This is a very practical manual

1. SERVICE REPAIR
J30XMT J35XMT J40XMT [F160]

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 HOUSING AND
STEERING CONTROL UNIT, 1600 SRM 655 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
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.
FIGURE 2 – HYDRAULIC SCHEMATIC
STEER CYLINDER
STEERING
PUMP
STEERING
CONTROL
UNIT
STRAINER
HYDRAULIC TANK
RELIEF
1200 psi
L-PORT R-PORT
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
FIGURE 3 – STEERING COLUMN
1
2
3
4
5
6
7
8
6
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
28
15
20
1
3
4
1. GROMMET
2. FRONT COVER
3. REAR COVER
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
FIGURE 4 – STEERING COLUMN COMPONENTS
21. PIN
22. COTTER PIN
23. CONTACTOR
24. STEER COLUMN
25. CAPSCREW
26. LOCKWASHER
27. WASHER
28. BRACKET
29. STEERING CONTROL UNIT
6. Make an identification of the hydraulic hoses at the
steering control unit so that they can be connected cor-
rectly 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. Straighten the cotter pin
and remove the cotter pin and clevis pin retaining the
latch. If necessary, remove the latch knob from the latch
by removing the two capscrews.

6. 5
POWER STEERING PUMP AND MOTOR
DESCRIPTION
(See FIGURE 6)
The power steering pump and motor is located under the
floor plates on the left side of the truck. The power steer-
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 operator 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 steering control unit 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 cannot 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 (lifts, 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
34
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
pumpandmotor.FollowtheinstructionsinPERIODIC
MAINTENANCE 8000 SRM 528 or the OPERAT-
ING 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 (lifts, 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-
tionsfoundinthesectionTHEDCMOTOR,620SRM
145.
Installation
WARNING
The power steering pump and motor is heavy. Be
sure that all lifting devices (lifts, 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) torque.
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 at re-
moval procedure.
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 0.259
cubic inches displacement while the 36 volt power
steering pump has a 0.323 cubic inches 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 the needle bearings.
6. If necessary, remove the nut, gasket, screw and
springs.
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.

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9. 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 coupling on the drive shaft. Install the
spider in the coupling.
7. 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. OIL SEAL
9. KEY
10. DRIVE SHAFT
11. GASKET
12. COUPLING
13. SPIDER
FIGURE 7 – POWER STEERING PUMP
1
2
3 4 5
5
6
7
8
9
10
11
12
13
4 3
12

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° turning angle. The steer wheel and tire as-
sembly is mounted on a stub axle which is welded to the
vertical member of the steer axle. The steer axle is ro-
tated by a hydraulic steering cylinder. The power steer-
ing 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. Discon-
nect 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 170 NSm (125 lbf ft) torque.
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. LOCKPLATE
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 the section PE-
RIODIC MAINTENANCE, 8000 SRM 584 or the
OPERATING MANUAL for the recommended
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 47 NSm
(35 lbf ft) 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. Carefully remove the clamping bolt and the optical
interrupter.
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. Disassemblethe 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.