Steering Axle: RS45-30CH, RS45-27IH, RS46-33CH, RS46-30IH, RS46-36CH, RS46-33IH (A222)
Uploaded by
stefan corjucSteering Axle: RS45-30CH, RS45-27IH, RS46-33CH, RS46-30IH, RS46-36CH, RS46-33IH (A222)
Uploaded by
stefan corjucSTEERING AXLE
RS45-30CH, RS45-27IH, RS46-33CH, RS46-30IH,
RS46-36CH, RS46-33IH [A222]
PART NO. 897953 1600 SRM 639
SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly
fastened, and that the load being lifted is balanced. Make sure the crane, cables, and
chains have the capacity to support the weight of the load.
• Do not lift heavy parts by hand, use a lifting mechanism.
• Wear safety glasses.
• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair
on electric lift trucks. Disconnect the battery ground cable on internal combustion lift
trucks.
• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT
THE LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Mainte-
nance section.
• Keep the unit clean and the working area clean and orderly.
• Use the correct tools for the job.
• Keep the tools clean and in good condition.
• Always use HYSTER APPROVED parts when making repairs. Replacement parts
must meet or exceed the specifications of the original equipment manufacturer.
• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before
using force to remove parts.
• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs,
or if the unit needs repairs.
• Be sure to follow the WARNING and CAUTION notes in the instructions.
• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel
are flammable. Be sure to follow the necessary safety precautions when handling these
fuels and when working on these fuel systems.
• Batteries generate flammable gas when they are being charged. Keep fire and sparks
away from the area. Make sure the area is well ventilated.
NOTE: The following symbols and words indicate safety information in this
manual:
WARNING
Indicates a condition that can cause immediate death or injury!
CAUTION
Indicates a condition that can cause property damage!
Steering Axle Table of Contents
TABLE OF CONTENTS
General ............................................................................................................................................................... 1
Description ......................................................................................................................................................... 1
How to Put ReachStacker on Blocks................................................................................................................. 2
How to Lift Steer Tires .................................................................................................................................. 2
Steering Axle Assembly ..................................................................................................................................... 2
Up to 1527 ...................................................................................................................................................... 2
Remove....................................................................................................................................................... 2
Install ......................................................................................................................................................... 3
Starting With 1528 ........................................................................................................................................ 4
Remove....................................................................................................................................................... 4
Install ......................................................................................................................................................... 5
Wheels and Hubs ............................................................................................................................................... 6
Remove and Disassemble .............................................................................................................................. 6
Clean .............................................................................................................................................................. 6
Assemble and Install ..................................................................................................................................... 7
Spindles, Bearings, and Tie Rods...................................................................................................................... 8
Remove ........................................................................................................................................................... 8
Install ............................................................................................................................................................. 9
Steering Cylinder ............................................................................................................................................... 10
Up to 1532 ...................................................................................................................................................... 10
Remove and Disassemble.......................................................................................................................... 10
Clean and Inspect...................................................................................................................................... 11
Assemble and Install................................................................................................................................. 11
Starting With 1533 ........................................................................................................................................ 11
Remove and Disassemble.......................................................................................................................... 11
Clean and Inspect...................................................................................................................................... 13
Assemble and Install................................................................................................................................. 13
Torque Specifications ......................................................................................................................................... 14
Troubleshooting.................................................................................................................................................. 14
This section is for the following models:
RS45-30CH, RS45-27IH, RS46-33CH, RS46-30IH, RS46-36CH,
RS46-33IH [A222]
©2005 HYSTER COMPANY i
"THE
QUALITY
KEEPERS"
HYSTER
APPROVED
PARTS
1600 SRM 639 Description
General
This section has the description and repair procedures for the steering axle. For information on other parts of
the steering system, see the section Steering System 1600 SRM 637.
Description
The steering axle assembly includes an axle housing, the seal are at the center of the rod. Oil pressure on
steering cylinder, tie rods, tie rod pins, and two spin- one side of the piston moves the piston in the bore.
dle and hub assemblies. See Figure 1. The steering As the piston moves, it pushes an equal amount of
axle mounts to the frame with a center pivot pin. The oil from the opposite end of the cylinder. The oil
center pivot pin permits the steering axle to move as returns to the steering control unit.
the ReachStacker® travels over rough surfaces.
When the piston in the cylinder reaches the end of
The steering cylinder mounts to the axle housing the stroke, a relief valve limits the oil pressure so
with four bolts. The ends of the piston rod extend the components are not damaged. The relief valve is
from both ends of the cylinder. A single piston and located in the flow amplifier.
1. AXLE HOUSING 8. SPLIT PIN 15. ROLL PIN
2. GREASE FITTING 9. TIE ROD 16. WASHER
3. PIN 10. BUSHING 17. CAPSCREW
4. SNAP RING 11. PLATE 18. THRUST WASHER
5. SPHERICAL BEARING 12. CAPSCREW 19. GROOVE PIN
6. WASHER 13. SHIM/THRUST WASHER 20. KING PIN
7. LOCK NUT 14. SPINDLE
Figure 1. Steer Axle Assembly
1
Steering Axle Assembly 1600 SRM 639
Tie rods connect the steering cylinder to the spindles. The wheel hub rotates on two tapered roller bearings.
A king pin supports the spindle in the axle housing. An adjustment nut sets the preload on the bearings.
Each spindle turns on two bushings and thrust wash- Grease seals in the inner hub and a cover on the hub
ers. Covers on the top and bottom of the axle housing protect the bearings from dirt and water.
protect the king pins and bushings from dirt and wa-
ter.
How to Put ReachStacker on Blocks
HOW TO LIFT STEER TIRES the total weight of the ReachStacker [approxi-
mately 54,000 kg (119,070 lb)] as shown on the
WARNING nameplate. Put the jack under the steering axle
or frame to lift the ReachStacker. Put blocks un-
The ReachStacker® must be put on blocks for
der the frame as supports for the ReachStacker.
some types of maintenance and repair. The sur-
face must be solid, even, and level when the
ReachStacker is put on blocks. Verify that any
blocks used to support the ReachStacker are
solid, one-piece units. Verify the lifting devices
used during repairs can lift the weight of the
parts and assemblies.
1. Apply the parking brake. Put blocks on both
sides (front and back) of the drive tires to prevent
movement of the ReachStacker. See Figure 2.
2. Fully lower and retract the boom. 1. STEERING TIRES
3. Use a hydraulic jack to lift the steering tires. Ver- Figure 2. Put ReachStacker on Blocks
ify that the jack has a capacity of at least 2/3 of
Steering Axle Assembly
NOTE: The steering axle assembly without the 2. Put the unit onto blocks so the steering axle can
wheels weighs approximately 3400 kg (7497 lb). be removed. Follow the instructions on How to
Lift Steer Tires in this section.
UP TO 1527
3. It is not required, but removal of the wheels can
Remove make it easier to remove the steer axle. See
Wheels and Hubs, Remove and Disassemble for
WARNING the procedure to remove the wheels.
The rear counterweight for the ReachStacker® 4. Disconnect the hydraulic lines at the steering
weighs approximately 3350 kg (7387 lb). The cylinder. Install caps onto the cylinder, and put
main counterweight weighs approximately plugs into the hydraulic lines. The caps will pre-
13,500 kg (29,762 lb). Verify the lifting devices vent the spindles from turning when the axle is
used during repairs can lift the weight of the removed from the unit. Disconnect the brake
parts. lines at the brake calipers. Install caps on the
calipers and put plugs into the hoses.
1. Verify the wheels are set for straight travel.
Remove the counterweight(s). See the section 5. Insert 340 mm (13.38 in.) long M30×3.5 studs
Frame 100 SRM 631 for the procedure to re- into the mounting plates. Install a nut and
move counterweights. washer on each stud.
2
1600 SRM 639 Steering Axle Assembly
6. Slide a floor jack under the steering axle. Raise damage. Replace all worn or defective parts. See Fig-
the axle by tightening the nuts on the M30×3.5 ure 1 and Figure 3.
studs until the weight is removed from the pivot
pin. 1. Apply grease to the pivot pin bushings.
2. Carefully move the axle assembly into position
WARNING under the ReachStacker. Align the axle assem-
The pivot pin weighs approximately 135 kg bly to the frame and rubber mounts. Raise the
(295 lb). Use a lifting device that can support axle assembly into place with a jack. Install the
the weight of the item. Verify all chains, hooks, four M30×3.5 studs, nuts, and washers to hold
slings, etc. are in good condition and have the the steer axle in position. Tighten the 4 studs
correct capacity. uniformly until the axle is in position to install
the pivot pin.
7. Remove the plate that holds the pivot pin in the
frame. See Figure 1 and Figure 3. The end of the 3. Apply grease to the pivot pin. Install the pivot
pivot pin has an M30×3.5 threaded hole. Install pin and spacers. Install the retainer plate and
a threaded puller in the pivot pin. Pull the pivot tighten the two capscrews to 200 N•m (150 lbf ft).
pin out of the frame. Install the grease fittings.
8. Slowly lower the axle assembly by loosening the 4. Loosen the 4 studs uniformly until the studs are
4 studs uniformly until it is clear of the frame unloaded. Remove the M30×3.5 studs and the
and the rubber mounts are loose, see Figure 4. floor jack.
Carefully move the axle assembly from under the
ReachStacker. 5. Remove the plugs and caps and connect the hy-
draulic lines to the steering cylinder. Turn the
Install steering wheel several times from one stop to the
other stop. Check for hydraulic leaks.
Before installation of the axle assembly, check the
axle housing, pivot pin, spacers, and bushings for
A. DRIVE DIRECTION
1. SPACER 5. WASHER
2. BUSHING 6. CAPSCREW
3. PIVOT PIN 7. GREASE FITTINGS
4. RETAINER PLATE
Figure 3. Steering Axle Mounting
3
Steering Axle Assembly 1600 SRM 639
2/3 of the total weight of the ReachStacker [ap-
proximately 54,000 kg (119,070 lb)] as shown on
the nameplate. Put the jack under the steering
axle or frame to lift the ReachStacker. Remove
the blocks from under the frame and lower the
ReachStacker.
1. SPECIAL FITTING
Figure 5. Remove Air From Steer Cylinder
STARTING WITH 1528
Remove
1. FLANGE 5. WASHER
2. CAPSCREW 6. SPACER
3. RUBBER MOUNT 7. FLANGE WARNING
4. NUT 8. PIN The heaviest rear counterweight (cast) weighs
Figure 4. Rubber Mounts approximately 7000 kg (15,432 lb). The heavi-
est main counterweight (cast) weighs approx-
6. Remove air from the steering system as follows: imately 14,000 kg (30,865 lb), and the heaviest
main counterweight (fabricated) weighs ap-
a. Turn the steering wheel several times from proximately 19,300 kg (42,549 lb). Verify the
one stop to the other stop. lifting devices used during repairs can lift the
weight of the parts.
b. Open the special fittings on each end of the
steering cylinder to remove air from the
cylinder. See Figure 5. WARNING
Before removing the counterweight, put blocks
c. Repeat Step a and Step b until all of the air under the mast assembly so that the lift truck
is removed from the system. cannot fall forward.
7. Remove the plugs and caps and connect the brake 1. Verify the wheels are set for straight travel.
lines to the calipers. Open the special fittings on Remove the counterweight(s). See the section
the calipers to remove air from the system. Frame 100 SRM 1174 for the procedure to re-
move counterweights.
8. Install the wheels on the steer axle.
2. Put the ReachStacker on blocks so the steering
9. Use a hydraulic jack to lift the steering tires.
axle can be removed. Follow the instructions on
Verify that the jack has a capacity of at least
How to Lift Steer Tires in this section.
4
1600 SRM 639 Steering Axle Assembly
3. It is not required, but removal of the wheels can 6. Slide a floor jack under the steering axle. Raise
make it easier to remove the steer axle. See steering axle with the floor jack until the weight
Wheels and Hubs, Remove and Disassemble for is removed from the pivot pin.
the procedure to remove the wheels.
4. Disconnect the hydraulic lines at the steering WARNING
cylinder. Install caps onto the cylinder, and put The pivot pin weighs approximately 135 kg
plugs into the hydraulic lines. The caps will pre- (295 lb). Use a lifting device that can support
vent the spindles from turning when the axle is the weight of the item. Verify all chains, hooks,
removed from the ReachStacker. slings, etc. are in good condition and have the
correct capacity.
NOTE: There is a slab counterweight assembled un-
derneath the steering axle on model RS46-36CH and 7. Remove the plate that holds the pivot pin in the
RS46-33IH when a fabricated main counterweight is frame. See Figure 1 and Figure 3. The end of the
attached. See Figure 6. pivot pin has an M30×3.5 threaded hole. Install
a threaded puller in the pivot pin. Pull the pivot
5. If a slab counterweight is assembled, perform the pin out of the frame.
following steps:
8. Carefully move the axle assembly from under the
a. Slide a floor jack underneath the steering ReachStacker.
axle. Raise the floor jack so it is just support-
ing the slab counterweight. Install
b. Remove the four capscrews that hold the slab Before installation of the axle assembly, check the
counterweight underneath the steering axle. axle housing, pivot pin, spacers, and bushings for
damage. Replace all worn or defective parts. See Fig-
c. Carefully move the slab counterweight from ure 1 and Figure 3.
underneath the ReachStacker.
1. Apply grease to the pivot pin bushings.
2. Carefully move the axle assembly into position
under the ReachStacker. Align the axle assembly
to the frame. Raise the axle assembly into place
with a floor jack until the axle is in position to
install the pivot pin.
3. Apply grease to the pivot pin. Install the pivot
pin and spacers. Install the retainer plate and
tighten the two capscrews to 200 N•m (150 lbf ft).
Install the grease fittings.
4. Remove the floor jack.
5. If a slab counterweight must be installed, per-
form the following steps:
a. Move the slab counterweight into position
under the steering axle. Align the slab coun-
terweight to the steering axle.
b. Install the four capscrews and tighten to
1. SLAB COUNTERWEIGHT 600 N•m (443 lbf ft).
2. CAPSCREW
3. MAIN COUNTERWEIGHT (FABRICATED) 6. Remove the plugs and caps and connect the hy-
Figure 6. Slab Counterweight draulic lines to the steering cylinder. Turn the
steering wheel several times from one stop to the
other stop. Check for hydraulic leaks.
5
Wheels and Hubs 1600 SRM 639
7. Remove air from the steering system as follows: 9. Verify the wheels are set in a straight line of
travel. Install the counterweights. See the sec-
a. Turn the steering wheel several times from tion Frame 100 SRM 1174 for the procedure to
one stop to the other stop. install counterweights.
b. Open the special fittings on each end of the 10. Use a hydraulic jack to lift the steering tires. Ver-
steering cylinder to remove air from the ify the jack has a capacity of at least 2/3 of the
cylinder. See Figure 5. total weight of the ReachStacker as shown on
the nameplate. Put the jack under the steering
c. Repeat Step a and Step b until all of the air
axle or frame to lift the ReachStacker. Remove
is removed from the system.
the blocks from under the frame and lower the
8. Install the wheels on the steer axle. See Wheels ReachStacker.
and Hubs, Assemble and Install for the proce-
dure to install the wheels.
Wheels and Hubs
REMOVE AND DISASSEMBLE 4. Support the hub with a hoist or a lifting device.
Pull the hub assembly away from the spindle.
WARNING Remove the retainer ring and the inner bearing
ring from the spindle. Remove the oil seal from
Completely remove the air from the tires be-
the retainer ring.
fore removing them from the ReachStacker®.
Air pressure in the tires can cause the tire and 5. If wheel bearings are damaged, use a brass drift
rim parts to explode, which can cause serious to remove the bearing cups from the hub.
injury or death.
CLEAN
WARNING
The steer wheel and tire assembly weighs ap- WARNING
proximately 750 kg (1650 lb). Use the following Cleaning solvents can be flammable and toxic
procedure to remove the tire and wheel assem- and can cause skin irritation. When using
bly from the steer axle. Use a lifting device if cleaning solvents, always follow the solvent
the tire and wheel assembly must be lifted. manufacturer’s safety procedures.
1. Put the axle on the blocks so the tires are raised 1. Clean all moving parts with solvent. Verify the
from the floor. Completely remove the air from bearings are clean.
the tires. Remove the wheels.
2. Remove the capscrews that hold the brake CAUTION
caliper to the spindle. See Figure 7. Do not wash parts with steam or hot water
since it will be difficult to remove all of the
3. Remove the wheel hub cover plate. Loosen the surface moisture.
three setscrews on the adjustment nut. Remove
the adjustment nut. Remove the spacer. 2. Dry all component parts with an air jet or soft
cloth to avoid damage to the surface from abra-
WARNING sive particles.
To avoid personal injury, use a hoist to lift com- 3. Check that all surfaces are covered with a thin
ponents that weigh more than 23 kg (50 lb). film of oil to protect them against corrosion.
Verify the hoist or lift device is strong enough
to support the weight of the item. Verify all
chains, hooks, slings, etc. are in good condition
and have the correct capacity.
6
1600 SRM 639 Wheels and Hubs
1. CAPSCREW 9. O-RING
2. WASHER 10. RETAINER RING
3. WHEEL HUB COVER 11. OIL SEAL
4. ADJUSTMENT NUT 12. STUD
5. SPACER 13. WASHER
6. OUTER BEARING 14. WASHER
7. WHEEL HUB 15. NUT
8. INNER BEARING
Figure 7. Hub Assembly
ASSEMBLE AND INSTALL 6. Tighten the adjustment nut until the hub begins
to rotate.
If new wheel bearings are installed, use a press to
install the new bearing cups in the wheel hub. Verify 7. Wrap a rope tightly around the hub several
the bearings are filled with grease. See Figure 3. times. Pull on the rope with a spring scale.
Tighten the adjusting nut until the hub rotating
torque is 93.2 to 127.5 N•m (68.8 to 94.0 lbf ft).
CAUTION
Do not damage the seals during installation. 8. Tighten the setscrews on the adjustment nut.
1. Install the oil seal rings in the retainer ring. 9. Fill the area between the two bearings and be-
Press the seal ring into the retainer ring. tween the bearing and the cover with grease.
2. Install the inner bearing ring in the cup in the 10. Spread a seal compound on the inside of the
wheel hub. Verify the bearing is filled with wheel hub cover. Place the cover on the hub.
grease. Tighten the capscrews to 25 N•m (18.5 lbf ft)
in the sequence shown in Figure 8 and tighten
3. Install the retaining ring in the wheel hub. Use a again to 45.1 N•m (33 lbf ft) in the same se-
soft hammer to gently seat the retainer ring fully quence.
in the hub.
4. Carefully slide the hub onto the spindle.
5. Install the outer bearing on the spindle. Install
the spacer.
7
Spindles, Bearings, and Tie Rods 1600 SRM 639
alignment after tightening nuts 1 through 4. Fi-
nally, tighten the wheel nuts to 128 to 147 N•m
(94 to 108 lbf ft).
Figure 8. Wheel Hub Cover
WARNING
Add air pressure to the tires only in a safety
cage. Inspect the safety cage for damage be- Figure 9. Wheel Nuts
fore use. When air pressure is added, use a
chuck that fastens onto the valve stem of the
WARNING
inner tube. Verify there is enough hose to per-
mit the operator to stand away from the safety Check all wheel nuts after 2 to 5 hours of oper-
cage when air pressure is added to the tire. Do ation when a new ReachStacker begins opera-
not sit or stand by the safety cage. tion and on all ReachStackers when the wheels
have been removed and installed. Tighten the
11. Inflate the tire (check truck data plate for correct nuts in a cross pattern to the correct torque
inflate pressure). Mount the wheel and tighten value. When the nuts stay tight for 8 hours,
the wheel nuts to 70 N•m (52 lbf ft) in the se- the interval for checking the torque can be ex-
quence shown in Figure 9. Check for correct tended to 250 hours.
alignment of wheel parts and inside wheel to hub
12. Repeat the procedure for the other wheel.
Spindles, Bearings, and Tie Rods
REMOVE 2. With a puller, remove the pins from the tie rods.
3. Remove the snap rings from the tie rods.
WARNING
Completely remove the air from the tires be- 4. Remove the spherical bearings from the tie rods.
fore removing them from the ReachStacker®.
Air pressure in the tires can cause the tire and 5. Remove the upper and lower cover plates from
rim parts to explode, which can cause serious the axle housing.
injury or death.
Put the ReachStacker onto blocks so the tires are
CAUTION
raised from the floor. Completely remove the air from To avoid personal injury, use a hoist when lift-
the tires. See the section for the procedure for remov- ing components that weigh more than 23 kg
ing the wheel and tire assembly. Remove the wheel (50 lb). Verify the hoist or lift device is strong
and tire assembly from the steering axle hub. Re- enough to support the weight of the item. Ver-
move the hub from the steering axle spindle. See Fig- ify all chains, hooks, slings, etc. are in good
ure 3. condition and are of correct capacity.
1. Remove the split pins and lock nuts on the tie 6. Support the spindle with a hoist or lifting device.
rods. Remove the kingpin with a hydraulic press.
8
1600 SRM 639 Spindles, Bearings, and Tie Rods
7. Remove the spindle with support from a lifting S=A B 0.1 mm (S = A B 0.004 in.)
device or a hoist. Save the thrust washers and
bearings. where S = shims/thrust washer
A = distance across the axle housing
8. Remove the kingpin bushings from the axle hous-
ing. B = distance across the spindle
INSTALL 8. Install the shims/thrust washer and upper
thrust washer on the spindle and the upper
1. Install the lower cover plates for the spindle on
thrust washer in the axle housing.
the axle housing. See Figure 3.
9. Support the spindle with a hoist or lifting de-
WARNING vice and install it in the axle housing. Lubricate
Material that is cooled to very low tempera- the surfaces with molybdenum disulfide grease
tures can cause injury on contact. Wear protec- to ease installation.
tive clothing including insulated gloves, safety
glasses, and face shields. Handle liquid nitro- WARNING
gen and cooled parts carefully. Material that is cooled to very low tempera-
tures can cause injury on contact. Wear protec-
2. Cool the upper and lower bushings to 200 to tive clothing including insulated gloves, safety
230 C ( 328 to 382 F) in liquid nitrogen. In- glasses, and face shields. Handle liquid nitro-
stall the lower bushing in the axle housing until gen and cooled parts carefully.
it contacts the lower cover.
10. Cool the kingpin to 200 to 230 C ( 328 to
3. Install shims with a total thickness of 1.5 mm 382 F). The top end of the kingpin is larger than
inside the lower bushing. the bottom end. Install the kingpin in the axle
4. Install the groove pins in the axle housing. housing from the top of the housing until it con-
tacts the shims installed in Step 3.
5. Install the lower and the upper thrust washers
on the axle housing. Measure the distance be- 11. Remove the lower cover and remove the shims.
tween the thrust washers on the axle housing. 12. Spread a sealant compound on the underside
See Figure 10. This is dimension A. of the cover plates. Install the cover plates.
Tighten the capscrews to 75 N•m (55 lbf ft) in
the sequence shown in Figure 11 and tighten
to 150 N•m (111 lbf ft) in the same sequence.
Tighten a final time to 383 N•m (283 lbf ft) in
the same sequence.
Figure 10. Dimensions A and B
6. Install the pins on the spindle. Measure the dis-
tance across the spindle. See Figure 10. This is
dimension B.
7. Subtract the measurement in Step 6 from the
measurement in Step 5. Select shims/thrust
washer so the thickness is 0.1 mm (0.004 in.)
less than the clearance. Figure 11. Kingpin Cover Plate
9
Steering Cylinder 1600 SRM 639
13. Fill the upper and lower bushing areas with
grease through the grease fittings.
14. Install the spherical bearings in the tie rods.
Align bearings as shown in Figure 12.
Figure 13. Spindle and Tie Rod Connection
WARNING
Add air pressure to the tires only in a safety
cage. Inspect the safety cage for damage be-
1. NOTCH fore use. When air pressure is added, use a
chuck that fastens onto the valve stem of the
Figure 12. Tie Rod Bearing
inner tube. Verify there is enough hose to per-
15. Install the snap rings in the tie rod. Install the mit the operator to stand away from the safety
bearing thrust washers above and below the snap cage when air pressure is added to the tire. Do
rings. not sit or stand by the safety cage.
16. Connect the tie rods. See Figure 13. Align the tie 17. Inflate the tires to 1000 kPa (145 psi) (check
rods with the spindle and steering cylinder ends. truck data plate). Mount the wheels and tighten
Grease the pin. Install the pin and washers and the wheel nuts to 140 N•m (103 lbf ft).
tighten the lock nuts. Install the split pins.
18. See the section for the procedure for installing
the wheel and hub assembly.
Steering Cylinder
UP TO 1532 2. Disconnect the tie rods. Remove the split pins,
lock nuts, and washers from the tie rod pins. Re-
Remove and Disassemble move the pins.
NOTE: The steer cylinder weighs approximately
WARNING
265 kg (584 lb).
To avoid personal injury, use a hoist to lift com-
ponents that weigh more than 23 kg (50 lb). 3. Remove the capscrews that fasten the cylinder to
Make sure the hoist or lift device is strong the axle frame. Remove the steering cylinder.
enough to support the weight of the item.
Make sure all chains, hooks, slings, etc. are in 4. Place a drain pan under the end of the steering
good condition and are of correct capacity. cylinder. Remove the cap for the hydraulic fitting
from each end cap. Push the rod toward the end
1. Disconnect the hydraulic lines at the steering of the shell that is over the drain pan. Oil will
cylinder. See Figure 14. Mark the locations of drain from the cylinder. Repeat the procedure for
the hydraulic lines to ensure correct assembly. the other end.
Install caps in the fittings on the cylinders and
put caps on the hydraulic lines.
10
1600 SRM 639 Steering Cylinder
fine emery cloth. Inspect the cylinder bore for dam-
age. Inspect the mounts for cracks.
Assemble and Install
Before installation of the steering cylinder, check the
shell, joint and guide assemblies, piston flange, rod,
and seals for damage. Replace all worn or damaged
parts. See Figure 14.
1. Put the O-rings and seals into warm hydraulic
oil.
CAUTION
Do not damage the O-rings, seals, or wipers
during installation.
2. Lubricate the guide rings and joints with O-ring
lubricant and install them into the guide assem-
blies. Lubricate the piston seals and install them
onto the piston. Install one piston flange and end
flange onto the cylinder rod.
3. Carefully slide the cylinder rod and piston into
the shell. Keep the cylinder rod aligned in the
center of the shell during installation so the
parts are not damaged. Carefully slide the pis-
1. SHELL 8. GUIDE ton flange into the shell. Carefully install the
2. PISTON SEALS 9. O-RING
3. ROD 10. JOINT other piston flange onto the rod and shell. Put
4. WIPER RING 11. GUIDE ASSEMBLY caps on the hydraulic fittings of the end caps.
5. CAPSCREW 12. PISTON FLANGE
6. CAPSCREW 13. BACKUP RING 4. Install the cylinder onto the axle frame. Install
7. END FLANGE 14. O-RING the spacers between the cylinder mounts and the
axle frame. Tighten the capscrews to 1200 to
Figure 14. Steering Cylinder 1400 N•m (885 to 1033 lbf ft).
5. Carefully remove one end flange from the shell. 5. Install the tie rods.
Carefully pull the cylinder rod and piston from
the shell. Keep the cylinder rod aligned in the 6. Remove the caps and connect the hydraulic lines
center of the shell during removal so the parts to the steering cylinder.
are not damaged. Remove the piston flange from
the rod. Remove the other end flange and piston STARTING WITH 1533
flange from the shell. Remove all seals, wipers,
guides, and O-rings. Remove and Disassemble
Clean and Inspect WARNING
To avoid personal injury, use a hoist to lift com-
WARNING ponents that weigh more than 23 kg (50 lb).
Cleaning solvents can be flammable and toxic Make sure the hoist or lift device is strong
and can cause skin irritation. When using enough to support the weight of the item.
cleaning solvents, always follow the solvent Make sure all chains, hooks, slings, etc. are in
manufacturer’s safety procedures. good condition and are of correct capacity.
Clean all parts in solvent. Inspect the piston rod 1. Disconnect the hydraulic lines at the steering
for grooves or damage. Remove small scratches with cylinder. See Figure 15. Mark the locations of
11
Steering Cylinder 1600 SRM 639
the hydraulic lines to ensure correct assembly. 2. Disconnect the tie rods. Remove the split pins,
Install caps in the fittings on the cylinders and lock nuts, and washers from the tie rod pins. Re-
put caps on the hydraulic lines. move the pins.
1. CYLINDER ROD 7. CAPSCREW 13. ROD SEAL
2. NUT 8. WASHER 14. O-RING
3. ANCHOR ROD 9. WASHER 15. RING
4. SHELL 10. O-RING 16. PISTON RING
5. PISTON 11. RING 17. PISTON SEAL
6. CYLINDER FLANGE 12. ROD RING
Figure 15. Steering Cylinder
12
1600 SRM 639 Steering Cylinder
NOTE: The steer cylinder weighs approximately Assemble and Install
265 kg (584 lb).
Before installation of the steering cylinder, check the
3. Remove the capscrews that fasten the cylinder to shell, joint and guide assemblies, piston flange, rod,
the axle frame. Remove the steering cylinder. and seals for damage. Replace all worn or damaged
parts. See Figure 15.
4. Place a drain pan under the end of the steering
cylinder. Remove the cap for the hydraulic fitting 1. Put the O-rings and seals into warm hydraulic
from each end cap. Push the rod toward the end oil.
of the shell that is over the drain pan. Oil will
drain from the cylinder. Repeat the procedure for CAUTION
the other end.
Do not damage the O-rings, seals, or wipers
5. Remove from one side, four nuts from the four during installation.
anchor rods, and remove the anchor rods from
2. Lubricate the seals, rings, and O-rings with
the cylinder flanges.
O-ring lubricant and install.
NOTE: Keep the cylinder rod aligned in the center of
3. If necessary, apply adhesive to the thread of the
the shell during removal so the parts are not dam-
piston and cylinder rod. Install the piston onto
aged.
the cylinder rod.
6. Carefully remove one cylinder flange from the
4. Install one cylinder flange with rings and seal
shell and cylinder rod. Carefully pull the cylin-
onto the cylinder rod.
der rod, piston, and second cylinder flange from
the shell. Remove the second cylinder flange NOTE: Keep the cylinder rod aligned in the center
from the cylinder rod. Remove all seals, rings, of the shell during installation so the parts are not
and O-rings. If necessary, remove the piston from damaged.
the cylinder rod and clean the thread from the
piston and cylinder rod. 5. Carefully slide the cylinder rod, piston, and cylin-
der flange into the shell. Carefully install the
Clean and Inspect second cylinder flange onto the cylinder rod and
shell. Install the four anchor rods through the
WARNING two cylinder flanges with the nuts. Put caps on
the hydraulic fittings of the end caps.
Cleaning solvents can be flammable and toxic
and can cause skin irritation. When using 6. Install the cylinder onto the axle frame. Install
cleaning solvents, always follow the solvent the spacers between the cylinder mounts and the
manufacturer’s safety procedures. axle frame. Tighten the capscrews to 1200 to
1400 N•m (885 to 1033 lbf ft).
Clean all parts in solvent. Inspect the piston rod
for grooves or damage. Remove small scratches with 7. Install the tie rods.
fine emery cloth. Inspect the cylinder bore for dam-
age. Inspect the mounts for cracks. 8. Remove the caps and connect the hydraulic lines
to the steering cylinder.
13
Troubleshooting 1600 SRM 639
Torque Specifications
Hub Cover Capscrews Spindle Plate Capscrews
45.1 N•m (33 lbf ft) 383 N•m (283 lbf ft)
Wheel Hub Capscrews Cylinder Mount Capscrews
333.5 N•m (246 lbf ft) 1200 to 1400 N•m (885 to 1033 lbf ft)
Steering Wheel Nuts Slab Counterweight Capscrews
128 to 147 N•m (94 to 108 lbf ft) 600 N•m (443 lbf ft)
Troubleshooting
PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION
The steering wheels do not The oil level is low or there is no oil Fill tank. Check for leaks.
move when the steering in the tank.
wheel is turned.
The steering control unit is dam- Repair or install new control unit.
aged.
No oil flow from the steering control Repair or install new components.
unit to the steering cylinder. Check for leaks.
Slow or difficult steering. Relief valve for the steering system Adjust or install new relief valve.
needs adjustment.
Low oil pressure from the hydraulic Check for restrictions.
pump.
Seal in the steering cylinder has a Install new seal.
leak.
Steering control unit is worn or has Repair or install new control unit.
damage.
Steering wheel turns the The hydraulic lines are not con- Connect lines properly. Remove air
tires in the wrong direction. nected correctly at the steering from the system.
cylinder or at the steering control
unit.
Steering function contin- The steering control unit was assem- Repair or install new control unit.
ues after the steering wheel bled wrong or has damage.
stops.
14
1600 SRM 639 Troubleshooting
PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION
There is air in the steering The oil level in the tank is low. Add hydraulic oil as necessary.
system. Check for leaks.
Air was not removed after repair to Remove air from the system.
the hydraulic or steering system.
The hydraulic pump has an air leak Repair system. Remove air from the
at the inlet. system.
15
NOTES
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
16
TECHNICAL PUBLICATIONS
