service repair manual

1. SERVICE REPAIR
S3.50-5.50XM (Europe) [F004]
PART NO. 1510478 8000 SRM 988

2. 8000 SRM 988 Electrical System
Tire Sizes
Model Steering Drive
S3.50 (S70XM) 18 × 6 × 12.1 22 × 9 × 16
S4.00 (S80XM) 18 × 7 × 12.1 22 × 9 × 16
S4.50-5.50XM (S100-120XM) 18 × 8 × 12.1 22 × 12 × 16
Hydraulic System
Item Specification
Hydraulic System Capacity 39.3 liter (10.4 gal)
Hydraulic Tank Capacity
(Total Tank Capacity)
35.5 liter (9.4 gal)
Relief Pressures*
Main Control Valve
Lift Circuit 22.0 MPa (3200 psi)
Tilt and Auxiliary Circuit 15.5 MPa (2250 psi)
Steering Circuit 10.7 MPa (1550 psi)
Hydraulic Pump**
Capacity 89 liter/min (23.5 gal/min)
Priority Flow None
*Oil temperature 50 to 100 C (120 to 210 F) and engine speed at 2500 rpm.
**Oil temperature 80 to 100 C (176 to 210 F) and engine speed at 2550 rpm.
Electrical System
Alternator Output
38 Amps @ 650 rpm (Hot)
GM V-6
62 Amps @ 2200 rpm (Hot)
42 Amps @ 650 rpm (Hot)
Perkins
62 Amps @ 2500 rpm (Hot)
All Models - 12 Volt, Negative Ground
1

3. Capacities 8000 SRM 988
Engine Specifications
Item GM V-6 4.3 Perkins 1004-4
Number of Cylinders 6 4
Firing Order 1-6-5-4-3-2 1-3-4-2
Bore 102.00 mm (4.00 in.) 103.00 mm (4.055 in.)
Stroke 88.40 mm (3.50 in.) 127.00 mm (5.00 in.)
Displacement 4.3 liter (262.4 in.3
) 4.0 liter (244.0 in.3
)
Compression Ratio 9.3:1 18.5:1
Idle Speed 675 to 725 rpm 725 to 775 rpm
Governor Speed 2400 to 2500 rpm 2450 to 2550 rpm
Stall Speed
Broken in Engine 1810 (Gas) 1735 (LPG)
+300/-50 rpm
2050 rpm ±50 rpm
New Engine 1710 (Gas) 1635 (LPG)
+300/-50 rpm
1950 rpm ±50 rpm
Timing 0 BTDC at 650 rpm 2 BTDC (Static)
Oil Pressure (Minimum) 207 to 380 kPa (30 to 55 psi) 280 kPa (41 psi)
Valve Clearance
Intake Not adjustable 0.20 mm (0.008 in.) Cold
Exhaust Not adjustable 0.45 mm (0.018 in.) Cold
Capacities
Item Quantity
Engine Oil
GM V-6 4.7 liter (5.0 qt)
Perkins 1004-4 8.0 liter (8.5 qt)
Cooling System 18.9 liter (20.0 qt)
Hydraulic Tank (Total Tank Capacity) 35.5 liter (9.4 gal)
Transmission 15.1 liter (16.0 qt)
Differential 5.7 liter (6.0 qt)
Fuel Tank 34.0 liter (9.1 gal)
Brake Fluid 0.2 liter (0.5 pt)
2

4. 8000 SRM 988 Lift Truck Weights
Lift Truck Weights
Unit kg lb
S3.50XM (S70XM) 5,515 11,937
S4.00XM (S80XM) 5,780 12,742
S4.00XM BCS (S80XM BCS) 5,995 13,217
S4.50XM (S100XM) 6,768 14,920
S4.50XM BCS (S100XM BCS) 7,245 15,973
S5.50XM (S120XM) 7,433 16,387
S5.50XMS (S120XMS) 7,527 16,589
S5.50XMSPRS (S120XMSPRS) 7,820 17,241
NOTE: Lift trucks equipped with overhead guard, mast, carriage, load backrest, forks, and LPG engine.
NOTE: S3.50-4.00XM (S70-80XM) and S4.00XM BCS (S80XM BCS) have 3099 mm (122 in.) two-stage LFL
mast.
S4.50-5.50XM (S100-120XM), S4.50XM BCS (S100XM BCS), S5.50XMS (S120XMS), and S5.50XMSPRS
(S120XMSPRS) have 2845 mm (112 in.) two-stage LFL mast.
3

5. Transmission Pressures (Single-Speed Powershift) 8000 SRM 988
Transmission Pressures (Single-Speed Powershift)
Port
No.
Transmission Pressures*
1 System
Pressure
1170 to 1380** kPa
(170 to 200 psi)
**Relief pressure
1379 kPa (200 psi)
2 Forward
Clutch
895 to 1035 kPa
(130 to 150 psi)
3 Reverse
Clutch
895 to 1035 kPa
(130 to 150 psi)
4 Torque
Converter
655 to 760 kPa
(95 to 110 psi)
5 Lubrication
Pressure
35 to 105 kPa
(5 to 15 psi)
6 Modulator
Pressure
Pressure Variation
*Oil temperature at least 50 to 65 C (120 to 150 F) and engine speed at 2000 rpm.
NOTE: The difference between Forward and Reverse clutch pressure must not be more than:
• Manufacturing limit 48 kPa (7 psi)
• Service limit 70 kPa (10 psi)
4

6. 8000 SRM 988 Mast Speeds
Mast Speeds
Two-Stage Full Free-Lift Mast
Lifting Lowering
No Load Rated Load No Load Rated Load
Unit
m/sec ft/min m/sec ft/min m/sec ft/min m/sec ft/min
S3.50-4.00XM
(S70-80XM)
0.60 118 0.56 111 0.36 70 0.50 99
S4.50XM
(S100XM)
0.51 101 0.48 94 0.32 63 0.45 89
S5.50XM
(S120XM)
0.51 101 0.44 87 0.32 63 0.47 92
Two-Stage Limited Free-Lift Mast
Lifting Lowering
No Load Rated Load No Load Rated Load
Unit
m/sec ft/min m/sec ft/min m/sec ft/min m/sec ft/min
S3.50-4.00XM
(S70-80XM)
0.68 134 0.62 123 0.47 93 0.55 108
S4.50-5.50XM
(S100-120XM)
0.55 108 0.53 105 0.42 82 0.51 100
Three-Stage Full Free-Lift
Lifting Lowering
No Load Rated Load No Load Rated Load
Unit
m/sec ft/min m/sec ft/min m/sec ft/min m/sec ft/min
S3.50-4.00XM
(S70-80XM)
0.63 124 0.58 114 0.44 87 0.53 105
S4.50XM
(S100XM)
0.52 102 0.51 100 0.39 76 0.47 92
S5.50XM
(S120XM)
0.52 102 0.45 89 0.39 76 0.47 92
5

7. Torque Specifications 8000 SRM 988
Torque Specifications
FRAME
Counterweight Capscrew
1022 N•m (755 lbf ft)
ENGINE - GM V-6
Intake Manifold Capscrews
47 N•m (35 lbf ft)
Valve Cover Capscrews
10 N•m (7 lbf ft)
Exhaust Manifold Capscrews
35 N•m (25 lbf ft)
Center Port 25 N•m (20 lbf ft)
Outer Ports 50 N•m (35 lbf ft)
Camshaft Sprocket Capscrews
25 N•m (20 lbf ft)
Vibration Damper Capscrew
81 N•m (60 lbf ft)
Main Bearing Cap Capscrews
70 N•m (50 lbf ft)
Connecting Rods
45 N•m (35 lbf ft)
Flywheel Capscrews
80 N•m (60 lbf ft)
Flywheel Housing Capscrews
50 N•m (40 lbf ft)
Engine Mount to Engine Capscrews
30 N•m (25 lbf ft)
Engine Mount to Mount Plate Bolts
65 N•m (50 lbf ft)
Engine Mount to Flywheel Housing Capscrews
165 N•m (120 lbf ft)
Engine Mount Bolts
120 N•m (90 lbf ft)
ENGINE - PERKINS
Engine Mount to Engine Capscrews
65 N•m (50 lbf ft)
Engine Mount Bolts
120 N•m (90 lbf ft)
TRANSMISSION
Transmission Cover Capscrews
40 N•m (30 lbf ft)
Oil Pump Capscrews
40 N•m (30 lbf ft)
Torque Converter Housing Capscrews
40 N•m (30 lbf ft)
Control Valve Capscrews
20 N•m (15 lbf ft)
Differential Case Capscrews
140 N•m (105 lbf ft)
Ring Gear Capscrews
140 N•m (105 lbf ft)
Output Gear Nut
750 N•m (550 lbf ft)
Torque Converter Drive Plate Capscrews
45 N•m (35 lbf ft)
Differential Bearing Caps
225 N•m (166 lbf ft)
DRIVE AXLE
Brake Assembly to Axle Nuts
340 to 375 N•m (251 to 277 lbf ft)
Axle Mount to Frame
320 to 350 N•m (235 to 258 lbf ft)
Axle Shaft Flange Capscrews
225 to 250 N•m (166 to 184 lbf ft)
Axle Housing to Transmission Capscrews
65 N•m (48 lbf ft)
Hub Adjustment Nut
205 N•m (151 lbf ft) Initial
35 N•m (26 lbf ft) Final
Wheel Nuts
610 to 680 N•m (450 to 502 lbf ft)
STEERING SYSTEM
Axle Mount Capscrews
90 N•m (66 lbf ft)
6

8. 8000 SRM 988 Torque Specifications
Bearing Cap for Spindle
45 N•m (35 lbf ft)
Tie Rod Castle Nut
175 N•m (129 lbf ft)
Steering Cylinder Capscrews
225 N•m (166 lbf ft)
Wheel Bearing Adjustment Nut
200 N•m (148 lbf ft) Initial
35 N•m (26 lbf ft) Final
BRAKE SYSTEM
Back Plate Capscrews
340 N•m (251 lbf ft)
HYDRAULIC SYSTEM
Capscrews for Special Blocks for
Pump Drive Chain
20 N•m (15 lbf ft)
MAIN CONTROL VALVE
Through Bolt Nuts (5/16 in.)
20 N•m (15 lbf ft)
Through Bolts Nuts (3/8 in.)
45 N•m (35 lbf ft)
TILT CYLINDERS
Piston Nut
400 to 440 N•m (295 to 325 lbf ft)
Retainer
400 to 500 N•m (295 to 370 lbf ft)
Rod End Lock Capscrews
90 N•m (66 lbf ft)
Anchor Pin Retainer Capscrews
77 N•m (57 lbf ft)
LIFT CYLINDERS
Main Lift Cylinder Retainer Cap
340 to 410 N•m (251 to 302 lbf ft)
Free-Lift Cylinder Retainer Cap
400 to 475 N•m (295 to 350 lbf ft)
Free-Lift Cylinder Mount Capscrews
121 N•m (89 lbf ft)
MAST
Pivot Pin Capscrews
320 N•m (236 lbf ft)
Sideshift Carriage
Lower Hook Capscrews 78 N•m (58 lbf ft)
Side Roller Mount Capscrews 90 N•m (66 lbf ft)
7

9. 1600 SRM 326 Description
General
This section has the description and repair procedures for the steering axle. For information on the steering
control unit, see the section Steering Control Unit.
Description
The steering axle assembly includes an axle frame,
steering cylinder, tie rods, and two spindle and hub
assemblies. The steering axle is articulated and is
connected to the frame with center pivot mounts.
The center pivot mounts permit the steering axle
to move in the frame mount when the lift truck
travels over rough surfaces. See Figure 1, Figure 2,
Figure 3, and Figure 4.
1. STEERING AXLE
2. COVER
3. CLAMP
4. COTTER PIN
5. SNAP RING
6. TIE ROD AND BUSHING
7. CASTLE NUT
8. CAPSCREW
9. CAP
10. BEARING CONE
11. BEARING CUP
12. SEAL
13. WEAR SLEEVE
14. SPINDLE (RH)
15. SPINDLE (LH)
16. O-RING
17. SHIM
18. BEARING CAP
19. LUBE FITTING
20. SCREW
21. SEALANT
22. STEER CYLINDER
23. OIL SEAL
24. CAP (HUB)
25. WASHER
26. MOUNT
27. PLATE
28. LOCKWASHER
29. WHEEL
30. GREASE FITTING
31. PIN
Figure 1. Steering Axle E3.50-5.50XL (E70-120XL, E70-120XL3) (C098), S3.50-5.50XL (S70-120XL)
(D004), S3.50-5.50XM (S70-120XM) (E004, F004) and E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS)
(D098/E098)
1

10. Description 1600 SRM 326
Figure 2. Steering Axle H8.00-16.00XL (H165-360XL) (D019, E007), H8.00-12.00XM (H170-280HD)
(F007, G007, H007), H13.00-14.00XM (H300-330HD) (E019, F019, G019), H16.00XM-6 (H360HD) (E019,
F019, G019), H10.00-12.00XM-12EC (H360HD-EC) (E019, F019, G019)
2

11. 1600 SRM 326 Description
Legend for Figure 2
1. HUB ASSEMBLY
2. STUD
3. BEARING CUP
4. WEAR SLEEVE
5. HUB CAP
6. COTTER PIN
7. NUT
8. WASHER
9. LOCKWASHER
10. CAPSCREW
11. BEARING CONE
12. BEARING CAP
13. SHIM
14. OIL SEAL
15. LUBE FITTING
16. PIN
17. PLUG
18. SPINDLE
19. FRAME
20. SHAFT
21. TIE ROD
22. BUSHING
23. ANCHOR
24. STEERING CYLINDER
25. FITTING
26. O-RING
27. FLANGE
28. LUG NUT
29. HANGER CUP
1. STEERING AXLE
2. STEER CYLINDER
3. SPINDLE (LH)
4. SEAL
5. BEARING CONE
6. SPINDLE (RH)
7. HUB
8. BEARING CUP
9. STUD (WHEEL)
10. WEAR SLEEVE
11. TIE ROD
12. CAPSCREW
13. NUT (SPINDLE)
14. CAP (HUB)
15. SHIM
16. CAP ASSEMBLY
17. PIN
18. SNAP RING
19. O-RING
20. GREASE FITTING
21. COTTER PIN
22. MOUNT
23. PLATE
24. WASHER
25. NUT
26. LUG NUT
27. PIN
28. PLUG AND SEALANT
29. CLAMP
30. OIL SEAL
31. BEARING CAP
32. CAPSCREW
33. COVER
Figure 3. Steering Axle H3.50-5.00XL (H70-110XL) (G005)
3

12. Description 1600 SRM 326
Figure 4. Steering Axle H6.00-7.00XL (H135-155XL, H135-155XL2) (F006, G006)
4

13. 1600 SRM 326 Description
Legend for Figure 4
1. STEERING AXLE
2. SHAFT
3. SEAL
4. PIN
5. SNAP RING
6. TIE ROD
7. CAPSCREW
8. LOCKWASHER
9. PLUG
10. BEARING CONE
11. BEARING CUP
12. WEAR SLEEVE
13. SPINDLE
14. O-RING
15. SHIM
16. SCREW
17. OIL SEAL
18. HUB
19. STUD
20. WHEEL NUT
21. WASHER
22. COTTER PIN
23. CAP
24. GREASE FITTING
25. BUSHING
26. BEARING CAP
27. STEER CYLINDER
The center pivots for the axle are installed in rubber
mounts on the following units:
H3.50-5.50XL (H70-110XL) (D004)
S3.50-5.50XL (S70-120XL) (G005)
S3.50-5.50XM (S70-120XM) (E004, F004)
E3.50-5.50XL (E70-120XL, E70-120XL3) (C098)
E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (D098/
E098)
The center pivots for the axle are installed in the
frame of the lift truck and rotate in fiber bushings
on the following units:
H6.00-7.00XL (H135-155XL, H135-155XL2) (F006,
G006)
H8.00-16.00XL (H165-360XL) (D019, E007)
H8.00-12.00XM (H170-280HD) (F007, G007, H007),
H13.00-14.00XM (H300-330HD) (E019, F019, G019),
H16.00XM-6 (H360HD) (E019, F019, G019), H10.00-
12.00XM-12EC (H360HD-EC) (E019, F019, G019)
The end caps of the steering cylinder are also the
mounts for the cylinder and are held to the axle by
capscrews. The ends of the piston rod extend from
both ends of the cylinder. A single piston and the
seal are at the center of the piston rod. Oil pressure
on one side of the piston moves the piston in the bore.
The piston pushes an equal amount of oil from the
opposite side of the cylinder. The oil returns to the
steering control unit.
When the piston in the steering cylinder reaches the
end of the stroke, a relief valve controls the oil pres-
sure. The relief valve for the steering system is in
the manifold block that is installed on the steering
control unit.
Each spindle turns on two tapered roller bearings in
the axle frame. The preload on the bearings is con-
trolled by shims at the lower bearing cap. The tie
rods that connect the spindle arms to the cylinder do
not have an adjustment.
The wheel hubs rotate on two tapered roller bear-
ings and are held on the spindles by a castle nut.
The bearing preload of the wheel hubs is adjusted by
the castle nut. The grease seals protect the bearings
from dirt and water. Wear sleeves prevent the seals
from causing wear on the hub.
5

14. Steering Axle Assembly Repair 1600 SRM 326
Steering Axle Assembly Repair
STEERING AXLE H3.50-5.00XL
(H70-110XL) (G005), S3.50-5.50XL
(S70-120XL) (D004), S3.50-5.50XM
(S70-120XM) (E004, F004), E3.50-5.50XL
(E70-120XL, E70-120XL3) (C098), AND
E3.50-5.50XL, E4.50XLS (E70-120Z,
E100ZS) (D098/E098)
Remove
WARNING
Put the lift truck on blocks. Follow the proce-
dures for raising the lift truck described in the
Operating Manual for this lift truck. The sur-
face must be solid, even, and level. Make sure
the blocks are solid, one-piece units. Make sure
the lifting devices used during repairs can lift
the weight of the parts.
The steering axle can be removed without removing
the counterweight.
1. Make sure wheels are set for straight travel. Put
blocks under frame in front of steer wheels and
under counterweight so steering axle can be re-
moved. The top of the axle frame must have
clearance under the counterweight so that the
steering axle can be removed.
2. It is not required, but it can make removal of the
axle easier if wheels are removed. See Wheels
and Hubs Repair (All Units) for wheel removal.
Disconnect hydraulic lines at steering cylinder.
Install caps on cylinder and put plugs in hy-
draulic lines. Caps will prevent spindles from
turning when axle is removed from the lift truck.
3. Slide a floor jack or forks of another lift truck
under steering axle. Raise lifting device until it
holds the weight of the axle assembly. Remove
four capscrews and nuts that fasten two brack-
ets under rubber mounts. Remove brackets and
slowly lower axle assembly. Carefully remove
axle assembly from under lift truck.
Install
1. Install rubber mounts on axle. Make sure part
number is away from axle frame and tapered
edge of rubber mount is at the top. See Figure 1
and Figure 3.
2. Apply a lubricant that is approved for use with
rubber (tire lubricant) to the rubber mounts.
Lubricant is used where rubber mount fits into
frame brackets.
3. Use a floor jack or another lift truck to put steer-
ing axle into position in the frame. Make sure
rubber mounts fit inside frame brackets for the
mounts. If necessary, lower weight of the lift
truck onto axle to make sure rubber mounts fit
completely in frame brackets.
4. Install bottom brackets for rubber mounts.
H3.50-5.00XL (H70-110XL) (G005) units.
Tighten four bolts for brackets to 88 N•m
(65 lbf ft).
S3.50-5.50XL (S70-120XL) (D004), S3.50-
5.50XM (S70-120XM) (E004, F004), E3.50-
5.50XL (E70-120XL, E70-120XL3) (C098), and
E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS)
(D098/E098) units. Tighten four bolts to
110 N•m (81 lbf ft).
5. Remove plugs and caps and connect hydraulic
lines to steering cylinder. Install wheels if they
were removed.
6. Operate steering system to remove air from sys-
tem. Turn steering wheel several times from one
wheel stop to other wheel stop. Check for hy-
draulic leaks.
6

15. 1600 SRM 326 Steering Axle Assembly Repair
STEERING AXLE H6.00-7.00XL
(H135-155XL, H135-155XL2) (F006,
G006), H8.00-16.00XL (H165-360XL) (D019,
E007), AND H8.00-12.00XM (H170-280HD)
(F007, G007, H007), H13.00-14.00XM
(H300-330HD) (E019, F019, G019),
H16.00XM-6 (H360HD) (E019, F019, G019),
H10.00-12.00XM-12EC (H360HD-EC) (E019,
F019, G019)
Remove
WARNING
Put the lift truck on blocks. Follow the proce-
dures for raising the lift truck described in the
Operating Manual for this lift truck. The sur-
face must be solid, even, and level. Make sure
the blocks are solid, one-piece units. Make sure
the lifting devices used during repairs can lift
the weight of the parts.
The steering axle can be removed without removing
the counterweight.
1. Make sure wheels are set for straight travel. Put
blocks under frame in front of steer wheels, so
steering axle can be removed. Top of axle frame
must have clearance under counterweight so
steering axle can be removed.
2. It is not required, but it can make removal of
the axle easier if the wheels are removed. Dis-
connect hydraulic lines at steering cylinder. In-
stall caps on cylinder and put plugs in hydraulic
lines. Caps will prevent spindles from turning
when axle is removed from under the lift truck.
3. Remove two dust covers from openings of bearing
caps.
4. 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 cap-
screws and washers that fasten two bearing caps
to frame. Remove bearing caps and slowly lower
axle assembly. Carefully remove axle assembly
from under lift truck.
Install
WARNING
Excessive play in the pivot bushings will result
in increased shock loadings to the pivot pins
and increased movement of the axle, and may
affect steering responsiveness. If movement in
the pivot bushings is more than 4 mm (0.16 in.),
or damage to the O-ring seals exists, replace
the bushings, flanges, and O-rings.
1. Install O-ring, spacer, and shims on each pivot
shaft. Lubricate pivot shafts with multipurpose
grease and install fiber bushing. See Figure 2
and Figure 4.
2. Use a floor jack or another lift truck to put steer-
ing axle into position in frame. Make sure fiber
bushings fit into mounts of frame.
3. Install bearing caps.
H6.00-7.00XL (H135-155XL, H135-155XL2)
(F006, G006) units. Tighten capscrews to
320 N•m (236 lbf ft).
H8.00-16.00XL (H165-360XL) (D019, E007),
and H8.00-12.00XM (H170-280HD) (F007,
G007, H007), H13.00-14.00XM (H300-330HD)
(E019, F019, G019), H16.00XM-6 (H360HD)
(E019, F019, G019), H10.00-12.00XM-12EC
(H360HD-EC) (E019, F019, G019) units.
Tighten capscrews to 380 N•m (280 lbf ft). After
installation, make sure there is zero clearance
between shims and frame. Add or remove shims
as necessary to get zero clearance.
4. Install dust covers in openings of bearing caps.
5. Remove plugs and caps, and connect hydraulic
lines to steering cylinder. Install wheels if they
were removed.
6. Operate steering system to remove air from sys-
tem. Turn steering wheel several times from one
wheel stop to other wheel stop. Check for hy-
draulic leaks.
7

16. Wheels and Hubs Repair (All Units) 1600 SRM 326
Wheels and Hubs Repair (All Units)
REMOVE AND DISASSEMBLE
WARNING
Completely remove the air from the tire before
removing the tire and wheel from lift truck.
Air pressure in the tires can cause the tire and
wheel parts to explode, causing serious injury
or death.
1. Raise axle to remove weight from tires, but have
tires still touching the floor. Loosen wheel nuts
just enough so they can be easily removed. Raise
axle so tires can be removed. Use a tire jack to
remove tires and wheels.
2. If a tire jack is not available, raise axle only
enough so tires are just touching the floor. Slide
tires from axle while they are still on the floor.
3. Remove hub cap, cotter pin and washer.
For E3.50-5.50XL (E70-120XL, E70-120XL3)
(C098), S3.50-5.50XL (S70-120XL) (D004),
S3.50-5.50XM (S70-120XM) (E004, F004) and
E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS)
(D098/E098) lift truck models, see Figure 1, for
H8.00-16.00XL (H165-360XL) (D019, E007)
and H8.00-12.00XM (H170-280HD) (F007,
G007, H007), H13.00-14.00XM (H300-330HD)
(E019, F019, G019), H16.00XM-6 (H360HD)
(E019, F019, G019), H10.00-12.00XM-12EC
(H360HD-EC) (E019, F019, G019) lift truck mod-
els, see Figure 2, for H3.50-5.00XL (H70-110XL)
(G005) lift truck models see figure Figure 3, and
for H6.00-7.00XL (H135-155XL, H135-155XL2)
(F006, G006) lift truck models, see Figure 4.
Remove outer bearing cone, outer bearing cup,
and remove hub from spindle.
4. Remove inner bearing cone, inner bearing cup
and wear sleeve.
5. Remove grease seal from spindle.
6. Repeat procedure for other hub.
CLEAN
WARNING
Cleaning solvents can be flammable and toxic
and can cause skin irritation. When using
cleaning solvents, always follow the recom-
mendations of the manufacturer.
Clean all parts with solvent. Make sure bearings are
clean and dry.
INSPECT
Inspect spindle to ensure it does not have any rough
or sharp areas that would prevent the bearings from
being correctly installed. If necessary, smooth any
rough or sharp areas before installing the bearings.
ASSEMBLE AND INSTALL
1. If bearings in hubs must be replaced, use a press
to install new bearing cups in hub. Install a new
wear sleeve in wheel hub.
CAUTION
Do not damage the seals during installation.
2. Install grease seal on spindle. Lubricate bearing
cones and seal surfaces with grease. Make sure
bearings are filled with grease. Install bearing
cone on spindle.
3. Carefully slide hub onto spindle. On some units,
the hub weighs enough to require a lifting device
during installation. Install outer bearing cone.
S3.50-5.50XL (S70-120XL) (D004), S3.50-
5.50XM (S70-120XM) (E004, F004), E3.50-
5.50XL (E70-120XL, E70-120XL3 ) (C098), and
E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS)
(D098/E098) units. Install solid wheel and hub
assembly onto spindle and install outer bearing
cone.
8

17. 1600 SRM 326 Wheels and Hubs Repair (All Units)
NOTE: For newer E3.50-5.50XL (E70-120XL,
E70-120XL3) (C098) lift truck models and
E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS)
(D098/E098) lift truck models, go to Step 5.
4. Install washer and castle nut. Tighten castle nut
to 203 N•m (150 lbf ft) while rotating wheel hub.
Loosen castle nut to less than 27 N•m (20 lbf ft).
Tighten castle nut to 34 N•m (25 lbf ft). Tighten
castle nut until cotter pin can be installed. In-
stall grease cap.
5. Tighten castle nut to 68 N•m (50 lbf ft). Back
off one quarter turn. Torque castle nut to 3 N•m
(25 lbf in). Tighten nut to nearest slot and lock
in place with cotter pin.
WARNING
Add air to the tires only in a safety cage. In-
spect safety cage for damage before use. When
adding air, use a clip on chuck with enough
hose to let the operator stand clear of the cage.
6. Install wheel on hub. Be careful not to damage
threads on studs.
7. H3.50-5.00XL (H70-110XL) (G005), H6.00-
7.00XL (H135-155XL, H135-155XL2) (F006,
G006) units. Install wheels on the hubs.
H3.50-5.00XL (H70-110XL) (G005) units.
Tighten nuts to 645 N•m (476 lbf ft).
H6.00-7.00XL (H135-155XL, H135-155XL2)
(F006), and H6.00-7.00XL (H135-155XL
(G006) units. Tighten nuts to 610 to 680 N•m
(450 to 502 lbf ft).
H8.00-16.00XL (H165-360XL) (D019, E007),
and H8.00-12.00XM (H170-280HD) (F007,
G007, H007), H13.00-14.00XM (H300-330HD)
(E019, F019, G019), H16.00XM-6 (H360HD)
(E019, F019, G019), H10.00-12.00XM-12EC
(H360HD-EC) (E019, F019, G019) units. Use
the following procedure to install wheels on the
hub:
a. Lubricate studs and nuts as shown in Fig-
ure 5. Do not get any oil on outer surfaces
of wheel or flange of nut.
b. Start with wheel nut at the top and tighten
nuts to 65 to 130 N•m (48 to 96 lbf ft) in
sequence shown. Make sure there is no dirt
between wheel and hub. The wheel must fit
over the pilot surface and be tight against the
hub. Tighten nuts to 640 to 680 N•m (472 to
502 lbf ft).
WARNING
When the wheels have been installed, check
all wheel nuts after 2 to 5 hours of operation.
Tighten the nuts to the correct torque. When
the nuts stay tight after an 8-hour check, the
interval for checking can be extended to time
specified in the Periodic Maintenance section.
8. Repeat procedure for other wheel.
X. NO LUBRICANT
1. WHEEL RIM
2. HUB
3. WHEEL STUD
4. WHEEL NUT
5. FLANGE
6. LUBRICATE
Figure 5. Wheels Installation
9

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19. Spindles and Bearings Repair (All Units) 1600 SRM 326
Spindles and Bearings Repair (All Units)
REMOVE
1. Remove wheels and hubs as described in Wheels
and Hubs Repair (All Units)
CAUTION
Do not hit the threads or the nut of the tie rod.
2. Disconnect tie rods as described in Tie Rods Re-
pair (All Units) procedures.
3. Remove grease cap from spindle, For lift truck
models E3.50-5.50XL (E70-120XL, E70-120XL3)
(C098), S3.50-5.50XL (S70-120XL) (D004),
S3.50-5.50XM (S70-120XM) (E004, F004) and
E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS)
(D098/E098), see Figure 1. For lift truck models
H8.00-16.00XL (H165-360XL) (D019, E007)
and H8.00-12.00XM (H170-280HD) (F007,
G007, H007), H13.00-14.00XM (H300-330HD)
(E019, F019, G019), H16.00XM-6 (H360HD)
(E019, F019, G019), H10.00-12.00XM-12EC
(H360HD-EC) (E019, F019, G019) see Figure 2.
For lift truck models H3.50-5.00XL (H70-110XL)
(G005) , see Figure 3. For Lift truck models
H6.00-7.00XL (H135-155XL, H135-155XL2)
(F006, G006), see Figure 4. Remove capscrews
from bearing cap and shims. If necessary, remove
bearing cup from bearing cap. See Figure 6.
4. Tilt spindle and lift spindle from axle. If bear-
ings must be replaced, remove upper and lower
bearings and seals from spindle. If wear sleeves
and bearing cups must be replaced, remove
them from axle frame. For lift truck mod-
els E3.50-5.50XL (E70-120XL, E70-120XL3)
(C098), S3.50-5.50XL (S70-120XL) (D004),
S3.50-5.50XM (S70-120XM) (E004, F004) and
E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS)
(D098/E098), see Figure 1. For lift truck models
H8.00-16.00XL (H165-360XL) (D019, E007)
and H8.00-12.00XM (H170-280HD) (F007,
G007, H007), H13.00-14.00XM (H300-330HD)
(E019, F019, G019), H16.00XM-6 (H360HD)
(E019, F019, G019), H10.00-12.00XM-12EC
(H360HD-EC) (E019, F019, G019) see Figure 2.
For lift truck models H3.50-5.00XL (H70-110XL)
(G005) , see Figure 3. For Lift truck models
H6.00-7.00XL (H135-155XL, H135-155XL2)
(F006, G006), see Figure 4.
5. Repeat procedure for other spindle.
CLEAN
WARNING
Cleaning solvents can be flammable and toxic
and can cause skin irritation. When using
cleaning solvents, always follow the recom-
mendations of the manufacturer.
Clean all parts in solvent. Make sure bearings are
clean and dry.
1. PRY BAR
2. BEARING CUP
3. BEARING CAP
Figure 6. Bearing Cup Removal
10

20. 1600 SRM 326 Spindles and Bearings Repair (All Units)
ASSEMBLE AND INSTALL
1. Install new seals on spindle. Lubricate seals with
grease. See Figure 1, Figure 2, Figure 3, Fig-
ure 4, Figure 7, and Figure 8.
2. Lubricate bearings with wheel bearing grease.
Make sure bearings are filled with grease. If nec-
essary, press new bearing cups into steering axle
frame and bearing cap. Install wear sleeve in
steering axle frame.
3. Install spindle in steering axle and make the fol-
lowing bearing adjustment:
a. H3.50-5.00XL (H70-110XL) (G005),
S3.50-5.50XL (S70-120XL) (D004),
S3.50-5.50XM (S70-120XM) (E004, F004),
E3.50-5.50XL (E70-120XL, E70-120XL3)
(C098), H6.00-7.00XL (H135-155XL,
H135-155XL2) (F006, G006), and
E3.50-5.50XL, E4.50XLS (E70-120Z,
E100ZS) (D098/E098) units. Install
bearing cap without O-ring. Measure
clearance between bearing cap and axle.
Remove bearing cap and install enough
shims to give a preload 0.00 to 0.127 mm
(0.000 to 0.005 in.). Install O-ring on
bearing cap. Install bearing cap and cap-
screws. Tighten capscrews to 45 N•m
(33 lbf ft) for H3.50-5.00XL (H70-110XL)
(G005), S3.50-5.50XL (S70-120XL) (D004),
S3.50-5.50XM (S70-120XM) (E004, F004),
E3.50-5.50XL (E70-120XL, E70-120XL3)
(C098), and H6.00-7.00XL (H135-155XL,
H135-155XL2) (F006, G006) units and
52 N•m (38 lbf ft) for E3.50-5.50XL,
E4.50XLS (E70-120Z, E100ZS) (D098/E098).
NOTE: Spindle bearings must have no clearance. In-
stall shims 0.00 to 0.13 mm (0.000 to 0.005 in.) less
than measured clearance.
b. H8.00-16.00XL (H165-360XL) (D019,
E007), and H8.00-12.00XM (H170-280HD)
(F007, G007, H007), H13.00-14.00XM
(H300-330HD) (E019, F019, G019),
H16.00XM-6 (H360HD) (E019, F019,
G019), H10.00-12.00XM-12EC (H360HD-
EC) (E019, F019, G019) units. 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). Mea-
sure gap. Install correct amount of shims to
equal the gap. Tighten capscrews to 77 N•m
(56.8 lbf ft).
4. Install grease cap on top of steering axle. Use a
sealant between grease cap and steering axle.
5. Install tie rod as described in Tie Rods Repair (All
Units) procedures.
6. Repeat procedure for other spindle.
11

21. Tie Rods Repair (All Units) 1600 SRM 326
Tie Rods Repair (All Units)
REMOVE
1. Remove wheels and hubs as described in Wheel
and Hub Repair (All Units) procedures.
CAUTION
Do not hit the threads or the nut of the tie rod.
NOTE: Spindle and tie rod can be removed as a unit
or separately.
2. H3.50-5.00XL (H70-110XL) (G005), S3.50-
5.50XL (S70-120XL) (D004), S3.50-5.50XM
(S70-120XM) (E004, F004), E3.50-5.50XL
(E70-120XL, E70-120XL3) (C098), and
E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS)
(D098/E098) units. Use the following proce-
dure to remove tie rods on these lift trucks (see
Figure 1, Figure 3, Figure 4):
a. Remove cotter pin and castle nut. To loosen
stud, hold a large hammer behind spindle
arm of spindle. Hit side of spindle arm with
another large hammer. The shock of the
hammer from hitting the spindle arm will
normally loosen tapered stud.
b. Disconnect tie rod at retaining pin inside
dust cover. It is necessary to raise steer
wheels 8 to 15 cm (3 to 6 in.) from the floor.
Remove lower snap ring, and use a hammer
and a drift to push pins for tie rods upward.
See Figure 7.
3. H8.00-16.00XL (H165-360XL) (D019, E007),
and H8.00-12.00XM (H170-280HD) (F007,
G007, H007), H13.00-14.00XM (H300-330HD)
(E019, F019, G019), H16.00XM-6 (H360HD)
(E019, F019, G019), H10.00-12.00XM-12EC
(H360HD-EC) (E019, F019, G019) units. Re-
move capscrew, anchor pin, and tie rod pin from
each end of the tie rod. See Figure 8.
4. H6.00-7.00XL (H135-155XL, H135-155XL2)
(F006, G006) units. Remove two snap rings
and pin from tie rod and steer cylinder rod. Re-
move two snap rings and pin from tie rod and
spindle arm. Remove tie rod from steer cylinder
rod and spindle arm. See Figure 4.
CLEAN
WARNING
Cleaning solvents can be flammable and toxic
and can cause skin irritation. When using
cleaning solvents, always follow the recom-
mendations of the manufacturer.
Clean all parts except the ends of the tie rods in sol-
vent. Make sure bearings are clean.
INSTALL
1. Use the following procedure to install tie rod to
spindle arm or steering cylinder (see Figure 1,
Figure 3, Figure 4, Figure 7, and Figure 8):
a. H3.50-5.00XL (H70-110XL) (G005),
S3.50-5.50XL (S70-120XL) (D004),
E3.50-5.50XL (E70-120XL, E70-120XL3)
(C098), H6.00-7.00XL (H135-155XL,
H135-155XL2) (F006, G006), and
E3.50-5.50XL, E4.50XLS (E70-120Z,
E100ZS) (D098/E098) units. Install
tie rod end into spindle arm and tighten
castle nut to 165 N•m (122 lbf ft). For
E3.50-5.50XL, E4.50XLS (E70-120Z,
E100ZS) (D098/E098) units tighten castle
nut to 175 N•m (129 lbf ft). If the hole in the
tie rod end and the slot in the castle nut do
not align, tighten castle nut until cotter pin
can be installed.
b. S3.50-5.50XM (S70-120XM) (E004, F004)
units. Install tie rod end into spindle arm
and tighten castle nut to 175 N•m (129 lbf ft).
If the hole in the tie rod end and the slot in
the castle nut do not align, tighten castle nut
until cotter pin can be installed.
12

22. 1600 SRM 326 Tie Rods Repair (All Units)
1. STEER AXLE
2. STEERING CYLINDER
3. BOOT
4. CLAMP
5. CLAMP
6. PIN
7. SNAP RING
8. TIE ROD ASSEMBLY
9. CASTLE NUT
10. COTTER PIN
11. WASHER
12. L.H. SPINDLE
13. BEARING CONE
14. BEARING CUP
15. SEAL
16. WEAR SLEEVE
17. R.H. SPINDLE
18. CAP
19. BEARING CONE
20. SEAL
21. SEAL
22. O-RING
23. SHIM(S)
24. CAPSCREW
25. LUBE FITTING
26. BEARING CAP
Figure 7. Steering Axle S3.50-5.50XL (S70-120XL) (D004), S3.50-5.50XM (S70-120XM) (E004, F004),
E3.50-5.50XL (E70-120XL, E70-120XL3) (C098), and E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS)
(D098/E098)
c. H8.00-16.00XL (H165-360XL) (D019,
E007) and H8.00-12.00XM (H170-280HD)
(F007, G007, H007), H13.00-14.00XM
(H300-330HD) (E019, F019, G019),
H16.00XM-6 (H360HD) (E019, F019,
G019), H10.00-12.00XM-12EC (H360HD-
EC) (E019, F019, G019) units. Install seals
on tie rod bushings. Use an alignment pin
to align seals with bushings. Lubricate pin
with an antiseize compound and install tie
rod pin into the tie rod and cylinder rod or
spindle arm. Grease fittings on tie rod pins
must face downward. Install anchor pin and
capscrew to fasten the pin. Tighten capscrew
in the anchor pin to 44 N•m (32 lbf ft).
NOTE: Tie rods do not have an adjustment.
13

23. Tie Rods Repair (All Units) 1600 SRM 326
A. H8.00-12.00XL (H165-280XL) (E007) AND H8.00-12.00XM (H170-280HD) (F007, G007, H007)
B. H13.00-16.00XL (H300-360XL) (D019), H13.00-14.00XM (H300-330HD) (E019, F019, G019), H16.00XM-6
(H360HD) (E019, F019, G019), AND H10.00-12.00XM-12EC (H360HD-EC) (E019, F019, G019)
1. AXLE FRAME
2. STEERING CYLINDER
3. ANCHOR PIN
4. CAPSCREW
5. PIN, TIE ROD
6. TIE ROD
7. BEARING CUP
8. BEARING CONE
9. GREASE CAP
10. SEAL
11. WEAR SLEEVE
12. SPINDLE
13. WHEEL HUB
14. HUB CAP
15. NUT
16. COTTER PIN
17. BEARING ASSEMBLY
18. ADHESIVE
19. GREASE FITTING
20. BEARING CAP
21. SHIMS
22. BUSHING, TIE ROD
23. PILOT SURFACE
Figure 8. Steering Axle H8.00-16.00XL (H165-360XL) (D019, E007) and H8.00-12.00XM (H170-280HD)
(F007, G007, H007), H13.00-14.00XM (H300-330HD) (E019, F019, G019), H16.00XM-6 (H360HD) (E019,
F019, G019), H10.00-12.00XM-12EC (H360HD-EC) (E019, F019, G019)
14

24. 1600 SRM 326 Steering Cylinder Repair
Steering Cylinder Repair
REMOVE AND DISASSEMBLE
NOTE: End caps of the steering cylinder are held in
the shell by the cylinder mount capscrews. To pre-
vent oil leaks at the caps, hold caps on shell during
removal. See Figure 9.
1. Disconnect hydraulic lines at steering cylinder.
Install caps on cylinder fittings and put plugs in
hydraulic lines.
2. Disconnect tie rods as described in the Tie Rods
Repair (All Units) procedures.
3. Loosen the capscrews that hold the cylinder to
the axle frame (do not remove capscrews) enough
to move the end caps to the maximum outer po-
sition of the mounting place.
4. Move the shell to one side of the assembly, to cap
one side of the shell.
5. Remove capscrews and washers that fasten
cylinder to axle frame. Hold end caps on shell
and remove steering cylinder.
6. Hold end of steering cylinder over a drain pan.
Remove hydraulic fitting cap from each end cap.
Push rod toward end of shell that is over drain
pan. Oil will drain from cylinder. Repeat proce-
dure for other end.
7. Remove one end cap from shell. Carefully pull
rod from shell. Keep rod in center of shell dur-
ing removal. Remove end cap from rod. Re-
move other end cap from shell. Remove all seals,
wipers, and O-rings.
CLEAN AND INSPECT
WARNING
Cleaning solvents can be flammable and toxic
and can cause skin irritation. When using
cleaning solvents, always follow the recom-
mendations of the manufacturer.
Compressed air can move particles so they
cause injury to the user or to other person-
nel. Make sure the path of the compressed air
is away from all personnel. Wear protective
goggles or a face shield to prevent injury to
the eyes.
1. Clean all parts in solvent. Use compressed air to
dry parts.
2. Inspect piston rod for grooves or damage. Re-
move small scratches with fine emery cloth. In-
spect cylinder bore for damage. Inspect mounts
for cracks.
ASSEMBLE AND INSTALL
CAUTION
Do not damage the O-rings, seals, or wipers
during installation.
1. Lubricate O-rings, seals, and wipers with O-ring
lubricant. Install O-rings, seals, and wipers. See
Figure 9.
2. Carefully slide rod into shell. Keep rod in center
of shell during installation. Slide end cap into
shell. Install other end cap on rod and shell. Put
caps on hydraulic fittings of end caps.
3. Hold end caps and install cylinder on axle frame
using capscrews and washers. Make sure end
caps are fully engaged with shell.
H3.50-5.00XL (H70-110XL) (G005), S3.50-
5.50XL (S70-120XL) (D004), S3.50-5.50XM
(S70-120XM) (E004, F004), E3.50-5.50XL
(E70-120XL, E70-120XL3) (C098), and
E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS)
(D098/E098) units. Tighten capscrews to
225 N•m (166 lbf ft).
H6.00-7.00XL (H135-155XL, H135-155XL2)
(F006, G006) units. Tighten capscrews to
245 N•m (181 lbf ft).
H8.00-16.00XL (H165-360XL) (D019, E007),
and H8.00-12.00XM (H170-280HD) (F007,
G007, H007), H13.00-14.00XM (H300-330HD)
(E019, F019, G019), H16.00XM-6 (H360HD)
(E019, F019, G019), H10.00-12.00XM-12EC
(H360HD-EC) (E019, F019, G019) units.
Tighten capscrews to 435 N•m (320 lbf ft).
15

25. Troubleshooting 1600 SRM 326
4. Install tie rods as described in the Tie Rods Re-
pair (All Units) procedures.
5. Remove plugs and caps, and connect hydraulic
lines to steering cylinder. Start engine, and
operate steering system to remove air from
cylinders and system. Turn steering wheel sev-
eral times from one wheel stop to the other wheel
stop.
1. SHELL
2. END CAP
3. PISTON ROD
4. PISTON SEAL
5. O-RING
6. BACKUP RING
7. ROD SEAL
8. WIPER SEAL
Figure 9. Steering Cylinder
Troubleshooting
PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION
The steering wheels do not
move when the steering
wheel is turned.
The hydraulic oil level is low or there
is no hydraulic oil in the tank.
Fill tank. Check for leaks.
The steering control unit is dam-
aged.
Repair or install new control unit.
No oil flow from the steering control
unit to the steering cylinder.
Repair or install new components.
Check for leaks.
16