YALE B810 GLP16-20AF LIFT TRUCK Service Repair Manual.pdf

GLP/GDP16-20AF (GP/GLP/GDP030-040AF) (B810)
SERVICE MANUAL CONTENTS
SECTION
PART
NUMBER
YRM
NUMBER
REV
DATE
FRAME............................................................................................................................ 524168415 0100 YRM 0545 01/05
MAZDA FE AND F2 ENGINE......................................................................................... 524158742 0600 YRM 0496 01/11
MAZDA HA/XA DIESEL ENGINES................................................................................ 524162461 0600 YRM 1019 01/11
COOLING SYSTEM........................................................................................................ 524150775 0700 YRM 0626 03/03
LPG FUEL SYSTEM (AISAN OPEN LOOP).................................................................. 524158747 0900 YRM 0925 12/03
LPG FUEL SYSTEM (AISAN CLOSED LOOP)............................................................. 524158748 0900 YRM 0948 10/06
SINGLE-SPEED POWERSHIFT TRANSMISSION-DESCRIPTION AND REPAIR....... 524168417 1300 YRM 0543 12/03
DRIVE AXLE................................................................................................................... 524168418 1400 YRM 0542 12/03
STEERING AXLE............................................................................................................ 524168419 1600 YRM 0532 10/04
STEERING CONTROL UNIT.......................................................................................... 524158753 1600 YRM 0720 11/06
BRAKE SYSTEM............................................................................................................ 524168420 1800 YRM 0540 05/02
HYDRAULIC SYSTEM AND GEAR PUMP.................................................................... 524168421 1900 YRM 0539 05/02
MAIN CONTROL VALVE................................................................................................ 524168422 2000 YRM 0541 05/02
TILT CYLINDERS........................................................................................................... 524150790 2100 YRM 0103 03/07
INSTRUMENT CLUSTER............................................................................................... 524158757 2200 YRM 0514 01/04
ELECTRICAL SYSTEM (MAZDA FE AND F2 ENGINES)............................................. 524158758 2200 YRM 0524 12/03
ELECTRICAL SYSTEM (MAZDA 2.5 DIESEL ENGINE)............................................... 524168423 2200 YRM 0550 05/02
MAST - DESCRIPTION................................................................................................... 524158890 4000 YRM 0521 03/06
MAST - REPAIR.............................................................................................................. 524158891 4000 YRM 0522 07/10
METRIC AND INCH (SAE) FASTENERS....................................................................... 524150797 8000 YRM 0231 10/13
DIAGRAMS..................................................................................................................... 524168426 8000 YRM 0544 06/04
CAPACITIES AND SPECIFICATIONS........................................................................... 524168425 8000 YRM 0546 01/11
PERIODIC MAINTENANCE............................................................................................ 524175034 8000 YRM 0959 06/09
Service information for Cummins diesel engines can be ordered through the Hyster Literature Distribution Center.
PART NO. 524175029 (10/13)

700 YRM 626 General
General
This section has the description and the checks for
some parts of the cooling system. Prodecures for
cleaning the radiator and troubleshooting are also
included in this section.
The cooling system has the following parts: radiator,
auxiliary coolant reservoir, water pump, thermostat, fan,
and fan shroud. See Figure 1.
1. AUXILIARY COOLANT RESERVOIR
2. RADIATOR CAP
3. RADIATOR
4. RADIATOR DRAIN VALVE
5. TOP RADIATOR HOSE
6. FAN SHROUD
7. BOTTOM RADIATOR HOSE
8. PORTS FOR TRANSMISSION OIL COOLER
Figure 1. Typical Radiator Arrangement
1

Description 700 YRM 626
Description
The purpose of the cooling system is to control the
operating temperature of the engine (and in some
units, the transmission, brakes, and hydraulic system).
A centrifugal water pump circulates coolant through
passages in the engine block and the radiator. A
thermostat is installed in the water outlet fitting on the
engine. As the coolant flows through the radiator, the
fan moves air through the radiator to help cool the
system.
The coolant is a mixture of water and antifreeze. The
antifreeze prevents the coolant from freezing in cold
weather, and thereby preventing damage to the engine
and radiator. The antifreeze also prevents rust and lu-
bricates the water pump.
RADIATOR
The radiator is the heat exchanger for the cooling sys-
tem. The fan causes air to flow through the radiator
and reduces the temperature of the coolant. The aux-
iliary coolant reservoir is connected to the radiator by
a hose. As the engine gets hot, the coolant expands.
During expansion, coolant moves from the radiator to
the reservoir. When the engine stops, the coolant be-
comes cool and contracts. The coolant in the reservoir
flows back into the radiator. In this way, the radiator is
kept filled with coolant during normal operation.
On units with a powershift transmission, an oil cooler is
built into the radiator. Oil from the transmission flows
through coils in the radiator tank to help control the oil
temperature.
RADIATOR CAP
The radiator cap is a pressure-vent type that lets the
pressure in the cooling system increase to 103 kPa
(15 psi). The pressure in the system prevents vapor
from forming in the coolant flowing to the water pump.
This action maintains the efficiency of the water pump
and the performance of the cooling system. The in-
crease in pressure also raises the boiling point of the
coolant mixture to approximately 125 C (257 F) at sea
level.
The radiator cap has a pressure valve and a vacuum
valve. The pressure valve is held against its seat by a
spring. The pressure valve opens when the pressure
in the cooling system exceeds 103 kPa (15 psi). The
vacuum valve is held against its seat by another spring.
The vacuum valve opens to relieve the vacuum created
when the coolant temperature decreases. In certain
conditions this vacuum can cause the radiator or top
hose to collapse.
THERMOSTAT
The thermostat is a device that controls coolant flow by
opening and closing to regulate coolant temperature.
The thermostat uses a wax pellet to control its oper-
ation. The wax pellet expands when it is heated and
contracts when it is cold. When heated, the wax pellet
pushes on the piston, causing the valve in the thermo-
stat to open. As the wax pellet cools, it contracts and
lets a spring close the valve. When the engine is first
started and the coolant is cold, the thermostat remains
closed. During this time the coolant circulates through
the engine, letting it warm quickly. As the engine be-
comes warm the thermostat opens, letting coolant cir-
culate through the radiator.
The opening and closing of the thermostat helps keep
the coolant within the operating limits of the system.
The same thermostat is used for summer and winter
seasons. Do not operate the engine without a thermo-
stat. The engine will take longer to get warm and may
run improperly. See Figure 2.
1. PISTON
2. VALVE SEAT
3. SPRING
4. DIAPHRAGM
5. WAX PELLET
6. FRAME
7. FLANGE
8. VENT HOLE
Figure 2. Typical Thermostat
2

700 YRM 626 Cooling System Checks
WATER PUMP
The centrifugal-type water pump is installed at the front
of the engine block. The inlet for the pump is con-
nected to the bottom of the radiator by a hose. From
the pump, coolant passes through the passages in the
engine block to the top of the radiator. The thermostat
controls the flow of coolant through the engine and ra-
diator.
FAN AND FAN SHROUD
The fan is used to provide airflow through the radiator
at all engine speeds. The fan is a pusher-type or puller-
type and can be installed on the water pump or on a
separate hub. The fan is driven by a drive belt from the
engine crankshaft.
The fan shroud ensures the airflow from the fan goes
through the core of the radiator.
Cooling System Checks
RADIATOR
WARNING
During engine operation, be careful not to touch the
fan, pulleys, or drive belts. Contact with these parts
can cause serious injury.
NOTE: The Repair procedures for the radiator are in the
Frame section of the Service Manual.
To check for water flow restrictions in the radiator, run
the engine until it is warm. Shut the engine OFF and feel
the radiator. The temperature must be even across the
radiator. (The radiator will be hotter near the top radiator
hose.) Cold spots on the radiator indicate restrictions.
If the radiator has leaks, have it repaired by trained per-
sonnel.
THERMOSTAT
WARNING
CAUTION
DO NOT operate the engine without a thermostat.
The engine and cooling system can be damaged.
NOTE: Repair procedures for the thermostat are in the
Engine section of the Service Manual.
1. Remove thermostat from cooling system. See Fig-
ure 3.
2. Mix solution of water with 33% antifreeze. Heat so-
lution to 14 C (57 F) above temperature on thermo-
stat.
3. Hold thermostat with wire and put it in solution.
Stir solution. If operating correctly, thermostat will
open.
4. Remove thermostat and put in same solution at
12 C (10 F) below temperature on thermostat.
Valve must close completely.
1. FAN
2. SPACER
3. HUB/PULLEY
4. WATER PUMP
5. THERMOSTAT
6. THERMOSTAT
HOUSING
Figure 3. Cooling System Components Typical
Arrangement
3

Radiator Cleaning 700 YRM 626
WATER PUMP
WARNING
NOTE: Repair procedures for the water pump are in the
Engine section of the Service Manual.
Run the engine until it is warm. Check the operation of
the water pump by holding the top radiator hose. If the
pump is operating, there will be pressure surges in the
hose. See Figure 3.
EXHAUST LEAKS
WARNING
To check for exhaust leaks into the cooling system, use
a kit for this purpose. Follow the manufacturer’s instruc-
tions when doing the test.
FAN AND FAN SHROUD
WARNING
WARNING
DO NOT try to repair a damaged fan. If a fan has a
bent blade or is cracked, install a new fan. A dam-
aged fan can break during use and cause damage
or serious injury.
NOTE: Repair procedures for the fan and shroud are in
the Frame section of the Service Manual.
1. When installing fan, make sure correct spacers are
installed and mounting capscrews are tight. See
Figure 1 and Figure 3.
2. When installing fan shroud, make sure correct seals
are on shroud. Before tightening capscrews, make
sure clearance around circumference of fan is even
with shroud. Also make sure 1/3 to 1/2 of cross-
section of fan blade extends into fan shroud.
3. Make sure WARNING labels are installed on
shroud.
Radiator Cleaning
DRAIN
WARNING
DO NOT remove the radiator cap from the radiator
when the engine is hot. When the radiator cap is
removed, the pressure is released from the system.
If the system is hot, the steam and boiling coolant
can cause burns.
CAUTION
Disposal of lubricants and fluids must meet local
environmental regulations.
1. Let coolant cool to room temperature. Put drain pan
under radiator. Remove radiator cap. See Figure 1.
2. Open drain valve or remove bottom radiator hose.
Remove drain plug from engine block to drain en-
gine.
CLEAN
CAUTION
Disposal of lubricants and fluids must meet local
environmental regulations.
1. Drain cooling system. Fill cooling system with clean
water.
2. Install radiator cap. Run engine until top radiator
hose is hot. Stop engine and let engine cool.
3. Drain water from radiator. If water is dirty, fill sys-
tem with water and repeat procedure until water is
clean.
CAUTION
Follow the manufacturer’s instructions when using
a chemical radiator cleaner.
4. If water does not clean system, use chemical radi-
ator cleaner.
4

700 YRM 626 Radiator Cleaning
CAUTION
Follow the manufacturer’s instructions when using
special equipment to reverse clean the radiator.
NOTE: On lift truck models GC070-120LJ/MJ (C818),
the cooling system may be equipped with an optional
radiator screen.
5. If radiator or cooling system is very dirty or has
restriction, use reverse cleaning method. This
method uses air pressure to force water through
radiator in opposite direction of normal flow.
WARNING
Compressed air can move particles so they cause
injury to the user or to other personnel. Make sure
the path of the compressed air is away from all per-
sonnel. Wear protective goggles or a face shield to
prevent injury to the eyes.
6. Check radiator fins. Clean exterior of radiator with
compressed air or water as needed.
FILL
1. Install drain plug in engine block. Close drain valve
or install bottom radiator hose as needed.
WARNING
Do not use an alcohol or methanol-base antifreeze.
They are flammable and can cause personal injury
or damage to the lift truck.
NOTE: Units with a Mazda engine must use a boron-
free type of antifreeze.
2. Fill cooling system with mixture of 50% water and
50% ethylene glycol antifreeze. Install radiator cap.
The 50/50 mixture will protect the cooling system to
37 C ( 35 F).
3. Use same coolant mixture to fill auxiliary coolant
reservoir to FULL mark. See Figure 4.
4. Start and run engine until thermostat opens. (Top
radiator hose will be warm.)
5. Check coolant level at auxiliary coolant reservoir.
Add coolant as necessary to keep level between
FULL and ADD marks.
1. ADD MARK
2. FULL MARK
3. AUXILIARY COOLANT RESERVOIR
4. FILL CAP
5. RADIATOR CAP
Figure 4. Auxiliary Coolant Reservoir
5

Troubleshooting 700 YRM 626
Troubleshooting
PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION
Coolant leaks. There is a leak in the radiator. Repair radiator.
There is a leak in a radiator hose or
coolant hose.
Install new hoses.
There is a leak from a plug or sensor
in the engine block.
Check sensors and plugs, and repair
leaks.
Water pump leaks. Install new water pump.
Thermostat housing leaks. Install new thermostat housing. Check
for correct installation of thermostat.
Cylinder head gasket is damaged. Install new head gasket.
Cylinder head is cracked. Install new cylinder head.
Engine block is cracked. Install new cylinder block.
The engine is too hot during
operation.
There is not enough coolant in the
cooling system.
Check coolant level in radiator and
coolant recovery bottle. Add coolant to
correct level.
The radiator is dirty. Drain and clean radiator. Clean radia-
tor fins with low pressure air or water
in reverse direction of normal airflow.
Be careful not to bend fins. Refill with
clean coolant.
The drive belt for water pump is not ad-
justed correctly, worn, or broken.
Check water pump drive belt. Adjust or
install new belt as required.
The thermostat is wrong heat range or
does not operate correctly.
Check heat range. Install new thermo-
stat.
The cooling system has restrictions. Drain and back-flush engine and radia-
tor. Refill with clean coolant.
The water pump is worn or damaged. Install new water pump.
The exhaust system has restrictions. Check exhaust system. Remove re-
strictions.
Ignition timing is not correct. Check and adjust timing.
Exhaust leaks into coolant. Head gasket(s) leaks. Install new gasket(s).
Cylinder head is damaged. Install new cylinder head.
6

1600 YRM 532 Description
General
This section has the description and repair procedures for the steering axle. For additional information on the parts of
the steering system, see the sections Steering Housing and Control Unit 1600 YRM 720 and Hydraulic System
and Gear Pump Assembly 1900 YRM 539.
Description
The steering axle assembly includes an axle frame,
steering cylinder, and two spindle and hub assem-
blies. See Figure 1. The steering axle is connected
to the frame with center pivot mounts. The center
pivot mounts on the axle frame are fastened to the lift
truck frame with rubber mounts. The steering axle can
make an articulated motion, which gives the lift truck
smoother travel over rough surfaces.
There are two plates welded to the steering cylinder
that allow the cylinder to be mounted to the axle frame.
The oil is kept inside the cylinder by O-rings, seals, and
wipers in the end caps. The piston rod extends from
both ends of the cylinder. A single piston and seal are
at the center of the rod. Oil pressure on one side of the
piston moves the piston in the bore, pushing an equal
amount of oil from the opposite end of the cylinder. This
oil returns to the steering control unit. When the piston
reaches the end of the stroke, a relief valve controls the
oil pressure so the components are not damaged.
NOTE: GP/GLP/GDP16-20AF/BF (GP/GLP/GDP030-040AF/BF) AND GLP/GDP16-20AF (GP/GLP/GDP030-
040AF) ARE SHOWN HERE. GC/GLC030-040AF IS SIMILAR.
1. SPINDLE AND HUB ASSEMBLY
2. AXLE FRAME
3. BRACKET
4. RUBBER MOUNT
5. STEERING CYLINDER
6. CYLINDER MOUNTING CAPSCREW
7. AXLE MOUNTING CAPSCREW
8. PIN
9. LINK
Figure 1. Steering Axle
1

Wheels and Hubs Repair 1600 YRM 532
Links connect the spindle arms to the cylinder. Each
spindle turns on two tapered roller bearings. The spin-
dle and bearings are held in the axle frame by a king-
pin. A roll pin and lock nut assembly hold each kingpin
in the axle frame. The wheel or hub rotates on two ta-
pered-roller bearings and is held on the spindle by a
castle nut. The castle nut adjusts the preload on the
bearings. Grease seals in the inner hub and a hub cap
protect the bearings from dirt and water.
Steering Axle Assembly Repair
REMOVE
WARNING
The steering axle assembly without the wheels
weighs approximately 115 kg (253.5 lb). To avoid
possible injury, use a lifting device if the steering
axle assembly must be lifted.
NOTE: The steering axle can be removed without re-
moving the counterweight.
1. Make sure the wheels are set for straight travel. Put
the lift truck on blocks so the steering axle can be
removed. See How to Put Lift Truck on Blocks in the
Periodic Maintenance section for your lift truck.
The top of the axle frame must have clearance un-
der the counterweight so the steering axle can be
removed. See Figure 1.
2. Disconnect hydraulic lines at steering cylinder. In-
stall caps on cylinder and put plugs in hydraulic
lines. The caps will prevent the spindles from turn-
ing when the axle is removed from under the lift
truck.
3. Slide a floor jack or the forks of another lift truck
under the steering axle. Raise lifting device until it
holds the weight of axle assembly. Remove four
capscrews that fasten two brackets under rubber
mounts. Remove brackets and slowly lower axle
assembly onto wheels. Carefully roll axle assembly
from under lift truck.
INSTALL
NOTE: The mounts of the steering axle have TOP
moulded into the rubber. Verify TOP is up when in-
stalling the mounts.
1. Install rubber mounts onto axle. See Figure 1.
2. Install bottom brackets. Tighten four bracket cap-
screws and nuts to 41 to 49 N•m (30 to 36 lbf ft).
3. Remove plugs and caps and connect hydraulic
lines to steering cylinder.
4. Operate steering system to remove air from sys-
tem. Turn steering wheel several times from one
stop to other stop. Check for hydraulic leaks.
Wheels and Hubs Repair
PNEUMATIC TIRES, REMOVE AND
DISASSEMBLE
WARNING
Completely remove the air from the tires before re-
moving them from the lift truck. Air pressure in the
tires can cause the tire and rim parts to explode
which can cause serious injury or death.
Never loosen the nuts that hold together the inner
and outer wheel halves when there is air pressure
in the tire.
1. Put axle onto blocks so tires are raised from floor.
Completely remove air from tires.
2. Remove wheels, grease cap, cotter pin, castle nut,
and outer bearing cone. Slide hub from spindle.
Remove inner bearing cone and seal from spindle.
See Figure 2.
3. If new wheel bearings must be installed, use a
brass drift to remove bearing cups.
4. Repeat the procedure for the other wheel.
2

1600 YRM 532 Wheels and Hubs Repair
1. AXLE FRAME
2. KNUCKLE
3. KINGPIN
4. UPPER SLEEVE
5. LOWER SLEEVE
6. BEARING
7. O-RING
8. GROOVE PIN
9. OIL SEAL
10. COTTER PIN
11. CASTLE NUT
12. GREASE FITTING
13. LINK
14. PIN
15. BUSHING
16. SCREW
17. LOCK NUT
18. GREASE FITTING
19. STEERING CYLINDER
20. SPACER
21. BOLT
22. WASHER
23. HUB (PNEUMATIC TIRES)
24. BOLT (PNEUMATIC TIRES)
25. WHEEL NUT (PNEUMATIC
TIRES)
26. HUB CAP
27. WASHER
28. BEARING
29. BEARING
30. OIL SEAL
31. FITTING
32. FITTING
33. LOCK NUT
34. RUBBER CUSHION
35. CUSHION COVER
36. WASHER
37. LOCKWASHER
38. BOLT
39. TIRE/WHEEL (CUSHION)
Figure 2. Steering Axle
3

Wheels and Hubs Repair 1600 YRM 532
CUSHION TIRES, REMOVE AND
DISASSEMBLE
WARNING
The steer wheel and tire assembly weighs approx-
imately 41 kg (90 lb). To avoid possible injury, use
a lifting device if the steer wheel and tire assembly
must be lifted.
NOTE: The steer axle does not have to be removed
from the truck to remove the wheel/hub assembly.
1. Apply a coat of axle grease to bottom surface of tire.
Put axle onto blocks so side of tire with the grease
just touches the floor.
2. Remove grease cap, cotter pin, castle nut, and
outer bearing cone. Slide wheel/hub assembly
from spindle. Remove inner bearing cone and seal
from spindle. See Figure 2.
3. If new wheel bearings must be installed, use a
brass drift to remove bearing cups.
PNEUMATIC TIRES, ASSEMBLE AND
INSTALL
WARNING
Cleaning solvents can be flammable and toxic and
can cause skin irritation. When using cleaning
solvents, always follow the solvent manufacturer’s
safety procedures.
1. Clean all parts with solvent. Make sure the bear-
ings are clean.
CAUTION
Do not damage the seals during installation.
2. If new wheel bearings are installed, use a press
to install new bearing cups in wheel or hub. See
Figure 2. Install grease seal on spindle. Lubricate
bearing cones and seal lips with grease. Make sure
bearings are filled with grease. Install bearing cone
onto spindle.
3. Carefully slide hub onto spindle. Install outer bear-
ing cone.
4. Install castle nut. Tighten castle nut to 200 N•m
(150 lbf ft) while hub is rotated.
5. Loosen castle nut to less than 27 N•m (20 lbf ft).
Tighten castle nut to at least 34 N•m (25 lbf ft).
6. Install cotter pin. If the hole for the cotter pin is
blocked, tighten castle nut until the cotter pin can
be installed.
WARNING
Add air pressure to the tires only in a safety cage.
Inspect the safety cage for damage before use.
When air pressure is added, use a chuck that fas-
tens onto the valve stem of the inner tube. Make
sure there is enough hose to permit the operator to
stand away from the safety cage when air pressure
is added to the tire. Do not sit or stand by the
safety cage.
7. Inflate the tire to 698 kPa (101 psi). Mount wheel
and torque wheel nuts to 114 to 136 N•m (84 to
100 lbf ft).
CUSHION TIRES, ASSEMBLE AND
INSTALL
WARNING
safety procedures.
1. Clean all parts with solvent. Make sure the bear-
ings are clean.
WARNING
The steer wheel and tire assembly weighs approx-
imately 41 kg (90 lb). To avoid possible injury, use
a lifting device if the steer wheel and tire assembly
must be lifted.
CAUTION
Do not damage the seals during installation.
2. If new wheel bearings are installed, use a press
to install new bearing cups in hub. See Figure 2.
Install grease seal on spindle. Lubricate bearing
cones and seal lips with grease. Make sure bear-
ings are filled with grease. Install bearing cone onto
spindle.
4

1600 YRM 532 Spindles, Bearings, and Tie Rods Repair
3. Apply a coat of axle grease to bottom surface of tire.
Carefully slide wheel/hub assembly onto spindle.
Install outer bearing cone.
4. Install castle nut. Tighten castle nut to 200 N•m
(150 lbf ft) while tire and wheel assembly is rotated.
5. Loosen castle nut to less than 27 N•m (20 lbf ft).
Tighten castle nut to at least 34 N•m (25 lbf ft).
6. Install cotter pin. If the hole for the cotter pin is
blocked, tighten castle nut until cotter pin can be
installed.
Spindles, Bearings, and Tie Rods Repair
PNEUMATIC TIRES, REMOVE
WARNING
Completely remove the air from the tires before re-
moving them from the lift truck. Air pressure in the
tires can cause the tire and rim parts to explode,
which can cause serious injury or death.
Never loosen the nuts that hold together the inner
and outer wheel halves when there is air pressure
in the tire.
1. Put the lift truck onto blocks so the tires are raised
from the floor. See How to Put Lift Truck on Blocks
in the Periodic Maintenance section for your lift
truck. Completely remove air from tires.
2. Remove wheels. See the section Wheels and Hubs
Repair for the procedure.
3. Remove hub from steering axle spindle.
4. Remove pin to disconnect link from spindle.
5. Remove kingpin lock nuts. Use a driver to remove
kingpin.
6. Use a driver to remove bearings and seals from
axle.
CUSHION TIRES, REMOVE
1. Put the lift truck onto blocks so the tires are raised
from the floor. See How to Put Lift Truck on Blocks
in the Periodic Maintenance section for your lift
truck.
2. Remove steer wheel and tire assembly from steer-
ing axle spindle. See the section Wheels and Hubs
Repair for the procedure.
3. Remove pin to disconnect link from spindle.
4. Remove kingpin lock nuts. Use a driver to remove
kingpin.
5. Use a driver to remove bearings and seals from
axle.
PNEUMATIC TIRES, INSTALL
1. If new spindle bearings are installed, use a press to
install new bearing cups into spindle. See Figure 2.
Lubricate bearing cones and seal lips with grease.
Lubricate O-rings with O-ring lubricant.
2. Install bearings, seals, sleeves, and O-rings into
spindle. If groove pin was removed from kingpin,
install new groove pin. Apply grease to kingpin.
Position spindle in axle and install king pin.
3. Install first lock nut onto kingpin and tighten lock nut
to 121 N•m (89 lbf ft). Completely loosen lock nut,
then tighten lock nut to 30 N•m (22 lbf ft).
4. Install second lock nut onto kingpin. While holding
first lock nut so it does not turn, tighten second lock
nut to 81.5 to 98 N•m (60 to 72 lbf ft).
5. Connect links. Align setscrews with setscrew holes
in pins. Tighten setscrews and lock nuts.
WARNING
Add air pressure to the tires only in a safety cage.
Inspect the safety cage for damage before use.
When air pressure is added, use a chuck that fas-
tens onto the valve stem of the inner tube. Make
sure there is enough hose to permit the operator to
stand away from the safety cage when air pressure
is added to the tire. Do not sit or stand by the
safety cage.
6. Inflate tires to 689 kPa (100 psi). Mount wheels
and tighten wheel nuts to 114 to 136 N•m (84 to
100 lbf ft).
5

Steering Cylinder Repair 1600 YRM 532
CUSHION TIRES, INSTALL
1. If new spindle bearings are installed, use a press to
install new bearing cups into spindle. See Figure 2.
Lubricate bearing cones and seal lips with grease.
Lubricate O-rings with O-ring lubricant.
2. Install bearings, seals, sleeves, and O-rings into
spindle. If the groove pin was removed from the
kingpin, install new groove pin. Apply grease to
kingpin. Position spindle in axle and install kingpin.
3. Install first lock nut onto kingpin and tighten lock nut
to 121 N•m (89 lbf ft). Completely loosen lock nut,
then tighten lock nut to 30 N•m (22 lbf ft).
4. Install second lock nut onto kingpin. While holding
first lock nut so that it does not turn, tighten second
lock nut to 81.5 to 98 N•m (60 to 72 lbf ft).
5. Connect links. Align setscrews with setscrew holes
in pins. Tighten setscrews and lock nuts.
6. Install steer wheel and tire assembly. See the sec-
tion Wheels and Hubs Repair for the procedure.
Steering Cylinder Repair
REMOVE AND DISASSEMBLE
1. Disconnect hydraulic lines at steering cylinder. See
Figure 3. Mark the locations of the hydraulic lines
to make sure of correct assembly. Install caps in
fittings on cylinders and put caps on hydraulic lines.
2. Remove setscrews from links. Remove pins.
3. Remove capscrews that fasten cylinder to axle
frame. Remove steering cylinder.
4. Hold end of steering cylinder over a drain pan. Re-
move cap for hydraulic fitting from each end cap.
Push rod toward end of shell that is over drain pan.
Oil will drain from cylinder. Repeat the procedure
for the other end.
5. Carefully remove one guide assembly from shell.
Carefully pull cylinder rod and piston from shell.
Keep cylinder rod aligned in center of shell during
removal so the parts are not damaged. Remove
guide assembly from rod. Remove other guide as-
sembly from shell. Remove all seals, wipers, and
O-rings.
CLEAN AND INSPECT
WARNING
safety procedures.
1. Clean all parts in solvent.
2. Inspect piston rod for grooves or damage. Remove
small scratches with fine emery cloth. Inspect cylin-
der bore for damage. Inspect mounts for cracks.
ASSEMBLE AND INSTALL
1. Put dust seals, U-packings, O-rings, and piston
seals into warm hydraulic oil.
CAUTION
Do not damage the O-rings, seals, U-packings, or
wipers during installation.
2. Lubricate dust seals and U-packings with O-ring lu-
bricant and install them into guide assemblies. Lu-
bricate piston seals and install them onto piston.
Install one guide assembly onto cylinder rod. See
Figure 3.
3. Carefully slide cylinder rod and piston into shell.
Keep cylinder rod aligned in center of shell during
installation so the parts are not damaged. Care-
fully slide guide assembly into shell. Carefully in-
stall other guide assembly onto rod and shell. Put
caps on hydraulic fittings of end caps.
4. Install cylinder onto axle frame using capscrews.
Install spacers between cylinder mounts and axle
frame. Tighten capscrews to 294 to 353 N•m (217
to 260 lbf ft).
5. Install links between cylinder and spindles. Install
pins. Align setscrews with setscrew holes in pins.
Tighten setscrews and lock nuts.
6. Remove caps and connect hydraulic lines to steer-
ing cylinder. Operate steering system to remove air
from cylinder and hydraulic system. Turn steering
wheel several times from one stop to the other.
6

1600 YRM 532 Torque Specifications
1. ROD ASSEMBLY
2. GUIDE ASSEMBLY
3. DUST SEAL
4. U-PACKING
5. O-RING
6. O-RING
7. PISTON SEAL
8. SNAP RING
9. ROD BUSHING
10. PIN BUSHING
Figure 3. Steering Cylinder
Torque Specifications
Steering Axle Mounting Bolts
41 to 49 N•m (30 to 36 lbf ft)
Castle Nut (Initial)
200 N•m (148 lbf ft)
Castle Nut (Final)
34 N•m (25 lbf ft)
Spindle Nut (Initial)
121 N•m (89 lbf ft)
Spindle Nut (Final)
30 N•m (22 lbf ft)
Spindle Lock Nut (Initial)
81 to 98 N•m (60 to 72 lbf ft)
Steering Cylinder Mounting Bolts
294 to 353 N•m (217 to 260 lbf ft)
7

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