the best service repair manual

1. SERVICE REPAIR
J40XM2 J50XM2 J60XM2 [A216]

2. 1400 SRM 575 Description
General
This section has the description and repair procedures for the differential, speed reducer, drive axle, and the
mounts for the axle housing.
Description
The drive unit assembly is fastened to the frame of
the lift truck by the axle mounts. See Figure 1 and
Figure 2. The outer ends of the axle housings are
the spindles for the wheel bearings. The cups for the
wheel bearings are pressed into the wheel hubs. The
nut on the end of the spindle holds and adjusts the
preload on the wheel bearings. The axle shafts are
fastened to the hubs by capscrews. Studs and nuts
fasten the wheel to the hub and brake drum. The
back plate and brake assemblies are fastened to the
axle mounts.
1. DIFFERENTIAL
2. SPINDLE (AXLE
HOUSING)
3. AXLE MOUNT
4. SPEED REDUCER
5. TRACTION MOTOR
Figure 1. Drive Unit Assembly J2.00-3.20XM
(J40-60XM, J40-60XM2) (A216)
The speed reducer and differential are assembled as
a single unit. See Figure 8. The pinion in the speed
reducer engages the splines on the shaft of the trac-
tion motor. The cluster gear transfers power from
the pinion to the reduction gear. The reduction gear
is engaged with the drive gear on the differential.
1. DIFFERENTIAL
2. SPINDLE (AXLE
HOUSING)
3. AXLE MOUNT
4. SPEED REDUCER
5. TRACTION MOTOR
Figure 2. Drive Unit Assembly J2.00-3.20XM
(J40-65Z) (A416)
1

3. Drive Axle, Speed Reducer, and Differential Repair 1400 SRM 575
Drive Axle, Speed Reducer, and Differential Repair
REMOVE
NOTE: The traction motor can be removed as a sep-
arate unit. See the section Frame 100 SRM 582 for
the procedure to remove the traction motor.
WARNING
The lift truck must be put on blocks for some
types of maintenance and repair. The removal
of the following assemblies will cause large
changes in the center of gravity: attachment,
mast, drive axle, battery, and the counter-
weight. When the lift truck is put on blocks,
put additional blocks in the following posi-
tions:
a. Before removing the drive axle, put blocks
under the counterweight so the lift truck
cannot tip backward.
b. Before removing the battery or counter-
weight, put blocks under the mast assem-
bly so the lift truck cannot tip forward.
Put the lift truck on blocks only if the surface
is solid, even, and level. Make sure that any
blocks used to support the lift truck are solid,
one-piece units.
1. Disconnect the battery connector.
2. Remove the mast assembly as described in Mast,
Repairs 4000 SRM 522.
3. Use a crane and chains to put the lift truck on
blocks as shown in Figure 3. Make sure the crane
has the capacity to lift the weight of the lift truck.
See the nameplate for the weight of the lift truck.
4. Remove the floor plates. Remove the drive
wheels. Disconnect the brake lines to the wheel
cylinders. Put caps on the open fittings.
5. Disconnect the parking brake cables from the
levers of the service brakes. Drain the oil from
the differential.
6. Put a floor jack under the drive unit assembly.
Make sure the drive unit assembly has stability;
then, remove the nuts and bolts from the axle
mounts. Remove the alignment pins from the
frame. The alignment pins can be a tight fit. See
the procedures in Figure 4 and Figure 5. Slide
the drive unit assembly from the lift truck.
a. Method 1. See Figure 4.
(1) Use a grade 8 bolt that is the maximum
diameter possible and long enough to go
through the spacer (cup) and pin. Put
a washer and nut on the threaded end
against the alignment pin. The washer
and nut must be smaller than the holes
in the frame and axle mount.
(2) Install the spacer and bolt through the
pin from the frame side. Use a wrench
to pull the alignment pin out of (re-
moval) or into (installation) the axle
mount and frame members.
b. Method 2. See Figure 5.
(1) Use a threaded rod (bolt) as described
in Method 1, but long enough to go
through the alignment pin, spacer
(cup), and hydraulic cylinder with a
hollow piston. The washer and nut on
the end of the bolt must be smaller than
the holes in the frame and axle mount
when the pin is removed.
Figure 3. Put Lift Truck on Blocks
2

4. 1400 SRM 575 Drive Axle, Speed Reducer, and Differential Repair
A. REMOVAL B. INSTALLATION
1. FRAME
2. AXLE MOUNT
3. BOLT
4. SPACER (CUP)
5. ALIGNMENT PIN
Figure 4. Axle Mount Arrangement (Method 1)
(2) Install the spacer (cup), hydraulic cylin-
der, and threaded rod through the
alignment pin from the frame side.
Operate the hydraulic cylinder in the
direction away from the frame and pull
the pin out of (removal) or into (in-
stallation) the axle mount and frame
members.
A. REMOVAL B. INSTALLATION
1. FRAME
2. AXLE MOUNT
3. BOLT
4. SPACER (CUP)
5. ALIGNMENT PIN
6. HYDRAULIC CYLINDER (WITH
HOLLOW PISTON)
Figure 5. Axle Mount Arrangement (Method 2)
3

5. Drive Axle, Speed Reducer, and Differential Repair 1400 SRM 575
DISASSEMBLE
1. Remove the axle shafts. See Figure 6 and Fig-
ure 7. If necessary, remove the brake assemblies
as described in the section Brake System 1800
SRM 566.
2. Remove the capscrew that holds the right-hand
axle mount to the speed reducer housing. Re-
move the axle mounts from the axle housing.
3. Remove the expansion plug from the differential
housing. Remove the nuts and washer from the
reduction gear.
4. Remove the capscrews that hold the speed re-
ducer housing to the differential housing. Sep-
arate the housings.
5. Remove the bearing caps from the speed reducer
housing. Remove the capscrews that hold the
halves of the speed reducer housing together.
Separate the housings.
1. OIL LEVEL PLUG
2. DRIVE AXLE HOUSING
3. O-RING
4. SPINDLE
5. RH AXLE MOUNT
6. ALIGNMENT PIN
7. WASHER
8. ISOLATOR
9. SPACER
10. SPEED REDUCER HOUSING
11. NUTS AND BOLT (MOTOR
SUPPORT)
12. DC TRACTION MOTOR
13. LH AXLE MOUNT
14. GREASE FITTING
15. BUSHING
16. DIFFERENTIAL HOUSING
17. BREATHER
Figure 6. Drive Unit Parts J2.00-3.20XM (J40-60XM, J40-60XM2) (A216)
4

6. 1400 SRM 575 Drive Axle, Speed Reducer, and Differential Repair
6. Remove the gears, bearings, and shims from the
speed reducer housing.
7. Remove the lock plates for the adjustment nuts
for the differential. Remove the capscrews for the
differential bearing caps. Remove the bearing
caps and adjustment nuts.
8. Remove the drive gear from the differential case.
See Figure 8. If necessary, disassemble the dif-
ferential. See Figure 9.
1. OIL LEVEL PLUG
2. DRIVE AXLE HOUSING
3. O-RING
4. SPINDLE
5. RH AXLE MOUNT
6. ALIGNMENT PIN
7. WASHER
8. ISOLATOR
9. SPACER
10. SPEED REDUCER HOUSING
11. NUTS AND BOLT (MOTOR SUPPORT)
12. AC TRACTION MOTOR
13. LH AXLE MOUNT
14. GREASE FITTING
15. BUSHING
16. DIFFERENTIAL HOUSING
17. BREATHER
Figure 7. Drive Unit Parts J2.00-3.20XM (J40-65Z) (A416)
5

7. Drive Axle, Speed Reducer, and Differential Repair 1400 SRM 575
CLEAN
WARNING
Always wear safety glasses.
Cleaning solvents may be flammable and toxic
and can cause severe skin irritation. When us-
ing cleaning solvents, always comply with the
solvent manufacturer’s recommended safety
precautions.
Compressed air can move particles so that they
cause injury to the user or to other personnel.
Make sure that the path of the compressed air
is away from all personnel. Wear protective
goggles or a face shield to prevent injury to the
eyes.
Clean the parts of the drive axle with a cleaning sol-
vent. Dry the parts with compressed air.
1. DRIVE GEAR
2. DIFFERENTIAL
3. DIFFERENTIAL BEARING CAP
4. ADJUSTMENT NUT
5. CAPSCREW AND LOCK
PLATE
6. SPEED REDUCER HOUSING
7. BEARING CUP
8. BEARING CONE
9. CLUSTER GEAR
10. SHIMS
11. BEARING CAP
12. O-RING
13. REDUCTION GEAR
14. PINION
15. ALIGNMENT PIN
16. DIFFERENTIAL HOUSING
17. EXPANSION PLUG
18. LOCK NUT
19. LOCK RING
20. BEARING LOCK NUT
Figure 8. Speed Reducer and Differential Assembly
6

8. 1400 SRM 575 Drive Axle, Speed Reducer, and Differential Repair
INSPECT
1. Check the gears for wear or damage. Inspect the
spider gears and axle gears for worn teeth. In-
spect the cross for wear where the gears turn.
The cross and the holes for the cross in the dif-
ferential case must fit tightly.
2. Inspect the bearings and bearing surfaces for
damage.
3. The mounts must turn freely on the axle hous-
ing. The splines for the axle shafts must not be
damaged.
1. DIFFERENTIAL
CASE
2. THRUST WASHER
3. PINION
4. SIDE GEAR
5. SPIDER
Figure 9. Differential
ASSEMBLE
WARNING
Hot parts. Wear protective clothing and gloves
to prevent burns.
1. If the drive gear was removed from the differen-
tial case, put the drive gear in hot water that is
82 to 105 C (180 to 220 F) for approximately 10
minutes. Remove the drive gear from the water
and put it on the differential case. Do not use
a press or a hammer to install the drive gear.
Install the twelve capscrews and special hard-
ened washers. Tighten the capscrews to 111 N•m
(82 lbf ft). Make sure the drive gear is in the cor-
rect position against the flange of the differential
case.
2. Lubricate and install a side gear and thrust
washer in the differential case as shown in Fig-
ure 10. Make sure the side of the thrust washer
with dents is toward the side gear.
3. Install the spider (cross), differential pinions,
and thrust washers into the differential case as
shown in Figure 11.
4. Install the second side gear and thrust washer
over the spider and differential pinions as shown
in Figure 12. Put the second half of the dif-
ferential case over the first half and the gears
as shown in Figure 12. Make sure the marks
are aligned. Install four of the capscrews in a
cross pattern. Tighten the capscrews to 50 N•m
(37 lbf ft). Install the remaining capscrews and
tighten them in a cross pattern.
5. Install the bearing cones on the differential case.
1. SIDE GEAR
2. THRUST WASHER
3. DIFFERENTIAL CASE
Figure 10. Install Side Gear and Thrust Washer
7

9. Drive Axle, Speed Reducer, and Differential Repair 1400 SRM 575
1. SPIDER, DIFFERENTIAL PINIONS, AND
THRUST WASHERS
Figure 11. Spider (Cross), Pinions, and Thrust
Washers Installation
1. DIFFERENTIAL CASE
2. ALIGNMENT MARKS
Figure 12. Second Half of Differential Case
Installation
6. Apply axle lubricant on the inner diameter of the
bearing cups and on both bearing cones that are
installed on the differential. Do not permit lubri-
cant on the outer diameter of the bearing cups or
the bearing bores of the housing.
7. Install the differential assembly into the hous-
ing. The bearing cups must fit correctly into the
bores of the housing.
8. Install the two bearing adjustment nuts into po-
sition in the housing bores. Use your hand to
tighten each adjustment nut against the bearing
cup. Use the adjustment nuts to put the drive
gear in the correct location as shown in Figure 13.
9. Align the marks on the bearing caps with the
marks on the housing. See Figure 14. Tighten
the capscrews for the bearing caps to 95 to
110 N•m (70 to 81 lbf ft).
10. Tighten the adjustment nuts to 14 N•m (10 lbf ft)
to remove the clearance between the adjustment
nuts and the bearings. Loosen the adjustment
nut only until there is zero clearance between
the bearings and the adjustment nuts. Tighten
each adjustment nut one notch more than zero
clearance to put a preload on the bearings. Check
that the rotating torque is 1.7 to 4.0 N•m (15 to
35 lbf in).
11. Install the retainers for the adjustment nuts.
Tighten the hex capscrews to 19 N•m (14 lbf ft).
12. Install the bearing cup and O-ring in the differ-
ential housing. Apply a bead of sealant (Loctite®
515 or equivalent) to the flange of the differen-
tial housing. Install the speed reducer housing to
the differential housing. Tighten the capscrews
to 52 N•m (38 lbf ft).
13. Install the reduction gear in the speed reducer
housing. Install the bearing cone. Install the
lock nut with the pin away from the gear. Use
a thread adhesive (Loctite 271 or equivalent) on
the threads of the nut. Tighten the lock nut to
135 N•m (100 lbf ft). Rotate the reduction gear
at least five times. Loosen the lock nut until the
bearings are loose. Tighten the lock nut to 7 N•m
(5 lbf ft). Install the lockwasher, rotating the nut
as necessary to align the holes. Install the outer
lock nut. Use a thread adhesive (Loctite 271 or
equivalent) on the threads of the nut. Tighten
the lock nut to 135 N•m (100 lbf ft).
14. Install the bearings and the cluster gear and pin-
ion in the speed reducer housing. Apply a bead of
sealant (Loctite 515 or equivalent) to the flange
of the speed reducer housing. Install the other
half of the speed reducer housing. Use a thread
sealant on the capscrews and tighten the cap-
screws to 38 N•m (28 lbf ft).
15. Install the bearing cap for the cluster gear with
a 2.54 mm (0.100 in.) shim pack and the bearing
cup. Install the capscrews for the bearing cap
8

10. 1400 SRM 575 Drive Axle, Speed Reducer, and Differential Repair
and tighten them evenly to 1.2 N•m (10 lbf in)
while rotating the gears. Measure the clearance
between the bearing cap and the housing in
three places (near the capscrews). Find the av-
erage of the three measurements. Add 0.15 mm
(0.006 in.) to the average measurement. Sub-
tract this dimension from 2.54 mm (0.100 in.) to
obtain the required shim pack. Install the shims,
O-ring, and bearing cap. Use a thread sealant
on the capscrews and tighten the capscrews to
19 N•m (14 lbf ft).
16. Adjust and install the bearing cap for the pinion
using the procedures described in Step 15.
1. BEARING CAP
2. PINION
3. SPEED REDUCER HOUSING
4. CLUSTER GEAR
5. O-RING
6. BEARING CUP (ALIGNMENT)
7. REDUCTION GEAR
8. BEARING LOCK NUT
9. LOCK RING
10. LOCK NUT
11. EXPANSION PLUG
12. ADJUSTMENT NUT
13. DIFFERENTIAL BEARING CAP
14. DIFFERENTIAL
15. DRIVE GEAR
16. BEARING CUP
17. SHIMS
Figure 13. Speed Reducer and Differential
17. Apply a bead of sealant (Loctite 515 or equiva-
lent) to the flange of the axle housing. Install
the differential housing onto the axle housing.
Tighten the bolts and capscrews that fasten the
two housings together to 38 N•m (28 lbf ft).
18. If removed, install the axle spindles on the axle
housing, Install new O-rings on the axle spindles.
See Figure 15. Install the axle spindle into the
axle housing. Tighten the capscrews to 90 N•m
(66 lbf ft). Lubricate the axle spindles with Never
Seez® and slide the mounts on the axle spindles.
19. Install the capscrew, washer, isolators, and
spacer between the right-hand axle mount
and the speed reducer housing. See Figure 6.
Tighten the capscrew to 165 N•m (122 lbf ft).
9

11. Drive Axle, Speed Reducer, and Differential Repair 1400 SRM 575
20. Install a new O-ring on the flange of the motor.
Use a sling to lift the traction motor. Align the
traction motor with the pinion in the speed re-
ducer.
1. BEARING CAP
2. ALIGNMENT MARKS
Figure 14. Bearing Caps Installation
Figure 15. New O-Rings Installation
21. Align the holes in the speed reducer and the mo-
tor housing. Install the capscrews that hold the
traction motor to the speed reducer. Tighten the
capscrews to 38 N•m (28 lbf ft).
22. Install the bolt and nuts at the support on the
bottom of the speed reducer housing. Adjust the
bolt until it touches the motor housing. Turn the
bolt an additional 1/2 turn counterclockwise to
push on the traction motor. Tighten the upper
nut. Tighten the lower nut to 33 N•m (24 lbf ft)
without moving the bolt.
INSTALL
1. Use a floor jack to slide the drive unit assembly
in position under the lift truck.
2. Align the bolt holes in the axle mounts and the
frame. Lubricate the alignment pins with Never-
Seez and install them. The alignment pins can
be a tight fit. See the procedures in Figure 4 and
Figure 5. Install the bolts that fasten the axle
mounts to the frame. Tighten the nuts and bolts
as follows:
a. If the torque wrench is on the head of the bolt,
tighten the bolt to 780 N•m (575 lbf ft).
b. If the torque wrench is on the nut, tighten
the nut to 715 N•m (528 lbf ft).
3. Assemble the brake assembly to the axle mount
as described in the section Brake System 1800
SRM 566.
NOTE: The outer wheel bearing is lubricated by gear
oil from the differential housing. The inner wheel
bearing is lubricated by wheel bearing grease. Do
not use too much grease to lubricate the inner wheel
bearing so that grease is pushed past the seal into
the area for the brakes.
4. Install a new oil seal in each hub. Install the oil
seal with the lip toward the outer bearing. Install
the inner bearing and seal. Put wheel bearing
grease on the inner bearing.
5. Install hub on the axle spindle. Be careful that
the seals are not damaged during installation.
Install the outer bearing, lock plate, and lock
nut. Tighten the lock nut to 205 N•m (151 lbf ft)
while rotating the hub. Loosen the lock nut un-
til the hub turns freely. The torque must be less
than 27 N•m (20 lbf ft). Tighten the lock nut
to 34 N•m (25 lbf ft) or until the first alignment
position after 34 N•m (25 lbf ft). Bend the lock
plate over the lock nut. See Figure 16.
10

12. 1400 SRM 575 Torque Specifications
Figure 16. Lock Plate Installation
6. Apply a bead of sealant (Loctite 515 or equiv-
alent) on the flange of the axle shaft. Install
the axle shafts and capscrews. Tighten the cap-
screws to 98 N•m (72 lbf ft).
7. Connect the brake lines to the wheel cylinders.
Make sure there is brake fluid in the reservoir.
Remove air from the brake system.
8. Adjust the clearance of the brake shoes as de-
scribed in the section Brake System 1800 SRM
566.
9. Install the wheels and tires. Tighten the wheel
nuts to 237 to 305 N•m (175 to 225 lbf ft).
10. Install and tighten the drain plug. Fill the differ-
ential housing with SAE 90 EP gear oil through
the fill hole until the oil level is even with the bot-
tom of the fill hole. Install the plug.
11. Install the mast as described in the section Mast,
Repairs 4000 SRM 522. Install the battery as
described in the section Periodic Maintenance
8000 SRM 1060. Remove the blocks so the lift
truck is on its tires.
Torque Specifications
Axle Mounts to Frame
Torque Wrench on Head of Bolt 780 N•m
(575 lbf ft)
Torque Wrench on Nut of Bolt 715 N•m (527 lbf ft)
Axle Housing to Differential Housing
38 N•m (28 lbf ft)
Axle Shaft Capscrews
98 N•m (72 lbf ft)
Back Plate to Axle Mount Capscrews
5/8 in. Capscrews 245 N•m (180 lbf ft)
1/2 in. Capscrews 125 N•m (92 lbf ft)
Bearing Cap Capscrews for Differ-
ential Bearings
95 to 110 N•m (70 to 81 lbf ft)
Bearing Cap Capscrews for Speed Reducer
19 N•m (14 lbf ft)
Differential Case Halves
50 N•m (37 lbf ft)
Drive Gear to Differential Case
111 N•m (82 lbf ft)
Retainer Capscrews for Adjustment Nuts
19 N•m (14 lbf ft)
Speed Reducer Housing to Differen-
tial Housing
52 N•m (38 lbf ft)
Traction Motor to Speed Reducer Housing
38 N•m (28 lbf ft)
Wheel Cylinder Capscrews
7/16 in. Capscrews 78 to 91 N•m (58 to 67 lbf ft)
1/2 in. Capscrews 91 to 102 N•m (67 to 75 lbf ft)
Wheel Nuts
237 to 305 N•m (175 to 225 lbf ft)
11

13. Troubleshooting 1400 SRM 575
Troubleshooting
PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION
The lift truck will not move. An axle shaft is broken. Install new axle shaft.
The differential is damaged. Repair differential.
Pinion is damaged. Install a new pinion.
Cluster gear or reduction gear is
damaged.
Install new gear(s).
The drive axle has leaks. The drain or fill plug has damaged
threads, is loose, or is missing.
Repair threads. Tighten plug. Install
missing part.
The O-rings or seals have damage. Install new O-rings and seals.
The drive axle housing is cracked. Install new drive axle housing.
Speed reducer housing is cracked. Install a new housing.
The drive axle makes noise. The bearings have damage. Install new parts.
The brake assembly is damaged. Repair brake assembly.
The oil level is low. Fill as required. Check for leaks.
The axle mounting capscrews are
loose.
Tighten capscrews to specified
torque.
Speed reducer gears are damaged. Install new gears.
12

14. 1600 SRM 485 General
General
There are two different steering systems available:
Power Steering and Power Steering with On-De-
mand. The difference in the components for each
system can be found in Figure 1 and Figure 2. This
section covers the description, disassembly, assem-
bly, checks, adjustments, and the troubleshooting
of the steering system. There is a description for
each part of the steering system at the beginning
of each repair section. On units with three wheels,
the steering system turns the Master Drive Unit
(MDU) to steer the lift truck. On units that have
four wheels and a steering axle, the steering system
operates the steering cylinder to steer the lift truck.
Additional information for the components of the
steering system is found in the Master Drive Unit
630 SRM 363 which contains the description and
repair of the MDU for the A1.00-1.5.XL (A20-30XL),
the Steering Axle for your unit, and the Steering
Control Unit for your lift truck model.
A modification has been made in the manifold as-
sembly of the steering control unit used in the A1.00-
1.50XL (A20-30XL) trucks that is different than the
unit described in the Steering Control Unit 1600
SRM 54. The four hydraulic ports are in the bottom
of the steering control unit. These ports connect to
the four hydraulic hoses for the steering system. The
four hydraulic ports on the side of the steering con-
trol unit are not used.
A. THREE WHEEL UNITS B. MANY FOUR WHEEL UNITS
1. STEERING WHEEL
2. OPTICAL ENCODER
3. ACTIVATOR
4. STEERING CONTROL UNIT
5. STEERING PUMP MOTOR
6. STEERING PUMP
7. PRESSURE SWITCH [EXCEPT A1.00-1.50XL
(A20-30XL)]
8. HYDRAULIC STEERING MOTOR
9. STEERING CHAIN
10. MASTER DRIVE UNIT
11. STEERING CYLINDER
12. STEERING AXLE
13. FROM TANK
14. TO TANK
*E3.50-5.50XL (E70-120XL, E70-120XL3) ONLY.
#POWER STEERING WITH ON-DEMAND ONLY.
Figure 1. Power Steering Components
1

15. General 1600 SRM 485
Figure 2. Power Steering Components E1.50-2.00XMS (E25-40XMS, E25-40XM2S)
2

16. 1600 SRM 485 Description
Legend for Figure 2
1. STEERING CYLINDER
2. TO STEERING CONTROL UNIT
3. PRESSURE CHECK FITTING
4. PUMP MOTOR
5. STEERING PUMP
6. PRESSURE SWITCH (ON-DEMAND STEERING
ONLY)
7. RETURN TO HYDRAULIC TANK
8. FROM HYDRAULIC TANK
9. MOUNT FOR STEERING MOTOR
Description
The steering system used on these lift trucks is a
hydraulic system that does not have a mechani-
cal connection between the steering wheel and the
MDU or steering axle. The control of the steering
is through a hydraulic circuit. See Figure 1 and
Figure 3. An electric motor drives a hydraulic pump.
To energize the motor, the key switch must be ON
and the seat switch must be closed. When the key
switch is first moved to the ON position, forward or
reverse direction must also be selected for the steer-
ing system to operate. After the starting sequence is
completed, the electric motor on the Power Steering
pump will run continuously. The pump motor with
the On-Demand system will operate only when the
steering wheel is turned. When the electric motor
operates the pump, hydraulic oil flows through the
power steering system.
When the steering wheel is rotated to steer the lift
truck, the hydraulic oil is routed to the steering mo-
tor at the MDU or to the steering cylinder on units
with a steering axle. There is a delay between the
last rotation of the steering wheel and the system
deenergizing in the Power Steering with On-Demand
system. This delay keeps the system operating when
the operator is not turning the steering wheel during
straight travel. The delay is approximately 1 second
on some truck models to between 4 and 5 seconds on
other models.
1. MOTOR
2. STEERING PUMP
3. PRESSURE TEST PORT
4. STEERING CONTROL UNIT
5. STEERING WHEEL
6. STEERING CYLINDER OR MOTOR
7. PRESSURE TEST PORT*
8. HYDRAULIC TANK
9. FILTER
*PRESSURE SWITCH FOR ON-DEMAND STEERING OPTION ONLY. REPLACES CHECK PORT.
Figure 3. Steering System Hydraulic Schematic
3

17. Steering Wheel and Column Assembly Repair 1600 SRM 485
A gear on the shaft of the steering wheel drives the
gear of the optical encoder as the steering wheel is
moved to steer the lift truck. The optical encoder
sends a signal to the activator. The activator com-
pletes the battery negative circuit for the steering
contactor to energize the steering pump motor. See
Figure 4 and Figure 19 for the electrical connections
for Power Steering with the On-Demand system.
Also see Diagrams section for your unit. The steer-
ing control unit is also operated by the steering
wheel to direct oil to the steering cylinder or hy-
draulic motor.
NOTE: On units with a steering axle, there is a
pressure switch in the hydraulic circuit. Any time
the system is operational and the system pressure
is above 2.07 kPa (0.3 psi), the switch energizes the
contactor for the steering pump motor. This pressure
switch allows the system to continue to operate even
if the steering wheel is not moving.
Units that have On-Demand steering have an opti-
cal encoder circuit. A gear on the shaft of the steering
wheel moves the gear of the optical encoder when the
steering wheel is moved. See Figure 4, Figure 6 and
Figure 7. The optical encoder sends a signal to the ac-
tivator assembly. The activator assembly completes
the battery negative circuit for the steering contactor
to energize the steering pump motor. The steering
wheel also operates the steering control unit. When
the steering wheel is rotated to steer the lift truck,
the hydraulic oil is sent to the steering cylinder on
the steering axle.
The steering control unit is a rotary valve operated
by the steering wheel. During the steering operation,
the steering control unit controls the direction of flow
and volume of oil to control the direction and degree
of turn. On units with an MDU, the hydraulic motor
has a sprocket on the output shaft that rotates the
MDU by a steering chain. On units that have a steer
axle, the steering cylinder moves the steering link-
age to move the steer wheels. Hydraulic oil returns
from the hydraulic motor or cylinder to the steering
control unit and then returns to the hydraulic tank.
If for any reason the steering pump does not operate,
a check valve permits the steering control unit to still
control the steering system. The lift truck is difficult
to steer when the steering pump is not operating, but
the steering control unit can operate the hydraulic
motor or steering cylinder and makes steering possi-
ble.
Steering Wheel and Column Assembly Repair
The upper end of the steering shaft has splines for
the steering wheel. A large nut holds the steering
wheel onto the steering shaft. The horn button is the
cover for the center of the steering wheel. The lower
end of the steering shaft has splines or a tang to en-
gage the steering control unit. A push rod allows the
horn button to actuate the horn switch. See Figure 4,
Figure 5, Figure 6 and Figure 7.
The steering column is adjustable and is held in posi-
tion by a latch. The steering column position can be
changed for different operators. The steering column
must be raised to the UP position to provide clear-
ance for the seat when removing or installing the
battery. There is a cover on the steering column for
access to the steering control unit, key switch, horn
switch, direction switch (if installed), optical encoder,
and on some units, the activator. The activator on
many of the XM units is under the instrument panel
to the left of steering column.
ASSEMBLY COMPONENTS, REMOVE
NOTE: See the section, Steering Control Unit for
your unit for the correct repair procedures for the
steering control unit.
NOTE: This procedure is for the removal of all com-
ponents of the steering column assembly. Usually it
is not necessary to remove all of the components. Do
only those steps of the procedure necessary to remove
the component you need to remove.
1. Disconnect the battery and attach a tag on the
truck battery connector, stating DO NOT CON-
NECT BATTERY. Raise the steering column to
the UP position. Remove the access cover from
the steering column.
2. Remove the housing of the steering column. Re-
move key switch. Make an identification of the
electrical wires and disconnect them from the key
switch.
4

18. 1600 SRM 485 Steering Wheel and Column Assembly Repair
Figure 4. Steering Wheel and Steering Column Assembly (Early XL Units)
5

19. Thank you very much for
your reading. Please Click
Here. Then Get COMPLETE
MANUAL. NO WAITING
NOTE:
If there is no response to
click on the link above,
please download the PDF
document first and then
click on it.

20. Steering Wheel and Column Assembly Repair 1600 SRM 485
Legend for Figure 4
NOTE: FOR CORRECT CONNECTION, SEE THE DIAGRAMS SRM FOR YOUR LIFT TRUCK.
A. DANFOSS B. TRW
1. TRUCK WIRE HARNESS
2. SNAP RING
3. PLASTIC TUBE
4. PIN
5. STEERING SHAFT
6. SOCKET HEAD SCREW
7. KEY SWITCH
8. CLAMP
9. BRACKET
10. STEERING CONTROL UNIT
11. LATCH
12. BRACKET
13. OPTICAL ENCODER AND BRACKET
14. DRIVE GEAR AND SETSCREW
15. ENCODER/ACTIVATOR WIRE HARNESS
16. ACTIVATOR
17. INPUT
18. OUTPUT
19. LEFT TURN
20. RIGHT TURN
3. Remove the instrument display panel or instru-
ment display meters and gauges. Early model
lift trucks can have either an instrument dis-
play cluster that wraps around the steering col-
umn, near the steering wheel, or instrument dis-
play meters and gauges that are located on both
sides of and near the bottom of the steering col-
umn. See the service manual sections Instru-
ment Cluster, Instrument Panel Indicators
and Senders or Electrical System for your lift
truck model for the removal procedures.
4. For later model lift trucks, the display panel is
located on the cowl, or steering column housing,
to the right of the steering column assembly. Dis-
connect all plugs connected to the display panel.
5. If installed, remove the handle, boot, and large
nut that fasten the direction switch. Remove the
direction switch from the housing of the steer-
ing column. Make an identification of the electri-
cal wires and disconnect them from the direction
switch.
6. Remove the capscrew that fastens the bracket for
the horn switch to the housing of the steering
column. Move the horn switch and bracket away
from the steering column.
7. Remove the horn cover, snap ring, and base plate
(not part of Petri steering wheel). Lift the push
rod and adjuster spool out the top of the steering
shaft. Remove the large hex nut and remove the
steering wheel from the shaft. A puller makes
removal of the steering wheel easier, but not all
steering wheels have puller holes.
8. If the lift truck has On-Demand steering, remove
the optical encoder and activator and the brack-
ets. See Figure 4, Figure 6, and Figure 7. It is
not necessary to remove the activator if it is not
in the steering column. See Make an identifica-
tion of the electrical wires and disconnect them
from the assemblies.
9. Make an identification of the hydraulic hoses
at the steering control unit so they can be con-
nected correctly during assembly. Some hoses
have swivel fittings to permit disconnecting at
the steering control unit. Disconnect the other
hoses at the base of the cowl, the control valve, or
the steering pump. Remove all mounting clamps
so that the hoses will turn freely and not become
twisted. Disconnect the hydraulic hoses at the
bottom of the steering control unit. Install plugs
at all hose ports and hoses to prevent dirt from
entering the system.
10. Remove the capscrews, lockwashers, and lock
plates that fasten the steering column to the
pivots on the lift truck. Remove the steering col-
umn from the lift truck. Make sure the electrical
wires and the hydraulic hoses are not damaged
as the steering column is removed.
6

21. 1600 SRM 485 Steering Wheel and Column Assembly Repair
NOTE: PETRI STEERING WHEEL SHOWN.
1. LATCH PIVOT PIN
2. COTTER PIN
3. BRACKET
4. HORN SWITCH
5. PIN
6. PUSH ROD
7. INTERNAL SNAP RING
8. STEERING WHEEL NUT
9. LOCK RING
10. SOCKET HEAD SCREW
11. ADJUSTER SPOOL NUT
12. HORN COVER
13. BASE PLATE
14. STEERING WHEEL
15. EXTERNAL SNAP RING
16. BEARING
17. STEERING SHAFT
18. PLASTIC TUBE
19. PLASTIC WASHER
20. SPRING
21. BRACKET
22. STEERING CONTROL UNIT
23. STEERING COLUMN
24. LATCH
25. SOCKET HEAD SCREW
Figure 5. Steering Wheel and Steering Column Assembly (Later XL Units)
7

22. Steering Wheel and Column Assembly Repair 1600 SRM 485
Figure 6. Steering Wheel and Steering Column Assembly (Early Model XM Units)
8

23. 1600 SRM 485 Steering Wheel and Column Assembly Repair
Legend for Figure 6
NOTE: FOR CORRECT CONNECTION, SEE THE DIAGRAMS SRM FOR YOUR LIFT TRUCK.
1. STEERING WHEEL, SHAFT, AND ON-DEMAND
STEERING PARTS
2. STEERING CONTROL UNIT
3. SPRING
4. WASHER
5. COTTER PIN
6. PIN
7. PUSH ROD
8. COLUMN TILT LEVER
9. SCREW
10. REAR COVER
11. MOUNT
12. CAPSCREW
13. PLATE
14. ALLEN HEAD CAPSCREW
15. PIVOT SHAFT
16. RETURN SPRING
17. FRONT COVER
18. BRACKET
19. OPTICAL ENCODER AND BRACKET
20. DRIVE GEAR AND SETSCREW
21. ENCODER/ACTIVATOR WIRE HARNESS
22. ACTIVATOR (UNDER INSTRUMENT PANEL TO
LEFT OF STEERING COLUMN)
23. TRUCK WIRE HARNESS
24. LATCH
11. Remove the steering shaft as follows:
a. Move the plastic tube and washer toward the
steering control unit and compress the spring
for the horn switch. Then remove the pin
that goes through the steering shaft and en-
gages the plastic tube.
b. Remove the external snap ring that holds the
bearing in the steering column. On units
that have On-Demand steering, loosen the
setscrew in the gear on the shaft. The re-
turn spring, washer, and tube are removed at
the same time as the steering shaft and bear-
ing are removed. Use a small pry bar at the
bottom of the steering shaft near the steer-
ing control unit to remove the steering shaft
and bearing (also, return spring, washer, and
tube) from the steering column.
12. Remove the two capscrews that hold the steer-
ing control unit and the bracket to the steering
column. Remove the four capscrews or nuts that
fasten the steering control unit to the bracket.
ASSEMBLY COMPONENTS, INSTALL
NOTE: This procedure is for the installation of all
components of the steering column assembly. Usu-
ally it is not necessary to install all of the compo-
nents. Do only those steps of the procedure neces-
sary to install the component you need to install.
1. Install the steering column on the cowl mounts.
Lubricate the pivots with multipurpose grease
and install the capscrews into the housing.
2. Fasten the two halves of the mount bracket to
the steering control unit. Make sure to install
bracket for activator if the activator is in the
steering column. Install the steering control unit
assembly into the steering column. Make sure to
install the horn switch and the switch bracket as
well as the two wire clamps on the same mount
capscrews.
3. For early model lift trucks, if the instrument
display panel or instrument display meters and
gauges were removed, install them. See the
service manual sections Instrument Cluster,
Instrument Panel Indicators and Senders
or Electrical System for your lift truck model
for the installation procedures.
4. For later model lift trucks, if the display panel
was removed, install it and connect all plugs to
the display panel.
5. If removed, install the wires on the key switch as
identified during removal. Install the key switch.
6. If removed, install the wires on the direction
switch as identified during removal. Install the
direction switch in the housing and install the
large nut, boot, and handle.
9

24. Steering Wheel and Column Assembly Repair 1600 SRM 485
Figure 7. Steering Wheel and Steering Column Assembly (Later Model XM Units)
10

25. 1600 SRM 485 Steering Wheel and Column Assembly Repair
Legend for Figure 7
1. ON-DEMAND STEERING COMPONENTS
2. FRONT COVER
3. BRACKET
4. PIVOT (STEERING) SHAFT
5. PLATE
6. LOCKWASHER
7. CAPSCREW
8. LOCK NUT
9. SCREW
10. STATIC GROUND PATCH
11. REAR COVER
12. COLUMN TILT LEVER
13. PUSH ROD
14. LATCH
15. SPRING
16. WASHER
17. COTTER PIN
18. PIN
19. STEERING CONTROL UNIT
20. PLUG (WITHOUT TURN SIGNAL)
21. OPTICAL ENCODER HOUSING AND BRACKET
22. DRIVE GEAR AND SETSCREW
23. OPTICAL ENCODER
24. HORN SYSTEM
25. STEERING WHEEL
26. STEERING COLUMN
27. RETURN SPRING
28. LARGE HEX NUT
29. INPUT
30. RIGHT TURN
31. LEFT TURN
32. RETURN
7. Install the bearing on the steering shaft. The
seal of the bearing must be toward the steering
wheel. Install the snap ring in the groove on the
steering shaft.
8. Put the steering shaft through the opening for
the bearing in the steering housing. Install the
gear for On-Demand steering onto the steering
shaft. Install the pin that holds the plastic tube
and flange for the horn switch. Install the plastic
tube, the plastic flange, and the spring onto the
steering shaft. Push the steering shaft into the
splines or align the tang of the steering control
unit. Install the snap ring that holds the bearing
in the steering housing.
9. If removed, install the optical encoder and
bracket assembly on the column housing. Make
sure the pinion gear of the optical encoder and
the drive gear on the steering shaft are correctly
aligned. Tighten the setscrew for the drive gear.
Install the wires on the activator as identified
during removal. The correct connections are
also shown in Figure 4, and Figure 6. Install the
activator on the bracket fastened to the steering
control unit.
10. Install the steering wheel. Install the large hex
nut onto the steering shaft. Install the push rod
and adjuster spool into the steering shaft. Install
the base plate (not part of Petri steering wheel),
the lock ring, and the horn cover.
WARNING
The hydraulic hoses MUST be connected to the
correct ports and fittings, or the steering sys-
tem will not operate as expected. This opera-
tion that is not expected can cause damage or
personal injury. Connect the hoses as identi-
fied during removal.
11. Connect the hydraulic hoses to the steering con-
trol unit, the cowl, the control valve, or the steer-
ing pump as removed during removal. Make sure
each hydraulic hose is connected to the correct
ports or fittings as identified during removal.
12. Connect the wire connectors at the bottom of the
steering column. Install the access cover on the
steering column.
11