YMM160001

Steering Axle
GP/GLP/GDP15-20AK [C812]; GP/GLP/GDP20-35RK/TK [B871]

Safety Precautions Maintenance and Repair

When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and that the load being lifted is balanced. Make sure the crane, cables, and chains have the capacity to support the weight of the load. Do not lift heavy parts by hand, use a lifting mechanism. Wear safety glasses. Disconnect the battery 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 YALE APPROVED parts when making repairs. Replacement parts must meet or exceed the specifications of the original equipment manufacturer. Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to remove parts. Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the unit needs repairs. Be sure to follow the WARNING and CAUTION notes in the instructions. Gasoline, Liquid Petroleum Gas (LPG), and Diesel fuel are flammable. Be sure to follow the necessary safety precautions when handling these fuels and when working on these fuel systems. Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the area. Make sure the area is well ventilated. NOTE: The following symbols and words indicate safety information in this manual:

WARNING
Indicates a condition that can cause immediate death or injury!

CAUTION
Indicates a condition that can cause property damage!

GENERAL
This section has the description and repair procedures for the steering axle. See the following sections for additional information on the parts of the steering system: Steering Control Unit, Hydraulic System and Gear Pumps, Hydraulic System, and Steering System. 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.

TRAIL AXLE
[1] General

The trail axle is supported by the articulating support on the rear center of the frame. Rubber is mounted on the support to mitigate the shock from the road surface. This is referred to as the center support swing type. Tilting of the body in the lateral direction due to the road surface state can be prevented and mitigation of the torsion force to the frame is attempted. The axle body has a welded construction and steering knuckles are attached to both ends. The hub and wheel are attached to the spindle of the knuckle and the intermediate link is coupled with the arm of the knuckle. Power cylinder operation turns the knuckle around the kingpin via the intermediate link to turn the wheel inside/outside. To correct the knob run-out of the full hydrostatic power steering unit, the potentiometer attached to the kingpin on the right side of the vehicle detects the rotational angle of the steertire and transmits signals to the controller. The controller compares the tire angle with steering wheel rotational angle sent from the sensor in steering column area for optimum control. See the section Steering Housing and Control Unit.

[2]

Specifications

[3]

Construction

NOTE) Steering axle for GP/GLP/GDP15-20AK shown in this figure.

Figure 1. Steering Axle

1. TRAIL AXLE WLDMT 2. POWER CYLINDER ASSY 3. FITTING O-RING 4. FITTING O-RING 5. BOLT 6. WASHER 7. KNUCKLE 8. KNUCKLE 9. INTERMEDIATE LINK 10. PIN 11. BUSHING LINK 12. SCREW 13. NUT HEX 14. LUBE FITTING 15. LUBE FITTING 16. OIL SEAL 17. NEEDLE 18. PIN KING 19. PIN KING 20. BEARING 21. SET SCREW SOCKET 22. NUT HEX 23. SHIM WASHER (T=0.2) 24. SHIM WASHER (T=0.5) 25. GASKET SENSOR

26. PLATE RING 27. BRACKET SENSOR 28. O-RING 29. PIN 30. HEAD BOLT 31. SENSOR STEERING 32. SCREW 33. PLATE WLDMT 34. HEXAGON FLANGE NUT 35. GASKET 36. PLATE 37. OIL SEAL 38. TAPER ROLLER BEARING 39. HUB 40. BEARING 41. WASHER 42. CASTLE NUT 43. PIN, COTTER 44. CAP HUB 45. BOLT HUB 46. NUT HUB 47. RUBBER PLATE 48. HEAD BOLT 49. RUBBER CUSHION

(1)

Removal

1. Stop the vehicle on a flat road surface and turn off the key switch. Activate the parking brake and apply wheel stoppers to the front wheels. 2. Remove the counter-weight. 3. Remove two hydraulic pipes connected to the power cylinder 4. Lift the body with a jack to a degree that wheels are slightly apart from the floor surface and put a wooden base below the frame. 5. From the articulating support for the trail axle, loosen 4 bolts (two bolts each for the front and rear) and remove the cap. At the same time, take out the trail axle assembly calmly onto the ground. (2) Disassembly

1. Put a wooden base below the trail axle body so that wheels will be slightly apart from the floor surface. 2. Remove the cushion rubber from the articulating shaft. 3. Remove the hub nut and then remove wheels. 4. Remove the hub cap with a screw driver, pull of the split pin, and remove the nut and washer. Then, remove the hub from the knuckle along with the outer bearing and inner bearing. 5. Remove the oil seal. 6. If necessary, knock the bearing outer lace from the hub by fitting a brass bar softer than the bearing roller or outer lace. 7. Loosen the lock nuts and setscrews on both sides of the intermediate link. 8. Remove pins connecting power cylinders and knuckle arms on both sides of the intermediate link. 9. Remove the intermediate link. 10. Remove the upper and lower plates on the knuckle attachment. 11. Remove the sensor steering on the tops of the right-side kingpin along with the bracket sensor and then remove the plate ring, O-ring, and pin. 12. Remove the sensor steering from the bracket sensor. Remove the plate welding from the shaft of the sensor steering. When loosening the nut, press the sensor plate welding so that an excessive force will not be applied to the sensor shaft and then remove the nut. 13. Remove the knuckle and kingpin stopper bolt. 14. Fit a soft brass bar, knock the kingpin down, and remove the knuckle. In this case, do not drop the thrust bearing and shim because they are removed at the same time. 15. Remove the needle bearing remaining on the trail axle. Knock out the needle bearing by using a special tool. 16. Remove the power cylinder from the axle body. (3) Check

Wash and check the disassembled parts. Correct or replace parts as necessary. 1. Each bearings lace surface wear, flaws, other damage, and rotation state 2. Oil seal lip damage or material degradation 3. Knuckle spindle flaws, deformation, and thread damage 4. Kingpin wear [C812] [B871] Reference outside diameter: 25 mm 28 mm Use limit dimension: 24.8 mm 27.8 mm

5. D e t e r i o ra t i o n o f t h e r u bb e r o n t h e articulating shaft Reference hole dimensions: See Fig. 3. If the permanent set is extremely large, replacement is required. 6. R u bb e r p l a t e d a m a g e, c ra ck s a n d permanent set of rubber (See Figure 4.) For permanent set of rubber, the rubber mating surface is smaller than the stopper boss upper surface, the rubber does not function. Therefore, replacement is required. 7. Intermediate link bending, wear and cracks 8. Pin, link bending, wear and cracks Reference outside diameter :17mm Use limit dimension :16.8mm 9. Bush, wear and damage. Reference inside diameter :17mm Use limit dimension :17.2mm 10. Trail axle body breakage and cracks 11. Tire and wheel damage, abnormal wear and cracks 12. Sensor steering damage 13. Wear of the pin on the plate welding 14. Power cylinder piston bending, wear and damage. (4) Assembly and combining

Fig. 3

Fig. 4

After check is completed, clean the parts again, assemble them and combine with the vehicle body. 1. Knock 4 needle bearings onto the trail axle body. Grease sufficiently. Fit the bearing with its punched side facing the knuckle. Knock the oil seal on the lower sides of the right and left. Note that the lip should be outside in knocking. (See Figure 5.) 2. Combine the knuckle with the trail axle body. Combine the thrust bearing on the top of the knuckle, insert the shim below the knuckle, and knock in the kingpin. Adjust end play of the knuckle within the range given below by selective use of shims.

Fig. 5

ADVICE
Take care not to assemble the thrust bearing in a wrong direction. (See the figure.) Knuckle end play: 0.2 mm

Fig. 6

Adjusting shim GP/GLP/GDP1520AK Part number Shim 909019302 909019303 Thickness (mm) 0.2 0.5 Quantity As required As required

Adjusting shim GP/GLP/GDP2035RK/TK Part number Shim 910521102 910521103 Thickness (mm) 0.2 0.5 Quantity As required As required

3. Fix the king pin hole and knuckle screw hole with an alignment lock bolt and then fix with the lock nut. 4. Combine the plate welding with the sensor steering. In this case, check the setting directions of the plate welding and sensor steering. 5. Knock in the pin on the top of the trail axle boss and combine parts between the gasket and bracket sensor. 6. Turn the knuckle fully clockwise to facilitate sensor installation. 7. Combine the sensor while making sure that the pin of the plate welding is accurately fitted into the slit of the kingpin.

ADVICE
To check fitting into the slit, make sure that sliding is only possible in the slit direction when the sensor is put on the upper surface of the trail axle boss. 8. Fit the gasket and plates onto the top and bottom of the kingpin. Grease sufficiently before fitting the plates. 9. Combine the power cylinder with the trail axle and tighten 4 bolts. Tightening torque: 294 to 353 Nm (3,000 to 3,600 kgcm) 10. Combine the intermediate link and pin link. Grease the pin link before combining. If it is hard to combine the pin, adjust tilting of the power cylinder. 11. Fix the pin link hole and knuckle screw hole with an alignment lock bolt and then fix with the lock nut. 12. With a brass bar for fitting, knock in the inner bearing outer lace and outer bearing outer lace alternately onto the hub. 13. Fit the inner bearing inner lace onto the hub and then coat Loctite around the oil seal. Knock in the grease coated one into the groove. 14. Fill the grease groove in the hub with grease and combine the hub assembly with the spindle. After combining, knock in the outer bearing inner lace. 15. Insert the washer and tighten the grooved low-profile nut. For sufficient tightening, knock the hub in the axial direction. Make sure that tightening is sufficient and then loosen the grooved low-profile nut. Grease the washer contact surface of the grooved low-profile nut and re-tighten it to give the specified pre-load to the bearing. The bearing pre-load is controlled by measuring the hub rotation torque. Hub rotation torque: 3 to 5 Nm (30 to 35 kgfcm) When the specified torque is obtained, fix the nut with the split pin.

16. 17. 18. 19. 20.

21. 22.

23.

Coat the sealant (pipe joint compound No. 51) on the hub cap and combine it. Insert the rubber onto the articulating shaft. Attach the rubber plate on the upper surface of the trail body. Attach the wheel assembly to the hub. Hub nut tightening torque: See [2] Specifications. Remove the trail axle assembly from the wooden base and move it by rolling. Attach to the body frame and tighten the cap temporarily. If it is hard to fit the rubber into the frame, coat soap water around the rubber for easier fitting. Lower the vehicle body to the ground and tighten the cap. Cap bolt tightening torque: 41 to 49 Nm (417 to 500 kgfcm) Combine the joint with the power cylinder and connect the hydraulic piping. For air bleeding from the power steering unit, lock-to-lock operation of the power cylinder is performed. The lock-to-lock operation should be repeated until air bleeding is completed. For whether air bleeding is completed or not, push and pull the tire in the state that the tire is above the ground by putting a wooden base below the trail axle assembly. It is hard to turn the tire if air is completely bled from the power steering unit. Check the hydraulic piping for oil leak.