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STEERING AXLE
S4.0-5.5FT, S5.5FTS (S80-120FT, S100FTBCS,
S120FTS, S120FTPRS) [J004];
H4.0FT5/FT6, H4.5FTS5, H4.5FT6, H5.0-5.5FT
(H80-120FT) [U005]

PART NO. 4128421 1600 SRM 1896

 HeavyManuals.com

SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• The Service Manuals are updated on a regular basis, but may not reflect recent design changes to the
product. Updated technical service information may be available from your local authorized Hyster®
dealer. Service Manuals provide general guidelines for maintenance and service and are intended for
use by trained and experienced technicians. Failure to properly maintain equipment or to follow in-
structions contained in the Service Manual could result in damage to the products, personal injury,
property damage or death.
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and
that the load being lifted is balanced. Make sure the crane, cables, and chains have the capacity to
support the weight of the load.
• Do not lift heavy parts by hand, use a lifting mechanism.
• Wear safety glasses.
• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift
trucks. Disconnect the battery ground cable on internal combustion lift trucks.
• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT
TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance section.
• Keep the unit clean and the working area clean and orderly.
• Use the correct tools for the job.
• Keep the tools clean and in good condition.
• Always use HYSTER APPROVED parts when making repairs. Replacement parts must meet or ex-
ceed 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 flamma-
ble. Be sure to follow the necessary safety precautions when handling these fuels and when working
on these fuel systems.
• Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the
area. Make sure the area is well ventilated.

NOTE: The following symbols and words indicate safety information in this
manual:

WARNING
Indicates a hazardous situation which, if not avoided, could result in death
or serious injury.

CAUTION
Indicates a hazardous situation which, if not avoided, could result in minor
or moderate injury and property damage.

On the lift truck, the WARNING symbol and word are on orange back-
ground. The CAUTION symbol and word are on yellow background.
 HeavyManuals.com
Table of Contents

TABLE OF CONTENTS

General .....................................................................................................................................................................1
Steering Axle Assembly Repair .............................................................................................................................. 2
Remove ................................................................................................................................................................ 2
Disassemble .........................................................................................................................................................2
Clean ....................................................................................................................................................................4
Inspect ................................................................................................................................................................. 5
Assemble ..............................................................................................................................................................5
Install ...................................................................................................................................................................6
Spindles, Bearings, and Tie Rods Repair ...............................................................................................................7
Spindles and Bearings ........................................................................................................................................ 7
S4.0-5.5FT, S5.5FTS (S80-120FT, S80-100FTBCS, S120FTS, S120FTPRS) (J004)................................... 7
Remove ........................................................................................................................................................7
Disassemble ................................................................................................................................................ 7
Clean ........................................................................................................................................................... 7
Inspect .........................................................................................................................................................8
Assemble ..................................................................................................................................................... 8
Install ..........................................................................................................................................................9
Spindles and Bearings ...................................................................................................................................... 10
H4.0FT5/FT6, H4.5FTS5, H4.5FT6, H5.0-5.5FT (H80-120FT) (U005) ..................................................... 10
Remove and Disassemble .........................................................................................................................10
Assemble and Install ................................................................................................................................10
Tie Rods ............................................................................................................................................................. 12
S4.0-5.5FT, S5.5FTS (S80-120FT, S80-100FTBCS, S120FTS, S120FTPRS) (J004)................................. 12
Remove ......................................................................................................................................................12
Install ........................................................................................................................................................13
Tie Rods ............................................................................................................................................................. 13
H4.0FT5/FT6, H4.5FTS5, H4.5FT6, H5.0-5.5FT (H80-120FT) (U005) ..................................................... 13
Remove ......................................................................................................................................................13
Install ........................................................................................................................................................14
Steering Cylinder Repair ...................................................................................................................................... 15
Remove and Disassemble ................................................................................................................................. 15
Clean and Inspect ............................................................................................................................................. 15
Assemble and Install ........................................................................................................................................ 15
Torque Specifications ............................................................................................................................................ 16

This section is for the following models:

S4.0-5.5FT, S5.5FTS (S80-120FT, S100FTBCS, S120FTS, S120FTPRS) [J004];

H4.0FT5/FT6, H4.5FTS5, H4.5FT6, H5.0-5.5FT (H80-120FT) [U005]

©2015 HYSTER COMPANY i

 HeavyManuals.com

"THE
QUALITY
KEEPERS"

HYSTER
APPROVED
PARTS
 HeavyManuals.com
1600 SRM 1896 General

General
This section has the description and repair The piston pushes an equal amount of oil from the
procedures for the steering axle. opposite side of the cylinder.

The steering axle assembly includes an axle frame,
steering cylinder, and two spindle and hub
assemblies. See Figure 1. The steering axle is
articulated and is connected to the frame by 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.
The end caps of the steering cylinder are also the
mounts for the cylinder and are held to the shell by
the mount capscrews. There are O-rings, seals, and
wipers in the end caps to seal the caps to the shell
and rod. 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 rod. Oil pressure on one
side of the piston moves the piston in the bore.
When the piston reaches the end of the stroke, a
relief valve in the steering circuit controls the oil
pressure. The tie rods that connect the spindle
arms to the cylinder are not adjustable.
Each spindle turns on two tapered roller bearings
in mounts in the axle frame. The preload on the
bearings is controlled by shims at the lower bearing
cap.
The wheels rotate on two tapered roller bearings
and are held on the spindles by a castle nut. The
bearing preload of the wheels is adjusted by the
castle nut. The grease seals protect the bearings
from dirt and water. Wear sleeves protect the hub
from wear by the seals.

A. CUSHION TRUCKS ONLY B. PNEUMATIC TRUCKS ONLY

1. AXLE FRAME 5. TIE ROD
2. MOUNT 6. SPINDLE
3. BRACKET 7. MOUNT
4. STEERING CYLINDER 8. HUB ASSEMBLIES

Figure 1. Steering Axle

1

Steering Axle Assembly Repair
Steering Axle Assembly Repair
REMOVE
WARNING
PUTTING THE LIFT TRUCK ON BLOCKS
The lift truck must be put on blocks for some
types of maintenance and repair. The removal of
the mast, drive axle, battery, or counterweight as-
semblies will cause large changes in the center of
gravity. When the lift truck is put on blocks, put
additional blocks in the following positions:
• If the mast and drive axle are removed, put
blocks under the counterweight so the lift
truck cannot fall backward.
• If the counterweight is removed, put blocks
under the mast so that the lift truck cannot
fall forward.
Put the lift truck on blocks on a solid, even, and
level surface. Verify the blocks or stands have
enough capacity to hold the lift truck. Use addi-
tional blocks next to the tires as necessary to pre-
vent movement of the lift truck. Verify the lifting
devices used during repairs can lift the weight of
the parts and assemblies.
See the Operating Manual or Periodic Mainte-
nance section for your lift truck model, for the
procedures to put the lift truck on blocks.
The steering axle can be removed without removing
the counterweight.
1. Verify wheels are set for straight travel. Put lift
truck on blocks so the steering axle will have
enough clearance to be removed. The top of the
axle frame must have clearance under the bot-
tom of the frame at the rear of the lift truck.
2. Disconnect hydraulic lines at steering cylinder.
Install plug fittings in cylinder and put caps on
hydraulic lines. Plug fittings will prevent spin-
dles from turning as axle is removed from un-
der the lift truck.
NOTE: Steering Axle Assembly may be mounted to
the frame with brackets or plates.
3. Slide floor jack or forks of another lift truck un-
der steering axle. Raise lifting device until it
holds the weight of the axle assembly.
2
HeavyManuals.com
1600 SRM 1896
a. To remove bracket type mounts, remove four
capscrews and nuts that fasten two brackets
under rubber mounts.
See Figure 2 for lift truck model:
• S4.0-5.5FT, S5.5FTS (S80-120FT,
S80-100FTBCS, S120FTS, S120FTPRS)
(J004)
See Figure 3 for lift truck model:
• H4.0FT/FT6, H4.5FTS5, H4.5FT6,
H5.0-5.5FT (H80-120FT) (U005)
b. Remove plates and slowly lower steering axle
assembly onto wheels. Carefully roll steering
axle assembly from lift truck.
DISASSEMBLE
1. Put axle on blocks so the wheels just touch the
floor. Remove hub cap. Remove cotter pin,
washer, and castle nut. Remove bearing cone
and discard cotter pin.
NOTE: Identify and tag the outer and inner bear-
ing cones so they can be reassembled in their origi-
nal locations.
NOTE: The wear ring may not be present on all
steering axles.
2. Slide wheel from spindle. Remove inner bearing
cone, wear ring, and oil seal from spindle.
See Figure 2 for lift truck model:
• S4.0-5.5FT, S5.5FTS (S80-120FT,
S80-100FTBCS, S120FTS, S120FTPRS)
(J004)
See Figure 3 for lift truck model:
• H4.0FT/FT6, H4.5FTS5, H4.5FT6,
H5.0-5.5FT (H80-120FT) (U005)
NOTE: If the bearing is replaced, then the associ-
ated bearing cup must be replaced also.
3. If the bearings must be replaced, use a brass
drift pin to remove the bearing cups and wear
ring.
4. Repeat Step 1 through Step 3 for the other
wheel.
 HeavyManuals.com
1600 SRM 1896 Steering Axle Assembly Repair

1. HUB CAP 10. OIL SEAL

2. CASTLE NUT 11. STEERING CYLINDER ROD
3. COTTER PIN 12. STEERING CYLINDER
4. WASHER 13. PADS
5. BEARING CONE (OUTER) 14. MOUNT
6. BEARING CUP (OUTER) 15. CAPSCREW
7. BEARING CUP (INNER) 16. WASHER
8. BEARING CONE (INNER) 17. PLATE
9. WEAR RING 18. NUTS

Figure 2. Spindle to Tie Rod Assembly for Lift Truck Model S4.0-5.5FT, S5.5FTS (S80-120FT,
S80-100FTBCS, S120FTS, S120FTPRS) (J004)

3
 HeavyManuals.com
Steering Axle Assembly Repair 1600 SRM 1896

CLEAN 1. Clean bearings by placing them in a wire bas-

WARNING
Cleaning solvents can be flammable and toxic and
can cause skin irritation. When using cleaning
solvents, always follow the solvent manufac-
turer’s recommended safety procedures.
WARNING
Compressed air is used for cleaning or drying
purposes, or for clearing restrictions. Wear pro-
tective clothing (goggles/shield, gloves, etc.) to
avoid injury to personnel.
ket and immersing in a container of fresh sol-
vent. Agitate the bearings in the solvent to re-
move all traces of old lubricant.
2. After cleaning the bearings, dry them with
clean compressed air. Take care to prevent
spinning the bearings when using a compressed
air jet.
3. Immediately wrap bearings in a lint-free cloth
to protect them from dust and other foreign
matter.

1. HUB CAP 11. MOUNT

2. CASTLE NUT 12. STEERING AXLE ASSEMBLY
3. COTTER PIN 13. MOUNT
4. WASHER 14. CAPSCREW
5. BEARING CONE 15. WASHER
6. BEARING CUP 16. NUT
7. HUB 17. STEERING CYLINDER ROD
8. WEAR RING 18. SPINDLE (LEFT SIDE SHOWN)
9. OIL SEAL 19. TIE ROD
10. LUBRICATION FITTING 20. STEERING CYLINDER

Figure 3. Spindle to Tie Rod Assembly for Lift Truck Model H4.0FT/FT6, H4.5FTS5, H4.5FT6, H5.0-5.5FT
(H80-120FT) (U005)

4
 HeavyManuals.com
1600 SRM 1896 Steering Axle Assembly Repair

INSPECT 203 N•m (150 lbf ft) while rotating the wheel
in both directions to properly seat the bear-
1. Inspect for loose, burned, missing, cracked or ings. Loosen the castle nut 1/4 turn. Tighten
damaged hardware. nut to 34 N•m (25 lbf ft). Pull on the wheel
axially to ensure that there is no end play. If
2. Inspect all parts for dents, holes, bends, burrs,
there is excessive end play, repeat Step 3
rust, corrosion or marred finish.
and Step 4.
NOTE: If the spindle, bearings or tie rods need to
b. H4.0FT/FT6, H4.5FTS5, H4.5FT6,
be repaired, go to Spindles, Bearings, and Tie Rods
H5.0-5.5FT (H80-120FT) (U005) - Tighten
Repair.
the castle nut to 200 to 220 N•m (148 to
162 lbf ft) while rotating the wheel in both
directions to properly seat the bearings.
ASSEMBLE Loosen the castle nut until wheel turns
NOTE: For specified lubricant to use, refer to the freely with no end play. Tighten nut to 35 to
following section, Periodic Maintenance 40 N•m (26 to 30 lbf ft).
8000SRM1902.

1. If necessary, use a press to install new bearing

cups in wheel or hub.

See Figure 4 for lift truck model:

• S4.0-5.5FT, S5.5FTS (S80-120FT,
S80-100FTBCS, S120FTS, S120FTPRS)
(J004)

See Figure 5 for lift truck model:

• H4.0FT/FT6, H4.5FTS5, H4.5FT6,
H5.0-5.5FT (H80-120FT) (U005)

2. Lubricate bearing cones with multipurpose

grease. Verify bearings are filled with grease.
Install oil seal, wear ring (if removed) and inner
bearing cone on spindle.

CAUTION
DO NOT damage the seals during installation. 1. WEAR RING
2. BEARING CONE (INNER)
3. Carefully slide wheel onto spindle. Install outer 3. BEARING CUP (INNER)
bearing cone. Install washer. 4. BEARING CONE (OUTER)
5. BEARING CUP (OUTER)
NOTE: Ensure that the washer is seated properly 6. HUB CAP
against the bearing cone and not against the shaft 7. COTTER PIN
8. CASTLE NUT
shoulder before tightening the castle nut. 9. WASHER
10. OIL SEAL
4. Install the castle nut and tighten as follows for
your lift truck: Figure 4. Bearing Arrangement for Lift Truck
Model S4.0-5.5FT, S5.5FTS (S80-120FT,
a. S4.0-5.5FT, S5.5FTS (S80-120FT, S80-100FTBCS, S120FTS, S120FTPRS) (J004)
S80-100FTBCS, S120FTS, S120FTPRS)
(J004) - Tighten the castle nut to

5
 HeavyManuals.com
Steering Axle Assembly Repair 1600 SRM 1896

See Figure 3 for lift truck model:

• H4.0FT/FT6, H4.5FTS5, H4.5FT6,
H5.0-5.5FT (H80-120FT) (U005)

2. Apply lubricant that is approved for use with

rubber to rubber mount. The lubricant is used
to ease assembly of the mount into frame and
brackets.

3. Use floor jack or another lift truck to put steer-

ing axle into position in frame. Verify rubber
mounts fit inside frame brackets for mounts.

NOTE: Steering axle assembly may be attached to

NOTE: RIGHT SIDE IS SHOWN. frame with brackets or plates.
1. OIL SLEEVE a. Install bottom brackets.
2. OUTER BEARING CUP AND CONE
3. HUB See Figure 2 for lift truck model:
4. INNER BEARING CUP AND CONE
5. CASTLE NUT • S4.0-5.5FT, S5.5FTS (S80-120FT,
6. COTTER PIN S80-100FTBCS, S120FTS, S120FTPRS)
7. HUB CAP (J004)
8. WASHER
Figure 5. Bearing Arrangement for Lift Truck See Figure 3 for lift truck model:
Model H4.0FT/FT6, H4.5FTS5, H4.5FT6, H5.0-5.5FT • H4.0FT/FT6, H4.5FTS5, H4.5FT6,
(H80-120FT) (U005) H5.0-5.5FT (H80-120FT) (U005)

5. Install new cotter pin in castle nut. If cotter pin 4. Proceed as follows for your lift truck:
cannot be installed, tighten castle nut to the
a. S4.0-5.5FT, S5.5FTS (S80-120FT,
first alignment position where the cotter pin
S80-100FTBCS, S120FTS, S120FTPRS)
can be installed.
(J004) - tighten four flange bolts to
6. Install hub cap. 215 N•m (159 lbf ft).

7. Repeat Step 1 through Step 6 for other wheel. b. H4.0FT/FT6, H4.5FTS5, H4.5FT6,
H5.0-5.5FT (H80-120FT) (U005) - tighten
INSTALL four bracket bolts and nuts to
90 N•m (66 lbf ft).
1. Install rubber mounts and top mount(s) on
axle. Verify face of rubber mount with the part 5. Remove plugs and caps and connect hydraulic
number is away from the axle. Verify part num- lines to steering cylinder.
ber will be right side up after axle assembly is
installed. 6. Operate steering system to remove air from
system. Turn steering wheel several times from
See Figure 2 for lift truck model: one stop to the other. Check for hydraulic leaks.
• S4.0-5.5FT, S5.5FTS (S80-120FT,
S80-100FTBCS, S120FTS, S120FTPRS)
(J004)

6

1600 SRM 1896
Spindles, Bearings, and Tie Rods Repair
SPINDLES AND BEARINGS
S4.0-5.5FT, S5.5FTS (S80-120FT,
S80-100FTBCS, S120FTS, S120FTPRS) (J004)
Remove
WARNING
PUTTING THE LIFT TRUCK ON BLOCKS
The lift truck must be put on blocks for some
types of maintenance and repair. The removal of
the mast, drive axle, battery, or counterweight as-
semblies will cause large changes in the center of
gravity. When the lift truck is put on blocks, put
additional blocks in the following positions:
• If the mast and drive axle are removed, put
blocks under the counterweight so the lift
truck cannot fall backward.
• If the counterweight is removed, put blocks
under the mast so that the lift truck cannot
fall forward.
Put the lift truck on blocks on a solid, even, and
level surface. Verify the blocks or stands have
enough capacity to hold the lift truck. Use addi-
tional blocks next to the tires as necessary to pre-
vent movement of the lift truck. Verify the lifting
devices used during repairs can lift the weight of
the parts and assemblies.
See the Operating Manual or Periodic Mainte-
nance section for your lift truck model, for the
procedures to put the lift truck on blocks.
1. Put the lift truck on blocks.
2. Remove the wheel and bearings. See Steering
Axle Assembly Repair, Disassemble section.
NOTE: To remove the spindle from the steering
rod, the tie rod can be disconnected at the retaining
pin inside the dust cover.
3. Loosen the clamps on the dust cover and slide
the dust cover off the steering cylinder rod. See
Figure 6.
4. Remove two snap rings from the pin holding
the tie rod to steering cylinder rod and remove
pin. See Figure 6.
HeavyManuals.com
Spindles, Bearings, and Tie Rods Repair
5. Remove the snap rings from the pin holding the
tie rod to the steering cylinder rod, then remove
the pin. If necessary, use a hammer and brass
drift to remove pin. Remove tie rod from steer-
ing cylinder rod.
6. If necessary, repeat the procedure for the other
spindle and tie rod.
Disassemble
1. Remove the grease cap from the spindle. Re-
move the capscrews from the bearing cap. Re-
move the bearing cap and shims. If necessary,
remove the bearing cup from the bearing cap as
shown in Figure 7.
2. Tilt the spindle and lift the spindle from the
axle. If necessary, remove the bearing and seals
from the spindle. If necessary, remove the wear
sleeve and bearing cup from the axle frame.
3. If necessary, repeat the procedure for the other
spindle and tie rod.
Clean
WARNING
Cleaning solvents can be flammable and toxic and
can cause skin irritation. When using cleaning
solvents, always follow the solvent manufac-
turer’s recommended safety procedures.
WARNING
Compressed air is used for cleaning or drying
purposes, or for clearing restrictions. Wear pro-
tective clothing (goggles/shield, gloves, etc.) to
avoid injury to personnel.
1. Clean bearings by placing them in a wire bas-
ket and immersing in a container of fresh sol-
vent. Agitate the bearings in the solvent to re-
move all traces of old lubricant.
2. After cleaning the bearings, dry them with
clean compressed air. Take care to prevent
spinning the bearings when using a compressed
air jet.
3. Immediately wrap bearings in a lint-free cloth
to protect them from dust and other foreign
matter.
7
 HeavyManuals.com
Spindles, Bearings, and Tie Rods Repair 1600 SRM 1896

Inspect Verify the bearings are filled with grease. If

1. Inspect for loose, missing, cracked, burned or
damaged hardware.
2. Inspect all parts for dents, holes, bends, burrs,
rust, corrosion, or marred finish.
Assemble
1. Install new seals on the spindle. Lubricate the
seals with grease. If necessary, press new bear-
ing cones on the spindle.
2. Lubricate the bearings with wheel bearing
grease.
necessary, press the new bearing cups into the
steering axle frame and bearing cap. Install the
wear sleeve in the steering axle frame.
3. Install the spindle in the steering axle. Install
the bearing cap without the O-rings. See Fig-
ure 8.
Measure the clearance between the bearing cap
and the axle. Remove the bearing cap and install
enough shims to give a preload of 0.00 to
0.13 mm (0.000 to 0.005 in.).

1. CLAMP 5. STEERING CYLINDER ROD

2. DUST COVER 6. PIN
3. CLAMP 7. TIE ROD
4. SNAP RING

Figure 6. Tie Rod for Lift Truck Model S4.0-5.5FT, S5.5FTS (S80-120FT, S80-100FTBCS, S120FTS,
S120FTPRS) (J004)

8
 HeavyManuals.com
1600 SRM 1896 Spindles, Bearings, and Tie Rods Repair

2. Tighten the castle nut until the new cotter pin

can be installed. Before installing cotter pin
tighten castle nut to 175 N•m (129 lbf ft).

3. Install the grease cap on the top of the steering

axle.

4. Install the bearings and wheel. See section

Steering Axle Assembly Repair, Assemble.

1. PRY BAR
2. BEARING CUP
3. BEARING CAP
4. O-RING NOTE: THE LUBRICATION FITTING NEEDS TO BE
Figure 7. Bearing Cup Removal ORIENTED TOWARDS THE CENTERLINE OF THE
LIFT TRUCK.

1. HUB CAP
NOTE: The spindle bearings must have no clear- 2. WASHER
ance. Install shims 0.00 to 0.13 mm (0.000 to 3. BEARING CONE (OUTER)
0.005 in.) less than the measured gap. 4. BEARING CUP (OUTER)
5. BEARING CONE (INNER)
4. Install the O-ring on the bearing cap. Apply 6. BEARING CUP (INNER)
7. WEAR SLEEVE
Loctite® 242 to threads of capscrews. Install the 8. OIL SEAL
bearing cap and capscrews. Tighten capscrews 9. CAPSCREW
to 44 N•m (32 lbf ft). 10. LUBRICATION FITTING
11. CAP ASSEMBLY
5. If necessary, repeat the procedure for the other 12. SHIM
spindle and tie rod. 13. BEARING CUP
14. BEARING CONE
15. SEAL
Install 16. O-RING
17. CAP
NOTE: Tie rod end may be attached to spindle arm 18. CASTLE NUT
by one of two methods, castle nut and cotter pin or 19. COTTER PIN
with snap rings, washers and pins. 20. TIE ROD
Figure 8. Spindle Assembly for Lift Truck Model
1. Install the tie rod to the spindle arm and steer- S4.0-5.5FT, S5.5FTS (S80-120FT, S80-100FTBCS,
ing cylinder. S120FTS, S120FTPRS) (J004)

9

Spindles, Bearings, and Tie Rods Repair
5. If necessary, repeat the procedure for the other
spindle and tie rod.
6. Remove the lift truck from blocks.
SPINDLES AND BEARINGS
H4.0FT5/FT6, H4.5FTS5, H4.5FT6, H5.0-5.5FT
(H80-120FT) (U005)
Remove and Disassemble
WARNING
PUTTING THE LIFT TRUCK ON BLOCKS
The lift truck must be put on blocks for some
types of maintenance and repair. The removal of
the mast, drive axle, battery, or counterweight as-
semblies will cause large changes in the center of
gravity. When the lift truck is put on blocks, put
additional blocks in the following positions:
• If the mast and drive axle are removed, put
blocks under the counterweight so the lift
truck cannot fall backward.
• If the counterweight is removed, put blocks
under the mast so that the lift truck cannot
fall forward.
Put the lift truck on blocks on a solid, even, and
level surface. Verify the blocks or stands have
enough capacity to hold the lift truck. Use addi-
tional blocks next to the tires as necessary to pre-
vent movement of the lift truck. Verify the lifting
devices used during repairs can lift the weight of
the parts and assemblies.
See the Operating Manual or Periodic Mainte-
nance section for your lift truck model, for the
procedures to put the lift truck on blocks.
1. Put the lift truck on blocks.
2. Remove the wheel and if necessary, the bear-
ings. See Steering Axle Assembly Repair, Dis-
assemble.
3. If the tie rod is to be replaced, remove two snap
rings and pin from steering cylinder rod. To
loosen and remove the pin, use a brass punch
and hammer. See Figure 9.
4. Remove two snap rings and pin from spindle.
To loosen and remove the pin, use a brass
punch and hammer. See Figure 9.
10
HeavyManuals.com
1600 SRM 1896
5. Disassemble the bottom half of the spindle as
follows:
a. Remove and discard cotter pin from castle
nut and remove castle nut from kingpin. See
Figure 10.
b. Remove the oil seal, sleeve, and bearing
cone.
NOTE: If the bearing cone is being replaced, the
bearing cup must be replaced.
c. If necessary, remove the bearing cup.
6. Disassemble the top half of the spindle as fol-
lows:
a. Remove pin and O-ring from kingpin.
b. Remove spacer, seal, and bearing cone.
NOTE: If the bearing cone is being replaced, the
bearing cup must be replaced.
c. If necessary, remove the bearing cup.
7. Repeat the procedure for the other spindle and
tie rod.
Assemble and Install
1. If new spindle bearings are installed, use a
press to install new bearing cups into spindle.
See Figure 10. Lubricate bearing cones and seal
lips with grease.
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. See Figure 10.
3. Install lock nut onto kingpin and tighten lock
nut to 175 N•m (129 lbf ft). Tighten castle nut
until new cotter pin can be installed.
4. Install tie rod to spindle housing. Align holes
and place lubricated pin into the spindle and tie
rod. Install the two snap rings on top and bot-
tom of pin.
5. If removed, install the bearings and install the
wheel. See section Steering Axle Assembly Re-
pair, Assemble.
 HeavyManuals.com
1600 SRM 1896 Spindles, Bearings, and Tie Rods Repair

6. Repeat the procedure for the other spindle and 7. Remove the lift truck from blocks.
tie rod.

1. SPINDLE (LEFT SIDE SHOWN) 4. TIE ROD ASSEMBLY

2. SNAP RING 5. PIN
3. SEAL 6. STEERING CYLINDER ROD

Figure 9. Tie Rod for Lift Truck Model H4.0FT5/FT6, H4.5FTS5, H4.5FT6, H5.0-5.5FT (H80-120FT) (U005)

11
 HeavyManuals.com
Spindles, Bearings, and Tie Rods Repair 1600 SRM 1896

TIE RODS
S4.0-5.5FT, S5.5FTS (S80-120FT,
S80-100FTBCS, S120FTS, S120FTPRS) (J004)

Remove

WARNING
PUTTING THE LIFT TRUCK ON BLOCKS

The lift truck must be put on blocks for some

types of maintenance and repair. The removal of
the mast, drive axle, battery, or counterweight as-
semblies will cause large changes in the center of
gravity. When the lift truck is put on blocks, put
additional blocks in the following positions:
• If the mast and drive axle are removed, put
blocks under the counterweight so the lift
truck cannot fall backward.
• If the counterweight is removed, put blocks
under the mast so that the lift truck cannot
fall forward.

Put the lift truck on blocks on a solid, even, and

level surface. Verify the blocks or stands have
1. HUB CAP enough capacity to hold the lift truck. Use addi-
2. CASTLE NUT tional blocks next to the tires as necessary to pre-
3. COTTER PIN vent movement of the lift truck. Verify the lifting
4. WASHER devices used during repairs can lift the weight of
5. BEARING CONE the parts and assemblies.
6. BEARING CUP
7. HUB
8. WEAR SLEEVE See the Operating Manual or Periodic Mainte-
9. OIL SEAL nance section for your lift truck model, for the
10. SPINDLE procedures to put the lift truck on blocks.
11. LUBE FITTING
12. CAP 1. Put the lift truck on blocks.
13. TIE ROD
14. SEAL 2. Remove the wheel and bearings. See Steering
15. O-RING Axle Assembly Repair, Disassemble.
16. SHIM
17. CAP ASSEMBLY
18. LOCKWASHER
19. CAPSCREW
Figure 10. Spindle Assembly for Lift Truck Model
H4.0FT5/FT6, H4.5FTS5, H4.5FT6, H5.0-5.5FT
(H80-120FT) (U005)

12

1600 SRM 1896
CAUTION
DO NOT hit the threads or the nut of the tie rod.
3. Remove the cotter pin and castle nut. Discard
cotter pin. Use a puller to remove the tie rod
end from the spindle arm. To loosen the tie rod
end, place a hammer behind the arm to hold
the arm. Hit the spindle arm with another
large hammer. See Figure 8.
4. Loosen the clamps on the dust cover and slide
the dust cover off the steering cylinder rod. See
Figure 6.
5. Remove the snap rings from the pin retaining
the tie rod to the steering cylinder rod, then re-
move the pin.
6. Slide the tie rod from the cylinder rod.
7. Remove the dust cover from the tie rod.
8. If necessary, remove the clamps from the dust
cover.
Install
1. Tighten the castle nut until the new cotter pin
can be installed. Before installing cotter pin
tighten castle nut to 163 N•m (120 lbf ft).
2. If removed, slide the clamps onto the dust
cover.
3. Slide the dust cover on the tie rod. See Fig-
ure 6.
4. Slide the tie rod into the steering cylinder rod.
5. Lubricate and install the pin to retain the tie
rod and steering cylinder rod together.
6. Install the snap rings.
7. Slide the dust cover on to the steering rod cylin-
der, against the rod-end shoulder.
8. Slide the clamps flush with the ends of the dust
cover and tighten clamps.
9. Install the bearings and wheel. See section
Steering Axle Assembly Repair, Assemble.
10. Repeat the procedure for the other tie rod.
11. Remove the lift truck from blocks.
HeavyManuals.com
Spindles, Bearings, and Tie Rods Repair
TIE RODS
H4.0FT5/FT6, H4.5FTS5, H4.5FT6, H5.0-5.5FT
(H80-120FT) (U005)
Remove
WARNING
PUTTING THE LIFT TRUCK ON BLOCKS
The lift truck must be put on blocks for some
types of maintenance and repair. The removal of
the mast, drive axle, battery, or counterweight as-
semblies will cause large changes in the center of
gravity. When the lift truck is put on blocks, put
additional blocks in the following positions:
• If the mast and drive axle are removed, put
blocks under the counterweight so the lift
truck cannot fall backward.
• If the counterweight is removed, put blocks
under the mast so that the lift truck cannot
fall forward.
Put the lift truck on blocks on a solid, even, and
level surface. Verify the blocks or stands have
enough capacity to hold the lift truck. Use addi-
tional blocks next to the tires as necessary to pre-
vent movement of the lift truck. Verify the lifting
devices used during repairs can lift the weight of
the parts and assemblies.
See the Operating Manual or Periodic Mainte-
nance section for your lift truck model, for the
procedures to put the lift truck on blocks.
1. Put the lift truck on blocks.
2. Remove the wheel and if necessary, the bear-
ings. See Steering Axle Assembly Repair, Dis-
assemble.
3. Remove the snap rings from the pin retaining
the tie rod to the spindle. Remove the pin. To
loosen and remove the pin, use a brass punch
and hammer. See Figure 11.
4. Remove the snap rings from the pin holding the
tie rod to the steering cylinder rod. Remove the
pin.
5. Slide the tie rod and washers from the spindle
housing and steering cylinder rod.
13
 HeavyManuals.com
Spindles, Bearings, and Tie Rods Repair 1600 SRM 1896

Install Install the two snap rings on top and bottom of

pin.
1. Place the tie rod and washers in position in the
spindle and steering cylinder rod. See Fig- 4. If removed, install the bearings and install the
ure 11. wheel. See Steering Axle Assembly Repair, As-
semble.
2. Align holes and place lubricated pin into the
spindle and tie rod. Install the two snap rings 5. Repeat the procedure for the other tie rod.
on top and bottom of pin.
6. Remove the lift truck from blocks.
3. Align holes and place lubricated pin into the
steering cylinder rod and tie rod.

1. SPINDLE (LEFT SIDE SHOWN) 4. TIE ROD ASSEMBLY

2. SNAP RING 5. PIN
3. SEAL 6. STEERING CYLINDER ROD

Figure 11. Tie Rod for Lift Truck Model H4.0FT5/FT6, H4.5FTS5, H4.5FT6, H5.0-5.5FT (H80-120FT) (U005)

14

1600 SRM 1896
Steering Cylinder Repair
REMOVE AND DISASSEMBLE
NOTE: The end caps of the steering cylinder are
held in the shell by the installation of cylinder
mount capscrews into the axle frame. To prevent oil
leaks at the caps, hold the caps on the shell during
removal.
NOTE: Hydraulic oil is to be disposed of in accord-
ance with local directives.
1. Disconnect and tag hydraulic lines at steering
cylinder. See Figure 12. Install caps in fittings
on cylinder and put fittings on hydraulic lines.
2. Remove the tie rods. See Spindles, Bearings,
and Tie Rods Repair, Tie Rods section.
3. Remove capscrews that fasten cylinder to axle
frame. Hold end caps on shell and remove
steering cylinder.
4. Hold end of steering cylinder over a container.
Remove plug for hydraulic fitting from each end
cap. Push rod toward end of shell that is over
container. Oil will drain from cylinder. Repeat
procedure for other end.
5. Carefully remove one end cap from shell and
slide off of rod. Carefully pull rod out of shell,
keeping rod centered in shell during removal.
Remove other end cap from shell. Remove all
seals, wipers, and O-rings. See Figure 12.
6. Remove piston seal. If present, remove two
guide rings.
CLEAN AND INSPECT
WARNING
Cleaning solvents can be flammable and toxic and
can cause skin irritation. When using cleaning
solvents, always follow the solvent manufactur-
er's recommended safety procedures.
HeavyManuals.com
Steering Cylinder Repair
1. Clean all metal parts in solvent.
2. Inspect piston rod for grooves or damage. Re-
move small scratches with fine emery cloth.
3. Inspect cylinder bore for damage
4. Inspect mounts for cracks.
ASSEMBLE AND INSTALL
CAUTION
Do not damage the O-rings, seals, or wipers dur-
ing installation.
1. Put O-rings, seals, guide rings, and wipers in
warm hydraulic oil.
2. Install O-rings, seals, guide rings, and wipers
as shown in Figure 12.
3. Lubricate O-rings, seals, and wipers with O-
ring lubricant and carefully install one end cap
on cylinder rod.
4. Carefully slide cylinder rod into shell and end
onto into shell. Keep cylinder rod aligned in
center of shell during installation so the parts
are not damaged. Install other end cap into
shell. Put caps on hydraulic fittings of end caps.
5. Hold end caps and install cylinder on axle
frame using capscrews. Tighten capscrews to
225 N•m (166 lbf ft).
6. Install tie rods. See section Spindles, Bearings,
and Tie Rods Repair, Tie Rods section.
7. Remove plugs and caps and connect hydraulic
lines as tagged during removal, to steering cyl-
inder. Operate steering system to remove air
from cylinders and system. Turn steering wheel
several times from one stop to the other. Check
that the steer cylinder operates lock to lock.
15
 HeavyManuals.com
Steering Cylinder Repair 1600 SRM 1896

1. ROD 7. PISTON SEAL

2. WIPER 8. ROD SEAL
3. END CAP 9. O-RING
4. O-RING 10. HYDRAULIC LINE PORT
5. BACKUP RING 11. GUIDE RING
6. SHELL

Figure 12. Steering Cylinder

Torque Specifications
Axle Mounting Bolts and Nuts Spindle Bearing Cap Capscrews
S4.0-5.5FT, S5.5FTS (S80-120FT,
S4.0-5.5FT, S5.5FTS (S80-120FT, S80-100FTBCS, S120FTS, S120FTPRS) (J004)
S80-100FTBCS, S120FTS, S120FTPRS) (J004) 44 N•m (32 lbf ft)
215 N•m (159 lbf ft)
H4.0FT5/FT6, H4.5FTS5, H4.5FT6, H5.0-5.5FT
H4.0FT5/FT6, H4.5FTS5, H4.5FT6, H5.0-5.5FT (H80-120FT) (U005) 45 to 50 N•m (33 to
(H80-120FT) (U005) 90 N•m (66.4 lbf ft) 37 lbf ft)

Hub Nut (Initial) Tie Rod Nut

S4.0-5.5FT, S5.5FTS (S80-120FT, S4.0-5.5FT, S5.5FTS (S80-120FT,
S80-100FTBCS, S120FTS, S120FTPRS) (J004) S80-100FTBCS, S120FTS, S120FTPRS) (J004)
203 N•m (150 lbf ft) 175 N•m (129 lbf ft)

H4.0FT5/FT6, H4.5FTS5, H4.5FT6, H5.0-5.5FT

(H80-120FT) (U005) 200 to 220 N•m (148 to
162 lbf ft)

Hub Nut (Final)

S4.0-5.5FT, S5.5FTS (S80-120FT,
S80-100FTBCS, S120FTS, S120FTPRS) (J004)
34 N•m (25 lbf in)

H4.0FT5/FT6, H4.5FTS5, H4.5FT6, H5.0-5.5FT

(H80-120FT) (U005) 15 N•m (133 lbf in)

16
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1600 SRM 1896 3/15