service repair manual

1. SERVICE REPAIR
J30XMT J35XMT J40XMT [C160]

2. 1
INTRODUCTION
GENERAL
The power steering system is a hydraulic system that
does not have a mechanical connection between the
steering wheel and the steer axle. The control of the
steering is through a hydraulic circuit.
The hydraulic circuit for the power steering includes a
common hydraulic tank, that is used for both the steer-
ing and other hydraulic functions of the lift truck. The
power steering pump is supplied by its own suction line.
The power steering pump directs the hydraulic oil to the
steering control unit located in the steering column
when the steering wheel is turned.
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
amount of oil that flows to the hydraulic steering cylin-
der. The steering cylinder actuates the steering linkage
to move the steer wheel. Hydraulic oil returns from the
steering cylinder to the steering control unit and then re-
turns to the hydraulic tank. See FIGURE 2 and
FIGURE 5.
If the steering pump does not operate, a check valve per-
mits the steering control unit to control the steering sys-
tem. The lift truck is difficult to steer when the steering
pump is not operating, but the steering control unit can
operate the steering cylinder and make steering pos-
sible. See the section, STEERING CONTROL UNIT,
1600 SRM 512 for information concerning the steering
control unit.
STEERING WHEEL AND COLUMN ASSEMBLY
DESCRIPTION (See FIGURE 1,
FIGURE 3, AND FIGURE 4)
The upper end of the steering shaft has splines for the
steeringwheel.Alargenutholdsthesteeringwheelonto
the steering shaft. The horn button is the cover for the
center of the steering wheel. The lower end of the steer-
ing shaft has splines to engage the steering control unit.
The steering column covers on the steering column give
access to the steering control unit, horn switch, and di-
rection switches.
This section does not cover the instrument panel, key
switch or directional controls which are covered in the
section ELECTRICAL SYSTEM, 2200 SRM 577.
Removal
NOTE: This procedure is for the removal of all com-
ponents of the steering column assembly. All compo-
nents are not often removed for a repair procedure. Do
only those steps of the procedure necessary to remove
the required component.
1. Disconnect the battery connector. Move the steer-
ing column to the most forward position. Remove the
steering column covers from the steering column.
1. FRONT COVER
2. REAR COVER
1
2
FIGURE 1 – STEERING COLUMN COVERS

3. 2
STEER CYLINDER
STEERING
PUMP
RELIEF
1300 psi
STEERING
CONTROL
UNIT
STRAINER
HYDRAULIC TANK
FIGURE 2 – HYDRAULIC SCHEMATIC
2. Make an identification of the electric wires and dis-
connect them from the key switch. If necessary, remove
the key switch from the steering column cover.
3. Make an identification of the electric wires and dis-
connectthemfromthedirectionalswitches.Removethe
two capscrews and washers retaining the directional
switch bracket to the steering column. Remove the
directional switches from the bracket , if necessary.
4. Remove the two capscrews and washers retaining
the shift lever assembly to the steering column and re-
move the shift lever assembly. If necessary, disassemble
the shift lever assembly.
1. STEERING WHEEL
2. STEERING COLUMN
3. STEERING CONTROL UNIT
4. KNOB
5. LATCH
6. COVER
7. COWL
8. MOUNT
1
2
3
4
5
6
7
8
6
FIGURE 3 – STEERING COLUMN
5. Remove the horn cover, snap ring and base plate.
Loosen the screws retaining the horn wire leads to the
base plate. Remove the large hex nut and remove the
steering wheel from the shaft. A puller makes removal
of the steering wheel easier.
WARNING
The hydraulic hoses MUST be connected to the cor-
rect ports and fittings or the steering system will not
operate as expected. This operation that is not ex-
pected can cause damage or personal injury. Make
sure the hoses are identified and connected correctly.

4. 3
18
17
19
29
27
26
24
25
2
23
8
7
9
5
6
22
21
11
10
16
12
14
13
31
15
20
1 3
4
1. GROMMET
2. COVER-UPPER
3. COVER LOWER
4. SCREW
5. KNOB-LATCH
6. SCREW
7. WASHER
8. SPRING
9. ROD
10. CAPSCREW
11. NUT
12. PLATE
13. CAPSCREW
14. LOCKWASHER
15. SPRING
16. SHAFT
17. NUT
18. HORN BUTTON
19. STEERING WHEEL
20. GEAR LATCH
21. PIN
22. COTTER PIN
23. CONTACTOR
24. STEER COLUMN
25. CAPSCREW
26. LOCKWASHER
27. WASHER
28. BRACKET
29. HAND PUMP
FIGURE 4 – STEERING COLUMN COMPONENTS
6. Make an identification of the hydraulic hoses at the
steering control unit so that the they can be connected
correctly during assembly. Remove all mount 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 to
prevent dirt fromenteringthesteeringhydraulicsystem.

5. 4
1. STEERING CONTROL UNIT
2. STEERING PUMP MOTOR
3. STEERING PUMP
4. STEERING POWER CYLINDER
5. FEED LINE
6. RETURN LINE
1
2
3
4
5
6
FIGURE 5 – POWER STEERING ARRANGEMENT
7. Use a set of locking pliers and position them under
the washer and spring on the rod between the latch and
steering column bracket. Carefully lift the pliers high
enough to compress the spring and move the rod out of
the detent in the latch. Remove the spring, washer and
rod from the steering column. Remove the cotter pin and
clevis pin retaining the latch. If necessary, remove the
latch knob from the latch by removing the two caps-
crews.

6. 5
POWER STEERING PUMP AND MOTOR
DESCRIPTION
(SEE FIGURE 6)
The power steering pump and motor is located under the
floorplatesontheleftsideonthetruck.Thepowersteer-
ing pump draws the hydraulic oil from the hydraulic
tank and directs the oil to the steering control unit
mounted in the steering column. The power steering
motor and pump operate when the key switch is ON and
the operator is on the seat (seat switch closed). A timer
stops the power steering motor six seconds after the op-
erator is off the seat (seat switch open) and the key
switch is still ON.
The power steering pump is a single section gear pump
that is fastened to the power steering motor. The outlet
(pressure port) of the pump is connected to the steering
control unit with a hydraulic hose. The inlet (suction
port) of the pump is connected to the hydraulic tank with
a hydraulic hose. Bushings at each side of each gear are
the bearings for the gear shafts. A gasket prevents leaks
between the pump body and stator section.
A relief valve in the outlet of the pump controls the hy-
draulic pressure in the steering system to 9.1 MPa (1300
psi). The relief valve does not normally need adjust-
ment. If the hydraulic pressure can not be adjusted to the
specification, the steering pump is normally worn or
damaged and must be repaired or replaced.
Removal
WARNING
The power steering pump and motor is heavy. Be
sure that all lifting devices (hoists, cables, chains,
slings etc.) are suitable and of adequate capacity to
lift the power steering pump and motor. The power
steering pump and motor can weigh approximately
30 lbs (13.6 kg). The power steering motor has ce-
ramic permanent magnets. If the motor falls, the
magnets can be damaged.
The power steering pump and motor must be removed
as a unit for servicing the pump. The power steering
pump and motor are mounted to the frame with rubber
isolator mounts.
1. PLATE
2. BRACKET
3. ISOLATOR
4. MOTOR
5. PUMP
1
2
3
4
5
FIGURE 6 – PUMP AND MOTOR
MOUNTING
1. Disconnect the battery. Remove the battery to gain
access to the mounting capscrews for the power steering
pump and motor. Follow the instructions in PERIODIC
MAINTENANCE 8000 SRM 528 or the OPERATING
MANUAL for battery removal information.
2. Remove the floor plate on the operator’s side of the
lift truck.
3. Mark the electrical wires for identification at as-
sembly. Remove the electrical wires.
NOTE: If the unit being worked on has brush wear
sensing or thermal sensing wires, be certain to remove
these wires before attempting to remove the power
steering pump and motor.
4. Disconnect the suction line to the power steering
pump.Removethein-linestrainerfrom thesuctionline.
Disconnect the discharge line from the power steering
pump. Plug both the hydraulic lines and the pump ports
to prevent dirt from entering the hydraulic system and to
prevent the hydraulic oil from leaking from the system.

7. 6
WARNING
The power steering pump and motor is heavy. Be
sure that all lifting devices (hoists, cables, chains,
slings etc.) are suitable and of adequate capacity to
lift the power steering pump and motor. The power
steering pump and motor can weigh approximately
30 lbs (13.6 kg). The power steering motor has ce-
ramic permanent magnets. If the motor falls, the
magnets can be damaged.
5. Remove the three capscrews, washers and brackets
retaining the power steering pump and motor to the lift
truck frame.
6. Carefully lift the power steering pump and motor
out of the lift truck.
7. If the motor must be serviced, follow the instruc-
tions found in the section THE D C MOTOR, 620
SRM 145.
Installation
WARNING
The power steering pump and motor is heavy. Be
sure that all lifting devices (hoists, cables, chains,
slings etc.) are suitable and of adequate capacity to
lift the power steering pump and motor. The power
steering pump and motor can weigh approximately
30 lbs (13.6 kg). The power steering motor has ce-
ramic permanent magnets. If the motor falls, the
magnets can be damaged.
1. Carefully locate the power steering pump and mo-
tor in the lift truck.
2. Align the power steering pump and motor and
brackets with the mounting holes in the frame. Install
the capscrews, washers and nuts to retain the pump and
motor to the lift truck frame. Tighten the nuts to 18 lbf ft
(25 NSm).
3. Remove the plugs from the discharge port and the
discharge line. Install the discharge line into the pump
port. Clean and inspect the in-line strainer. Replace the
in-line strainer, if necessary. Install the in-line strainer in
the suction line. Install the suction line on the suction
side of the pump.
4. Install all the electrical wires disconnected for re-
moval.
5. Install the floor plates.
6. Install the battery. Follow the instructions in the
PERIODIC MAINTENANCE 8000 SRM 528 or the
OPERATING MANUAL for battery installation in-
formation. Connect the battery.
REPAIRS
Disassembly
(See FIGURE 7)
NOTE: The 48 volt power steering pump has a 0.256
cu in displacement while the 36 Volt power steering
pump has a 0.323 cu in displacement. DO NOT MIX
THE COMPONENTS OF THE PUMPS.
1. Mark the pump halves and the motor to insure prop-
er alignment at assembly. Remove the four capscrews
and washers retaining the pump to the motor. Separate
the pump from the motor.
2. Remove the spider. Remove the capscrew retaining
the coupling to the drive shaft. Remove the coupling.
3. Remove the eight capscrews and washers retaining
the pump halves together. Carefully separate the halves
of the pump.
4. Remove the gears, drive shaft, keys, spacer and
idler shaft and gear.
WARNING
Be careful when removing or installing snap rings.
These snap rings can come loose during removal or
installation with enough force to cause an injury. Al-
ways use the correct snap ring pliers and wear eye
and face protection during removal and installation.
5. Remove the snap rings and remove the needle bear-
ings.
6. If necessary, remove the nut, gasket, screw, springs
and poppet.
7. Clean and inspect the needle bearings for damage.
Inspect the gears, idler shaft and gear and the drive shaft
for erosion or damage. Replace all defective parts. Re-
place the oil seal and gaskets.

8. 7
Assembly
Lubricate all components with clean hydraulic oil be-
fore assembly.
WARNING
Be careful when removing or installing snap rings.
These snap rings can come loose during removal or
installation with enough force to cause an injury. Al-
ways use the correct snap ring pliers and wear eye
and face protection during removal and installation.
1. Install the needle bearings in the pump halves.
Install the snap rings to retain the bearings.
2. Install the oil seal in the upper half of the pump.
Carefully install the drive shaft through the oil seal and
needle bearing. Install the keys on the drive shaft.
3. Install the idler shaft and gear in the needle bearing
of the upper half of the pump. Align and install the gear
on the drive shaft and key so it mates with the idler gear.
4. Install the spacer on the shafts. Install the remaining
two gears on the shafts.
5. Align the marks made at disassembly and carefully
install the bottom half of the pump. Install the eight
capscrews and washers to retain the pump halves to-
gether.
6. Install the poppet. Install the two springs, screw and
nut.
NOTE: The poppet valve must be adjusted after the
pump and motor is assembled. See the CHECKS AND
ADJUSTMENTS.
7. Install the coupling on the drive shaft. Install the
spider in the coupling.
8. Put a new gasket between the pump and motor.
Alignthepumpandmotorandinstallthefourcapscrews
and washers.
1. CAPSCREW
2. GASKET
3. NEEDLE BEARING
4. SNAP RING
5. GEAR
6. SPACER
7. IDLER SHAFT AND GEAR
8. POPPET
9. SPRING
10. SPRING
11. SCREW
12. GASKET
13. NUT
14. OIL SEAL
15. KEY
16. DRIVE SHAFT
17. GASKET
18. COUPLING
19. SPIDER
FIGURE 7 – POWER STEERING PUMP
1
2
3 4 5
5
6
7 8
9
10
11
12
14
15
17
16
18
19
18
13
4 3

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10. 8
STEERING TRUNNION ASSEMBLY
STEER AXLE
(See FIGURE 8)
The steer axle is a vertical mounted axle, supported in a
heavy duty bearing, located centrally at the rear of the
truck to provide a tight turning radius through a maxi-
mum of 90 degree turning angle. The steer wheel and
tire assembly is mounted on a stub axle which is welded
to the vertical member of the steer axle. The steer axle is
rotated by a hydraulic steering cylinder. The power
steering pump feeds the hydraulic oil to the steering
control unit, which directs the hydraulic oil to steering
cylinder. The steering cylinder turns the steer axle in the
opposite direction that the steering wheel is turned. One
end of the steering cylinder is mounted to the truck
frame. The other end of the steering cylinder is attached
to the steer axle.
WHEEL ASSEMBLY
Removal
1. Turn the steering wheel so that the drive tire is ac-
cessible. Move the key to the OFF position. Disconnect
the battery.
2. Chock the drive wheels and apply the parking
brakes.
3. Loosen the lug nuts retaining the wheel assembly.
WARNING
Do not place jacking equipment under the counter-
weight.
Before attempting to remove the wheel from the
steer axle, put blocks under each side of the frame.
The blocks must prevent the lift truck from falling
and causing injury or damage.
4. Using a suitable hoist or jacking equipment raise
the rear of the truck until the wheel is free to rotate. Put
the lift trucks on blocks, see HOW TO PUT A LIFT
TRUCK ON BLOCKS, in either the OPERATING
MANUAL or the PERIODIC MAINTENANCE,
8000 SRM 528.
WARNING
Lifting and carrying of tires is not recommended be-
cause their weight could be in excess of 100 lbs (45
kg). Where applicable use a wheel or tire dolly to as-
sist in the removal and installation of the wheel. Fol-
low the instructions in PERIODIC MAINTE-
NANCE 8000 SRM 528 or the OPERATING
MANUAL.
5. Unscrew the lug nuts and remove the wheel assem-
bly from the steer axle.
Installation
WARNING
Lifting and carrying of tires is not recommended be-
cause their weight could be in excess of 100 lbs (45
kg). Where applicable use a wheel or tire dolly to as-
sist in the removal and installation of the wheel. Fol-
low the instructions in PERIODIC MAINTE-
NANCE 8000 SRM 528 or the OPERATING
MANUAL.
1. Align the wheel assembly with the studs and install
on the wheel hub.
2. Install the lug nuts on the studs to retain the wheel
assembly. Tighten the nuts hand tight.
3. Lower the lift truck to the floor. Tighten the lug nuts
to the 170 NSm (125 lbf ft).
4. Remove the chocks from the wheels. Connect the
battery.
WHEEL HUB
Removal
1. Remove the wheel assembly. See WHEEL AS-
SEMBLY – REMOVAL.
2. Remove and discard the cotter pin. Remove the nut,
hub and special washer.

11. 9
24
23
1
21
20 19
22
18
17
14
15
16
15
14
27
31
32
30
33
34
35
36
27
28
29
39
38
40
1
2
3
4
5 6
7
8
25
26
11
29
28
27
10
9
12
13
37
1. COTTER PIN
2. NUT
3. SPACER
4. TORQUE ARM
5. BUSHING
6. SEAL
7. BEARING
8. SNAP RING
9. SEAL
10. BEARING
11. HOUSING
12. KEY
13. AXLE
14. SEAL
15. BEARING
16. SNAP RING
17. HUB
18. STUD
19. SPACER
20. WASHER
21. NUT
22. HUB CAP
23. NUT
24. TIRE AND WHEEL
25. CAPSCREW
26. WASHER
27. NUT
28. WASHER
29. WASHER
30. SHIMS
31. WASHER
32. BELLCRANK
33. BUSHING
34. PIN
35. LUBE FITTING
36. LOCK PLATE
37. CAPSCREW
38. LINK
39. BUSHING
40. WASHER
FIGURE 8 – STEERING AXLE ASSEMBLY

12. 10
WARNING
Be careful when removing or installing snap rings.
These snap rings can come loose during removal or
installation with enough force to cause an injury. Al-
ways use the correct snap ring pliers and wear eye
and face protection during removal and installation.
3. Remove and discard the nilos sealing rings. Re-
move the snap rings. Use a soft metal drift to remove the
bearing cones.
4. Inspect the bearings for damage. Inspect the axle
shaft for damage or corrosion. Inspect the wheel studs
for damage. Replace all damaged components.
Installation
1. Prior to installation pack the bearings and the new
nilos sealing rings with grease. See Section 2 for the rec-
ommended grease.
WARNING
Be careful when removing or installing snap rings.
These snap rings can come loose during removal or
installation with enough force to cause an injury. Al-
ways use the correct snap ring pliers and wear eye
and face protection during removal and installation.
2. Install the wheel bearings. Install the snap rings to
retain the bearings. Make certain that the snap rings are
seated in the wheel hub.
3. Carefully install the hub on the axle so that the seals
are not damaged.
4. Install the bearing spacer and special washer on the
axle. Install the slotted nut. Tighten the nut to 35 lbf ft
(47 NSm) torque. Rotate the wheel while tightening the
nut. If necessary, back off on the nut to align the nut and
the hole in the axle shaft.
5. Install a new cotter pin.
6. Install the wheel assembly. See WHEEL AS-
SEMBLY – INSTALLATION.
7. Remove the chocks from the drive wheels. Connect
the battery.
STEER AXLE ASSEMBLY
Removal
NOTE: The removal instructions listed are done with
the counterweight installed.
1. Remove the wheel assembly. See WHEEL AS-
SEMBLY – REMOVAL.
2. Disconnect the battery connector. Loosen the re-
tainers and remove the rear compartment cover.
WARNING
The capacitor in the controller can hold an electrical
charge after the battery is disconnected. To prevent
electrical shock and injury, discharge the capacitor
C1 after disconnecting the battery and before in-
specting or repairing any component in the rear
compartment. Wear safety glasses. Make certain the
battery has been disconnected. Use a screwdriver or
jumperwiretomakeashort-circuitacrossthetermi-
nals of the capacitor.
3. Removethewingnutsretainingtheinterfacecircuit
board cover.
4. Remove the nuts securing the interface board. Un-
plug and remove the interface board.
5. Remove the clamping bolt and the optical interrupt-
er.
6. Remove the interface mounting bracket.
7. Install a M16 50 eyebolt into the top of the axle
assembly. Attach lifting equipment to the lifting eye to
support the axle assembly.
8. Disassembletheself-lockingnutandwasherretain-
ing the cylinder rod end to the bellcrank.
9. Disassemble the self-locking nut steel washer and
nylon washer retaining the bellcrank to the bearing
housing.
10. Disassemble the self-locking nut steel washer and
nylon washer retaining the interlink assembly to the
torque arm.
11. Remove the bellcrank and interlink assembly. Re-
tain the shims used between the bellcrank and bearing
housing for reuse at assembly.
12. Remove the seven capscrews and washers retain-
ing the axle assembly to the frame.

13. 11
13. The axle may now be lowered and removed from
the lift truck.
14. Remove and discard the cotter pin. Remove the
slotted nut retaining the torque arm to the rear axle. Dis-
assemble the torque arm. Make certain not to loose the
key.
WARNING
Be careful when removing or installing snap rings.
These snap rings can come loose during removal or
installation with enough force to cause an injury. Al-
ways use the correct snap ring pliers and wear eye
and face protection during removal and installation.
15. Remove the bearing housing from the rear axle.
Remove the nilos sealing rings, the bearings and snap
rings.
16. Inspect all components for any sign of damage or
abnormal wear. All self-locking nuts, nilos sealing rings
and cotter pins must be replaced.
Installation
WARNING
Be careful when removing or installing snap rings.
These snap rings can come loose during removal or
installation with enough force to cause an injury. Al-
ways use the correct snap ring pliers and wear eye
and face protection during removal and installation.
1. Grease the bearings and the nilos sealing rings with
grease prior to installation. Install the snap ring into the
bearing housing. Install the bearings. Make certain the
bearings and the snap ring are properly seated. Install
the nilos sealing rings.
2. Carefully position the bearing housing onto the rear
axle. Install the key and torque arm onto the rear axle.
Install the washer and slotted nut. Tighten the nut to 84
NSm (62 lbf ft) torque. If necessary to align the nut with
the hole in the shaft, tighten the nut until they are
aligned. The nut must not be tightened above 108 NSm
(63 lbf ft) torque. Install a new cotter pin.
3. Position the rear axle into the truck and align the
holes in the bearing flange with those in the truck. Apply
adhesive sealant, LoctiteR 271 or equivalent to the
threads of the seven capscrews. Install the seven caps-
crews and washers to retain the rear axle in the truck.
Tighten the capscrews to 86 NSm (63 lbf ft) torque.
NOTE: Remember to check the torque of these caps-
crews every 350 hours as outlined in the Recommended
Schedule of Maintenance, see the section PERIODIC
MAINTENANCE, 8000 SRM 528.
4. Align the bellcrank and interlink assembly with the
torque arm, bearing housing and the rod end of the pow-
er steering cylinder. Remember to install the shims be-
tween the bellcrank and the bearing housing. Install a
nylon washer, a steel washer and a new self-locking nut
on the bellcrank. Tighten the nut just sufficiently to re-
move any vertical movement of the bellcrank.
5. Install a nylon washer, a steel washer and a new
self-locking nut onto the torque arm stud. Tighten the
nut just sufficiently to remove any vertical movement of
the interlink assembly.
6. Install a flat washer and a new self-locking nut on
the bellcrank stud mating with the rod end of the power
steering cylinder. Tighten the nut to 210 NSm (155 lbf ft)
torque.
7. Slack off on the lifting equipment. Remove the eye-
bolt.Installtheopticalinterrupterandtheclampingbolt.
Make certain that the optical interrupter is properly
aligned.
8. Install the interface card mounting bracket.
9. Install the wheel assembly. See WHEEL AS-
SEMBLY – INSTALLATION. Do not lower the lift
truck to the floor.
10. Install the interface board on the mounting bracket
and secure in place using the two nuts and washers.
11. Connect the wiring harness to the plug.
12. Connect the battery connector.
13. Rotate the steering wheel so the power cylinder is
in the fully closed position. Measure the distance be-
tweenthefaceofthecylindertotherodend.Thisdimen-
sion should be 74 mm (2.9 in). Adjust the rod end if nec-
essary to obtain this dimension.
14. Check to make certain that the optical interrupter
is operating properly. Turn the steering wheel to posi-
tion the rear wheel in the straight ahead position. The
optical interrupter should be perpendicular to the wheel.
Operate the wheel from full left to full right hand turn.
Check to see that the switches are operating properly.
Adjust the interrupter if necessary.

14. 12
15. Install the interface cover and the rear compart-
ment cover. Lower the lift truck to the floor.
16. Test operate the lift truck for proper operation be-
fore returning the truck to service.
POWER STEERING CYLINDER
(See FIGURE 9)
Removal
WARNING
Before attempting to remove the steering cylinder
from the lift truck, put blocks under each side of the
frame. The blocks must prevent the lift truck from
falling and causing injury or damage.
1. Park the lift truck in a level area. Block the wheels
and disconnect the battery.
2. Identify, disconnect and plug both cylinder ports
and hose connections to prevent dirt from entering the
system and to prevent the hydraulic oil from leaking.
3. Remove the cotter pin retaining the cylinder to the
frame. Remove the clevis pin and washers retaining the
cylinder to the frame.
4. Remove the self-locking nut and washer retaining
the cylinder rod end to the bellcrank.
5. Remove the steering cylinder.
FIGURE 9 – POWER STEERING CYLINDER
74 mm
(2.9 in)
Installation
1. Install the steering cylinder in the lift truck. Align
the stationary end of the cylinder with the truck frame
and the rod end with the bellcrank stud.
2. Install the washer and self-locking nut to retain the
rod end to the bellcrank. Tighten the nut to 150 NSm
(110 lbf ft).
3. Install the washers and the clevis pin to retain the
stationary end to the truck frame. Install a new cotter
pin.
4. Remove the plugs from the cylinder ports and the
hydraulic hoses. Connect the hoses to the correct ports.
5. Check the hydraulic level. Remove the blocks from
the wheels. Connect the battery.
6. Rotate the steering wheel so the power cylinder is in
the fully closed position. Measure the distance between
the face of the cylinder to the rod end. This dimension
should be 74 mm (2.9 in). Adjust the rod end if neces-
sary to obtain this dimension.
Disassembly
NOTE: The disassembly of the power steering cylin-
der should be carried out in a clean, dust free area. Use a
drip tray to catch any hydraulic oil remaining in the cyl-
inder.
1. Place the cylinder body in a soft-jawed vise. Re-
move the rod end and the locknut from the piston rod.
2. Use a spanner wrench to remove the end head.
3. Remove the piston, piston rod, spacer, packing, O-
ring and wiper from the cylinder.
4. Place the piston rod in a soft-jawed vise, taking care
not to damage the threads or chrome plated area of the
piston rod. Remove the nut retaining the piston on the
rod. Remove the piston and packing.
5. Removethespacer,O-ring,wiperandpackingfrom
the end head and piston.
WARNING
Cleaning solvents can be flammable and toxic, and
cancauseskinirritation.WearprotectionwhenhanĆ
dling solvents and always follow the recommendaĆ
tions of the manufacturer.
6. Clean all metal components in a suitable solvent.
7. Examine the all the components for grooving or
scoring. Replace all defective components. If the piston
rod and cylinder body are damaged, replace the com-
plete cylinder assembly. Replace all O-rings, packing
and wipers.

15. 13
Assembly
NOTE: Coat all components with clean hydraulic oil
before assembly.
1. Install the new wiper, packing and O-ring in the end
head. Install new packing in the piston. Assemble the
end head, spacer and piston on the piston rod. Place the
piston rod in a soft-jawed vise, taking care not to dam-
age the threads or chrome plated area of the piston rod.
Tighten the nut to 150 NSm (110 lbf ft).
2. Install the piston rod assembly into the cylinder
body. Tighten the end head to 163 to 176 NSm (120 to
130 lbf ft).
3. Install the power steering cylinder in the truck.
CHECKS AND ADJUSTMENTS
AIR IN THE STEERING SYSTEM
If there is air in the hydraulic lines of the steering sys-
tem, the operation will not be smooth. Rotate the steer-
ing wheel from stop to stop several times to remove the
air from the steering system. If the air can not be re-
moved from the steering system, check for leaks at the
power steering pump. Check for a loose fitting or a leak
at the inlet connection. If the O–ring or the oil seal be-
tween the power steering motor and the pump has a de-
fect, air will enter the hydraulic system.
Check The Operation
The purpose of this check is to make sure the steering
trunnion turns the correct degrees of its rotation (ap-
proximately 180 degrees). Put the lift truck on blocks so
that the weight of the lift truck is removed from the
steering trunnion.
Operate the power steering system. Rotate the trunnion
to its stop in one direction, then rotate the trunnion to its
stop in the other direction. Check that the steering
smoothly turns the trunnion. The face of the wheel is ap-
proximately parallel to the frame plate at the back of the
battery compartment when the steering trunnion is ro-
tated fully in each direction to its stops.
To check the operation of the printed circuit card that
controls the steering, see the section ELECTRICAL
SYSTEM 2200 SRM 577.
Steering Pressure
NOTE: The correct relief valve pressure for J30, J35
and J40XMT lift trucks is 9.1 MPa (1300 psi).
1. Install a pressure gauge in the power steering pump
discharge line (between the pump and the steering con-
trol unit).
2. Operate the steering pump and rotate the steering
wheel so that relief valve operates. Check that the maxi-
mum pressure is 9.1 MPa (1300 psi).
3. If the pressure is greater or less than 9.1 MPa (1300
psi), adjust the relief valve. If the pressure can not be ad-
justed correctly, change the power steering pump.
4. When the pressure checks are complete, remove the
pressure gauge.