Remove............................................................................................................................................................ 27
Clean and Inspect...........................................................................................................................................28
Install.............................................................................................................................................................. 28
Steering Cylinder (B238) ................................................................................................................................. 28
Remove............................................................................................................................................................ 28
Clean and Inspect...........................................................................................................................................31
Assemble and Install...................................................................................................................................... 31
Hubs (B238) ......................................................................................................................................................32
Remove and Disassemble...............................................................................................................................32
Clean and Inspect...........................................................................................................................................33
Assemble and Install...................................................................................................................................... 33
Spindle (B238) .................................................................................................................................................. 34
Remove............................................................................................................................................................ 34
Clean and Inspect...........................................................................................................................................35
Assemble and Install...................................................................................................................................... 35
Checks and Adjustments.....................................................................................................................................35
Maximum Steering Angle Adjustment (L007/K019).......................................................................................35
Maximum Steering Angle Adjustment (B238)................................................................................................ 36
Torque Specifications...........................................................................................................................................36
Steering Control Unit....................................................................................................................................... 36
Steering Axle..................................................................................................................................................... 36
Wheel Nuts........................................................................................................................................................ 36
Steering Cylinder.............................................................................................................................................. 36

ii
1600 SRM 1932 General

General
This manual provides general information on the would be a transmission solenoid, which is shown in
electrical system of B238, L007, and K019 lift Transmission Repair (ZF-WG161) 1300SRM1456
trucks. This manual provides a link between the
Repair information for the hydraulic pumps is in the
electrical schematic and the actual location of the
manual Hydraulic System 1900SRM1934.
electrical components on the lift truck.
For L007 and K019 the actual electrical schematic
The description and replacement procedures for the
drawings are shown in Diagrams 8000SRM1938.
electrical system components are located in the
For B238 Diagrams 8000SRM1982
relevant manual for the component. An example

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 1932

Figure 1. Steering System Schematic

2
1600 SRM 1932 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 1932

Figure 2. Steering System Main Component Identification

4
1600 SRM 1932 Description and Operation

Legend for Figure 2.

1. PRIORITY VALVE 6. MAIN CONTROL VALVE

2. STEERING CONTROL UNIT 7. STEERING 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 1932

The selection (position) of the priority spool is There are three 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 1900SRM1934

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 1932 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 1932

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. Steering 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 1932 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. Ensure
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 1932

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
must be performed or serious personal injury may
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.

6. Shut down the engine.

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 1932 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 1932

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
must be performed or serious personal injury may
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.

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 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. Ensure 4. Install the shuttle valve at port L and M on the
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 1932 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
must be performed or serious personal injury may
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 1932

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.

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

the tires to prevent movement of the lift truck.

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

NOT START THE ENGINE.

WARNING
Step 7, Step 8, andStep 9 must be performed to
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.
Ensure 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. Ensure
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 1932 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. For L007 and K019, check the fluid level in the

hydraulic tank. Add hydraulic fluid if
necessary, as specified in the maintenance
table in the manual Periodic Maintenance
8000SRM1939.
For B238 , check the fluid level in the hydraulic
tank. Add hydraulic fluid if necessary, as
specified in the maintenance table in the
manual Periodic Maintenance
8000SRM1982.
For B238, check the fluid level in the hydraulic
tank. Add hydraulic fluid if necessary, as
specified in the maintenance table in the
manual Periodic Maintenance
8000SRM1983

6. Start the engine and operate the steering

system. Ensure the steering control unit
operates correctly.

1. OPERATOR'S CAB
2. STEERING CONTROL UNIT WARNING
3. WASHER DO NOT try to locate hydraulic leaks by placing
4. CAPSCREW
hands on pressurized hydraulic components.
Figure 9. Steering Control Unit, View Under Hydraulic oil can be injected into the body by
Operator's Cab pressure.

7. Check for leaks.

Install
8. Lower the cab until it is in the fully lowered
CAUTION and latched position. Refer to the manual
Operator's Cab 0100SRM1390.
DO NOT force the steering control unit onto the
steering column shaft, as damage can occur.

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
Remove and Replace 1600 SRM 1932

WHEELS
Remove Wheels From Lift Truck

WARNING
The type of tire and tire pressure are shown on the
nameplate. Ensure the nameplate is correct for the
type of tires on the lift truck.
Wheels and tires must be changed and repaired by
trained personnel only.
Always wear safety glasses.
Always use a tire inflator with a clip-on chuck
when deflating or adjusting the tire pressure. The
tire inflator must be equipped with a pressure 1. HOSE LONG ENOUGH FOR USER TO STAND
gauge and a hose of at least 3 m (10 ft) length. OUTSIDE POTENTIAL TRAJECTORY OF
During deflation or when adjusting the tire EXPLOSION
pressure, the technician must not stand in-line
Figure 11. Adjusting Tire Pressure Position
with the axis of the wheel. See Figure 10.
Adjusting tire pressure is allowed only if residual
air pressure exceeds 80% of the pressure as CAUTION
indicated on the nameplate. Lift truck wheels are very heavy, use caution when
If the tire is removed from the truck and flat on the removing wheels or personal injury may occur.
ground, the technician should not have any body
part within the diameter of the tire when adjusting 1. Raise the lift truck as described in Putting a
the tire pressure. See Figure 11. Lift Truck on Blocks.
Wheels can explode and cause injury or death if 1. Attach a tire inflator as described above. Note
the above procedures are not followed. tire pressure. After air is drained from tire,
check the tire pressure to ensure there is no
residual pressure. Remove chuck. Remove the
tire stem valve core. Push a wire through the
valve stem to ensure that the stem does not
have a blockage causing a flow restriction. For
dual tires, remove air pressure from both tires
using the described procedure before loosening
the wheel nuts.

WARNING
Lift truck wheels are heavy and can cause
personal injury.

2. Remove the wheel nuts and remove the wheel

from the lift truck. Be careful NOT to damage
the studs when removing the wheels.

1. ACCURATE IN-LINE PRESSURE GAUGE 3. Use a tire jack to remove the wheel assembly.

Figure 10. Adjusting and Deflating Position

16
1600 SRM 1932 Remove and Replace

Install Wheels on Lift Truck STEER AXLE (L007/K019)

Install the wheel(s) and tires(s) on the hub. Remove

CAUTION WARNING
Check all wheel nuts after 2 to 5 hours of Put the lift truck on blocks. Follow the procedures
operation: when new lift trucks begin operation for raising the lift truck described in the Operating
and on all lift trucks when the drive wheels have Manual for this lift truck. The surface must be
been removed and installed. Tighten the nuts as solid, even, and level. Ensure the blocks are solid,
shown in Figure 12. When the nuts stay tight for 8 one-piece units. Ensure the lifting devices used
hours, the interval for checking the torque can be during repairs can lift the weight of the parts.
extended to 250 hours.

Start with the wheel nut at the top and tighten the
WARNING
nuts to 68 to 136 N•m (50 to 100 lbf ft) in the shown
Completely remove the air from the tire before
in Figure 12. Check to ensure that the wheel(s) is
removing the tire and wheel from lift truck. Air
tight against the hub, then tighten the nuts to 615
pressure in the tires can cause the tire and wheel
to 710 N•m (454 to 250 lbf ft).
parts to explode, causing serious injury or death.

NOTE: The steering axle can be removed without

CAUTION
removing the counterweight.
Check all wheel nuts after 2 to 5 hours of
operation: when new lift trucks begin operation 1. Remove the steer wheels. Raise axle to remove
and on all lift trucks when wheels have been weight from tires, but have tires still touching
removed and installed. Tighten the nuts in a cross the floor. Loosen wheel nuts just enough so
pattern to the correct torque value shown in they can be easily removed. Raise axle so tires
Figure 12. When the nuts stay tight for 8 hours, the can be removed. Use a tire jack to remove tires
interval for checking the torque can be extended to and wheels.
250 hours.
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.

3. Put blocks under frame in front of steer axle, so

steering axle can be removed. Top of steering
axle must have clearance under counterweight
so the steering axle can be removed.

4. Disconnect hydraulic hoses at steering cylinder.

Install caps on cylinder fittings at the end caps
and put plugs in hydraulic hoses. Caps will
prevent spindles from turning when axle is
removed from under the lift truck.

5. Slide a floor jack or forks of another lift truck

under steering axle. Raise lifting device until it
holds weight of axle assembly. Remove four
Figure 12. Wheel Nut Tightening Sequence for capscrews and washers that fasten two hanger
SteeringAxle and Standard Drive Axle cups to frame. Remove hanger cups and slowly
lower axle assembly. Carefully remove axle
assembly from under lift truck.

17
Remove and Replace 1600 SRM 1932

6. Remove bushing, shim and flange from steering steering responsiveness. If movement in the shaft
axle mounting shaft. Remove and discard seal bushings is more than 4 mm (0.16 in.), or damage
ring from shaft. to the seals ring exists, replace the bushings,
flanges, and seal ring.
Install
1. Install seal ring, flange, and shims on each
shaft. Lubricate shafts with multipurpose
WARNING grease and install bushing. See Figure 13.
Excessive play in the shaft bushings will result in
increased shock loadings to the shafts and
increased movement of the axle, and may affect

18
1600 SRM 1932 Remove and Replace

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 13. Steering Axle

19
Remove and Replace 1600 SRM 1932

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

steering axle into position in frame. Ensure
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, ensure the mounting bore in the spindle.
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.
Add air to the tires only in a safety cage. Inspect
safety cage for damage before use. When adding
NOTE: Tie rods do not have an adjustment for
air, use a clip on chuck with enough hose to let the
wheel alignment.
operator stand clear of the cage.
STEERING CYLINDER (L007/K019)
5. Install wheel on hub. See Wheels, Install. Remove
TIE ROD (L007/K019) 1. Disconnect tie rods at the steering cylinder by
removing cap screw, anchor pin and tie rod pin.
Remove See Tie Rod (L007/K019) .
1. Remove wheel as described. See Remove
Wheels From Lift Truck. 2. Rotate tie rods backward, out of slot in steering
cylinder. See Figure 14.
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 lb). 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. Ensure 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 15.

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
1600 SRM 1932 Remove and Replace

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 15.

1. HEX HEAD BOLT 5. CAPSCREW

2. WASHER 6. ANCHOR
3. TIE ROD PIN 7. STEERING CYLINDER
4. TIE ROD 8. AXLE FRAME

Figure 14. Steering Cylinder Mounting

21
Remove and Replace 1600 SRM 1932

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 15. 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. Ensure 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
1600 SRM 1932 Remove and Replace

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 (L007/K019)
NOTE: Always use new seals, O-rings, rod wipers, Remove and Disassemble
wear rings, and backup rings. Ensure all parts are 1. Remove the wheel. See Remove Wheels From
clean. Lift Truck.
1. Lubricate the piston seal and two guide rings
with clean hydraulic oil and install onto the 2. Remove grease cap from hub.
piston. See Figure 15.
3. Remove cotter pin, castle nut and washer from
2. Lubricate the seals, wipers, O-rings, and spindle.
backup rings with clean hydraulic and install
onto the end caps. NOTE: The hub assemblies for this truck model
weigh 58 to 63 kg (128 to 139 lb). Use a lifting
device when removing the hub assembly.
CAUTION 4. Remove outer bearing cone and hub from
Use caution when installing the piston rod into the spindle and put on a flat clean surface.
cylinder shell or damage to the cylinder shell may
occur. 5. Remove seal and inner bearing cone from hub.

3. Slide piston rod into cylinder shell. Keep piston Clean and Inspect
rod in center of cylinder shell during
installation.
WARNING
4. Slide end caps over piston rod, into cylinder Cleaning solvents can be flammable and toxic and
shell. Slide other end cap over piston rod and can cause skin irritation. When using cleaning
into cylinder shell. solvents, always follow the recommendations of
the manufacturer.
5. Move and install steering cylinder to steering
axle frame and install washers and cap screw. 1. Clean all parts with solvent. Ensure bearings
Tighten cap screws to 435 N•m (321 lbf ft). are clean and dry.

6. Remove plastic caps from fittings on steering 2. Inspect the bearings, bearing cups and seal.
cylinder at end caps. Also remove plugs from Replace as necessary. Use appropriate pushers
hydraulic hoses. when replacing cups with a press.

7. Connect hydraulic hoses to steering cylinder. 3. Inspect spindle and hub for cracks and damage.
Ensure spindle and hub do not have any rough
8. Rotate the tie rods with seals and spacers to or sharp areas that would prevent the bearings
align with the steering cylinder tie rod pin from being correctly installed. If necessary,
holes. smoothen any rough or sharp areas before
installing the bearings.
9. Install tie rod pins with grease fitting facing
downward, install anchor pins and secure with 4. Inspect the contact surface between spindle
cap screws. Tighten cap screws to and seal. Smoothen as necessary.
30 N•m (22 lbf ft).

23
Remove and Replace 1600 SRM 1932

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 16. Wheel Nut Tightening Sequence

5. Install washer and castle nut. Tighten castle SPINDLE (L007/K019)

nut to 203 N•m (150 lbf ft) while rotating Remove
wheel hub in both directions to properly seat
the bearings. Loosen castle until wheel hub 1. Remove wheel, tie rod and hub as described in
turns freely with no end play. Remove Wheels From Lift Truck,Hubs (L007/
K019) and Tie Rod (L007/K019) .
6. Tighten castle nut to 34 N•m (25 lbf ft) and
lock in place, with cotter pin, at first alignment 2. Remove three cap screws, three washers,
position that occurs at or above grease plate and O-ring from upper steering
34 N•m (25 lbf ft). If cotter pin cannot be frame. Discard O-ring. See Figure 13 .
installed tighten castle nut to first alignment
position where the cotter pin can be installed. 3. Remove three cap screws and three washers
from bearing cap and shims located on the
7. Completely fill hub cap with grease and install lower steering frame. See Figure 13. If
in hub. necessary, remove bearing cup from bearing
cap. See Figure 17.

WARNING NOTE: The spindle weighs 26.7 kg (58.9 lb) Use a

lifting device when removing or installing the
Add air to the tires only in a safety cage. Inspect
spindle.
safety cage for damage before use. When adding
air, use a clip on chuck with enough hose to let the 4. Tilt spindle and lift spindle from axle.
operator stand clear of the cage.

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. Ensure 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 16.

24
1600 SRM 1932 Remove and Replace

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 13.

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 STEERING AXLE (B238)
Figure 17. 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. Ensure the blocks are solid,
solvents, always follow the recommendations of one-piece units. Ensure the lifting devices used
the manufacturer. during repairs can lift the weight of the parts.

1. Clean all parts in solvent. Ensure bearings are

clean and dry. WARNING
Completely remove the air from the tire before
Assemble and Install removing the tire and wheel from lift truck. Air
1. Install new seals on spindle. Lubricate seals pressure in the tires can cause the tire and wheel
with grease. See Figure 13. parts to explode, causing serious injury or death.

2. Lubricate bearings with wheel bearing grease. NOTE: The steering axle can be removed without
Ensure bearings are filled with grease. If removing the counterweight.
necessary, press new bearing cups into steering
axle frame and bearing cap. Install wear sleeve
in steering axle frame.

25
Remove and Replace 1600 SRM 1932

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 18.
enough so tires are just touching the floor.
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. Ensure
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
axle must have clearance under counterweight 550 N•m (405 lbf ft).
so the steering axle can be removed.
4. After installation, ensure 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
Add air to the tires only in a safety cage. Inspect
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
1600 SRM 1932 Remove and Replace

1. WHEEL HUB 4. TIE ROD

2. STEERING AXLE HOUSING 5. PIVOT PIN
3. SPINDLE 6. STEERING CYLINDER

Figure 18. Steering Axle Assembly (B238)

TIE ROD (B238) 3. At the spindle side, loosen set screws and
remove tie rod pin.
Remove
1. Remove wheel as described in Wheels, Remove 4. Remove tie rod, spacers and seals.
procedures.

2. At the cylinder side, remove cotter pin, castle

nut and tie rod pin from the tie rod. See
Figure 19.

27
Remove and Replace 1600 SRM 1932

3. Re-lubricate bearings before re-installing tie

rod.

Install
1. Install seals and spacers on the tie rod ball
bearing and insert with the tie rod in the
spindle. Use an alignment pin to align tie rod
and spacers with the mounting bore in the
spindle. See Figure 19.

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).

1. GREASE FITTING 4. Apply EP2/3 grease to the grease nipples on the

2. TIE ROD PIN tie rod pins until grease escapes from the
3. COTTER PIN bearings.
4. CASTLE NUT
5. SET SCREW NOTE: Tie rods do not have an adjustment for
6. SPACER wheel alignment.
7. SEAL
8. SNAP RING
9. BALL BEARING STEERING CYLINDER (B238)
10. TIE ROD
Remove
Figure 19. Tie Rod Assembly 1. Disconnect tie rods at the steering cylinder by
removing cotter pin, castle nut and tie rod pin.
Clean and Inspect
2. Rotate tie rods backward, out of slot in steering
WARNING cylinder.
Cleaning solvents can be flammable and toxic and 3. Disconnect hydraulic hoses on steering cylinder
can cause skin irritation. When using cleaning at end caps. Install plastic caps on cylinder
solvents, always follow the recommendations of fittings and put plugs in hydraulic hoses. Caps
the manufacturer. will prevent piston rod from moving when
steering cylinder is removed from steering axle.
1. Ensure bearings are clean and not worn.
See Figure 20.
2. Verify tie rod does not show cracks.

28
1600 SRM 1932 Remove and Replace

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 20. 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 21 and Figure 22.
7. Remove nuts and washers at one of the end
caps.

29
Remove and Replace 1600 SRM 1932

1. CYLINDER SHELL 4. WASHER

2. CYLINDER TIE ROD 5. NUTS
3. CYLINDER END CAP

Figure 21. Steering Cylinder Assembly

30
1600 SRM 1932 Remove and Replace

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

Figure 22. Steering Cylinder

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.

Cleaning solvents can be flammable and toxic and
can cause skin irritation. When using cleaning 6. Replace damaged components as necessary.
solvents, always follow the recommendations of
the manufacturer. Compressed air can move Assemble and Install
particles so they cause injury to the user or to
other personnel. Ensure 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. Ensure 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 22.
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
Remove and Replace 1600 SRM 1932

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 (B238)
into cylinder shell.
Remove and Disassemble
5. Install tie-rods to the end caps. 1. Remove the wheel. See Remove Wheels From
Lift Truck.
6. Install washers and nuts to the tie rods and
tighten to 165 N•m (122 lbf ft). The tie rod will 2. Remove tie rod pin and tier rod at the spindle.
protrude approximately 5 mm (0.2 in.) out of See Tie Rod, Remove.
the nut.
3. Remove magnetic plug and collect draining oil
7. Install steering cylinder to hex head bolts on in a container.
axle frame using washers and nuts. Tighten
nuts to550 N•m (405 lbf ft). 4. Remove cap screws and washers from cover
plate, remove cover plate.
8. Remove plastic caps from fittings on steering
cylinder at end caps. Also remove plugs from 5. Remove cap screws from mounting plate,
hydraulic hoses. remove mounting plate and shims.

9. Connect hydraulic hoses to steering cylinder. 6. The hub weighs 55 kg (120 lb). Use a lifting
device to remove hub.
10. Rotate the tie rods with seals and spacers to
align with the steering cylinder pin holes. See 7. Catch the outer bearing cone as the hub is
Figure 19. moved from the spindle. See Figure 23.

11. Install tie rod pin, castle nut, and cotter pin to 8. Remove hub from spindle and put on a flat
connect steering cylinder to tie rod. clean surface.

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
1600 SRM 1932 Remove and Replace

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 23. Hub Assembly

Clean and Inspect 4. Inspect the contact surface between spindle

and seal. Smoothen as necessary.

WARNING Assemble and Install

Cleaning solvents can be flammable and toxic and
can cause skin irritation. When using cleaning
solvents, always follow the recommendations of CAUTION
the manufacturer. DO NOT damage the seals during installation.

1. Clean all parts with solvent. Ensure bearings 1. Apply oil and install inner bearing cone and
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
3. Inspect spindle and hub for cracks and damage.
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 24.

33
Remove and Replace 1600 SRM 1932

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 24. Mounting Plate Shimming
11. Re-shim the hub if rotating torque is lower
than
37 or higher than 47 N•m
SPINDLE (B238)
(27.2 or higher than 34.6 lbf ft). Remove
12. Install the cover plate and torque cap screws to NOTE: The spindle weighs 26.7 kg (58.9 lb). Use a
25 N•m (18 lbf ft). lifting device when removing or installing the
spindle.
13. Rotate the hub until the two fill plugs are at 1. Remove wheel, tie rod and hub as described in
the same height, remove both magnetic fill Wheels, Tie Rod (B238) and Hubs (B238) .
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 25.

34
1600 SRM 1932 Checks and Adjustments

1. Clean all parts in solvent. Inspect contact

surface and play between king pin and
bushings. Replace if worn or if play can be felt
when dry. Replace as necessary.

2. Use appropriate pushers when replacing cups

with a press.

3. Inspect spindle for cracks and damage.

Smoothen the contact surface between spindle
and hub seal as necessary.

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.)
1. STEERING AXLE less than measured clearance.
2. CAP SCREW
3. WASHER 4. Tighten three cap screws to 20 N•m (15 lbf ft).
4. CAP Rotate spindle, then tighten cap screws to
5. O-RING 20 N•m (15 lbf ft) again. Loosen cap screws and
6. BUSHING tighten again to 14 N•m (10 lbf ft).
7. KING PIN
8. SPINDLE
9. SET SCREW 5. Measure gap. Install correct amount of shims
10. LOCK NUT to equal the gap. Tighten cap screws to
11. THRUST BEARING 77 N•m (56.8 lbf ft).
12. O-RING
13. BEARING 6. Install new O-ring, grease plate and three cap
screws to top of steering frame. See Figure 25.
Figure 25. Spindle Assembly
7. Install tie rod. See Install.
Clean and Inspect
8. Repeat procedure for other spindle.
WARNING
9. Install hubs and wheels. See Hubs (B238) and
Cleaning solvents can be flammable and toxic and
Wheels.
can cause skin irritation. When using cleaning
solvents, always follow the recommendations of
the manufacturer.

Checks and Adjustments

MAXIMUM STEERING ANGLE The standard adjustment is 21.5 mm (0.85 in.).
ADJUSTMENT (L007/K019) The adjustment providing the shortest
allowable turning radius is 17.5 mm (0.70 in.).
1. The turning radius of the truck can be changed
by adjusting the bolts, which protrude at the
side of the spindles. See Figure 26.

35
Torque Specifications 1600 SRM 1932

2. A shorter turning radius is obtained by moving

more washers from the front side to the rear
side of the spindle. The maximum allowable
number of washers at the rear side is 7.

A. ADJUSTMENT

1. TIE ROD
2. SPINDLE
3. WHEEL HUB
4. STEERING AXLE
1. ADJUSTING BOLT
Figure 26. Steering Angle Adjustment (L007/K019) 2. WASHERS

MAXIMUM STEERING ANGLE Figure 27. Steering Angle Adjustment (B238)

ADJUSTMENT (B238)
1. The turning radius of the truck can be changed
by differently positioning the washers which
support the adjusting bolt. See Figure 27.

Torque Specifications
STEERING CONTROL UNIT WHEEL NUTS
Capscrews, Cover (Final Torque Value) Drive Wheels (Final Torque Value)
30 N•m (265 lbf in) 615 to 710 N•m (454 to 524 lbf ft)

Capscrews, Manifold Block Steer Wheels (Final Torque Value)

40 N•m (30 lbf ft) 615 to 710 N•m (454 to 524 lbf ft)

STEERING AXLE STEERING CYLINDER

Capscrews, Bearing Cap Capscrews, Steer Cylinder Mount
77 N•m (56.8 lbf ft) 435 N•m (321 lbf ft)

Castle Nut (Final Torque Value)

3 N•m (25 lbf in)

Capscrews, Steer Axle Mount

270 N•m (199 lbf ft)

36
 TECHNICAL PUBLICATIONS

1600 SRM 1932 12/19 (10/18)(9/18)(6/16)(12/15)(8/15)