This document provides repair procedures and descriptions for a steering axle assembly. It describes the main components of the steering axle, including the axle frame, steering cylinder, spindle assemblies, and wheel hubs. Safety warnings are provided for putting the lift truck on blocks before performing maintenance or repairs. Estimates are given for the weight of different lift truck models on the steering axle to help determine the lifting capacity needed. Torque specifications are also listed for various fasteners on the steering axle, steering cylinder, hydraulic pump, and other components.

1. SERVICE REPAIR
S25XL S30XL S35XL [B010]

2. 11
LIFT TRUCK WEIGHTS*
S1.25XL (S25XL) 2480 5466
UNIT kg lb
S1.50XL (S30XL) 2670 5890
S1.75XL (S35XL) 2850 6285
*Lift trucks equipped with overhead guard,
3264 mm (128.5 in) mast, 1219 mm (48 in)
forks, carriage, load backrest extension,
gasoline engine and operator.
H1.25XL (H25XL) 2530 5570
H1.50XL (H30XL) 2700 5950
H1.75XL (H35XL) 2895 6385
ITEM
CAPACITIES
QUANTITY
ENGINE OIL with Filter
COOLING SYSTEM
HYDRAULIC TANK
TRANSMISSION
DIFFERENTIAL
5.2 litre (5.5 qt)
5.2 litre (5.5 qt)
9.0 litre (9.5 qt)
FUEL TANK
BRAKE FLUID 0.2 litre (0.5 pt)
8.2 litre (6.8 qt)
26.0 litre (6.9 gal)
Mazda M4–121G
Isuzu C240
Mazda M4–121G
Isuzu C240
43.5 litre (11.5 gal)
7.8 litre (8.2 qt)
8.1 litre (8.6 qt)
HYDRAULIC SYSTEM
22.7 litre (6.0 gal)
LIFTING
LOWERING
UNIT
RATED LOADNO LOAD NO LOAD RATED LOAD
m/sec ft/min m/sec ft/min m/sec ft/min
.51 100 .44 87
.45 87 .39 77
m/sec
.43 85 .41 81
.38 75 .36 71
MAST SPEEDS
S/H1.25XL
(S/H25XL)
VISTA
TWO–STAGE
VISTA
FREE–LIFT
VISTA
THREE–STAGE
S/H1.50XL
(S/H30XL)
S/H1.75XL
(S/H35XL)
ft/min
All Units
m/sec
.59 116
.51 100
ft/min m/sec
.59 116
.51 100
ft/min
.47 .40 .39 .38 .54 .5493 79 77 77 106106
ELECTRICAL SYSTEM
ITEM ISUZU C240MAZDA M4–121G
All Models
Alternator Output
Hot
Ignition System
Point Setting
Spark Plugs
Type
Gap
35Amps @ 2600 rpm
0.4 to 0.5 mm
(0.016 to 0.020 in)
Later Units, N/A1
NGK BP–2E or
ND W9EPR
0.7 to 0.8 mm
(0.028 to 0.032 in)
N/A = Not Applicable
12 volt,
Negative Ground
12 volt,
Negative Ground
1 Electronic Ignition System
37 Amps @ 2600 rpm
N/A
N/A

3. 2
NOTES:
For HYSTER transmissions only.
All pressures are measured at 2000 rpm with oil temperature
at 50°C (130°F).
The difference in the Forward and Reverse clutch pressures
must not be more than 70 kPa (10 psi).
1. TEST PORT 1 – PRESSURE FROM TRANSMISSION
PUMP
2. TEST PORT 2 – PRESSURE TO FORWARD CLUTCH
3. TEST PORT 3 – PRESSURE TO REVERSE CLUTCH
4. TEST PORT 4 – OIL PRESSURE TO TORQUE
CONVERTER
5. TEST PORT 5 – OIL PRESSURE FROM OIL COOLER
6. TEST PORT 6 – MODULATOR PRESSURE
kPa
(psi)
965 to 1170
(140 to 170)
724 to 860
(105 to 125)
724 to 860
(105 to 125)
724 to 860
(105 to 125)
105 to 175
(15 to 25)
PORT 6
Modulator
Pressure
PORT 5
Lubrication
Pressure
PORT 4
Torque
Converter
PORT 3
Reverse
Clutch
PORT 2
Forward
Clutch
PORT 1
Transmission
Pump
Pressure
Variation
Pressure
4
1
6 3*
5*
2
TRANSMISSION PRESSURES
*On some T43 transmissions and on T42 transmissions before
serial number T42M 3040 (and one unit T42M 3068) test ports
3 and 5 are reversed.
NOTES:
For early (horizontal oil filter) transmissions only.
All pressures are measured at 2000 rpm with oil
temperature at 50°C (130°F).
1. TEST PORT 1 – MAIN REGULATOR
2. TEST PORT 2 – TORQUE CONVERTER
REGULATOR
3. TEST PORT 3 – OIL COOLER
4. TEST PORT 4 – FORWARD CLUTCH
PRESSURE
5. TEST PORT 5 – REVERSE CLUTCH
PRESSURE
6. TORQUE CONVERTER REGULATOR
kPa
(psi)
985 to 1103
(140 to 160)
758 to 896
(110 to 130)
345 to 383
(50 to 70)
655 to 793
(95 to 115)
655 to 793
(95 to 115)
PORT 5
Reverse
Clutch
PORT 4
Forward
Clutch
PORT 3
Oil
Cooler In
PORT 2
Torque
Converter
PORT 1
Main
Regulator
Pressure
4
6
2
3
1 5
TRANSMISSION PRESSURES

4. 33
HYDRAULIC SYSTEM
*Oil temperature at 55–65°C (130–150°F).
PUMP TYPE
Controlled Flow
Output to Control Valve @ 2000 rpm
and No Load
LIFT SYSTEM RELIEF PRESSURE*
STEERING SYSTEM RELIEF PRESSURE*
Gear Pump with Flow Control Valve
10.0 ± 1.0 litres/min (2.6 ± 0.26 gal/min)
32.9 litres/min (8.7 gal/min)
15.5 ± 0.35 MPa (2250 ± 50 psi)
11.0 ± 0.40 MPa (1595 ± 58 psi)
LIFT AND STEERING SYSTEM
TIRE PRESSURES
BIAS Ply Tires 93 kPa (115 psi)
RADIAL Ply Tires 1000 kPa (145 psi)
H1.25–1.75XL (H25–35XL)
S1.25–1.75XL
(S25–35XL)
H1.25–1.75XL
(H25–35XL)
MODEL
TRAVEL SPEEDS
FORWARD REVERSE
17.1 km/h
(10.61 mph)
20.9 km/h
(13.0 mph)
17.1 km/h
(10.6 mph)
20.9 km/h
(13.0 mph)
ENGINE SPECIFICATIONS
ENGINE ISUZU C240
450 kPa (65 psi) Min.
@ 3000 rpm
0.3 mm (0.012 in) Hot 0.45 mm (0.018 in) Cold
*Engines with 30 hours of operation or more
MAZDA M4–121G
Number Of Cylinders
Firing Order
Bore And Stroke
Displacement
Compression Ratio
Compression
Pressure
Oil Pressure
Ignition Timing
Idle Speed
Governed Speed
(No Load)
Stall Speed *
Thermostat Range
Cooling System
Pressure
4
1–3–4–2
82 mm x 94 mm
(3.23 in x 3.70 in)
1985 cm3 (121.1 in3)
8.0 :1
1075 kPa (156 psi)
@ 200 rpm
13° BTDC @ 625 rpm
600–650 rpm
2500–2600 rpm
2000–2100 rpm (Gas)
1950–2050 rpm (LPG)
75–78° C (167–172° F)
103 kPa (15psi)
N/A
N/A
390 kPa (57 psi) Min.
@ 1000 rpm
4
1–3–4–2
86 mm x 102 mm
(3.39 in x 4.02 in)
2369 cm3 (144.5 in3)
3040 kPa (441 psi)
@ 200 rpm
500–550 rpm
2500–2600 rpm
2100–2200 rpm
75–78° C (167–172° F)
103 kPa (15psi)
11.95 MPa (1706 psi)
14° BDTC Static
20.0 :1
Valve Clearance
Intake and Exhaust
Fuel Injector Pressure
Fuel Injection Timing
N/A
N/A = Not Applicable

5. 4
TORQUE SPECIFICATIONS
ITEM SPECIFICATION
FRAME
Counterweight Capscrews
Engine Mount to Frame
ENGINE (ISUZU C240)
Cylinder Head Capscrews
Crankshaft Pulley Capscrew
Connecting Rod Cap Capscrews
Flywheel Capscrews
Main Bearing Capscrews
Camshaft Gear Capscrew
Camshaft Thrust Plate Capscrew
Idler Gear Capscrew
ENGINE (MAZDA M4–121G)
Cylinder Head Bolts
Main Bearing Cap
Rod Bearing Cap
Timing Gear Case
Flywheel
Rocker Arm Support
Engine Mount to Engine
320 N.m (235 lbf ft)
53 N.m (39 lbf ft)
78 N.m (58 lbf ft)
167 N.m (123 lbf ft)
81 N.m (60 lbf ft)
108 N.m (80 lbf ft)
160 N.m (120 lbf ft)
108 N.m (80 lbf ft)
19 N.m (14 lbf ft)
26 N.m (19 lbf ft)
88 N.m (65 lbf ft)
81 to 88 N.m (60 to 65 lbf ft)
47 to 52 N.m (35 to 38 lbf ft)
16 to 23 N.m (12 to 17 lbf ft)
58 to 64 N.m (43 to 47 lbf ft)
28 to 41 N.m (21 to 30 lbf ft)
56 N.m (41 lbf ft)
TRANSMISSION
Drive Plate to Torque Converter
Torque Converter Housing to Engine
Differential Housing to Transmission
Torque Converter Housing
to Transmission
3/8 in capscrews
7/16 in capscrews
45 N.m (33 lbf ft)
38 N.m (28 lbf ft)
38 N.m (28 lbf ft)
37 to 43 N.m (27 to 32 lbf ft)
57 to 68 N.m (42 to 50 lbf ft)
DRIVE AXLE
Back Plate to Axle Mount Capscrews
Axle Mount to Frame Bolts and Nuts
Axle Housing to Differential Housing
Wheel Nut Studs
Wheel Nuts
Axle Capscrews (S–Series)
Axle Capscrews (H–Series)
122N.m (90 lbf ft)
325 to 380 N.m (240 to 280 lbf ft
65 N.m (49 lbf ft)
155 N m (115 lbf ft)
155 N.m (115 lbf ft)
155 N.m (115 lbf ft)
20 N.m (15 lbf ft)
STEERING AXLE
Pivot Lock Bolt
Steering Cylinder End Plug
Cylinder Mount Capscrews
King Pin Nuts
Wheel Bearing Nut
Wheel Nuts (H–Series)
66 N.m (50 lbf ft)
407 to 475 N.m (300 to 350 lbf ft
130 N.m (96 lbf ft)
90 N m (66 lbf ft) Initial
34 N.m (25 lbf ft) Final
200 N.m (150 lbf ft) Initial
34 N.m (25 lbf ft) Final
237 to 305 N.m (175 to 225 lbf ft)
BRAKES
Back Plate to Axle Mount
Capscrews 122 N.m (90 lbf ft)

6. 55
TORQUE SPECIFICATIONS
ITEM SPECIFICATION
HYDRAULIC PUMP
Adjustment Screw Acorn Nut
Plug for Relief Valve
Plug for Regulator Valve
Capscrews for Body
28 to 31 N.m (20 to 23 lbf ft)
34 to 39 N.m (25 to 29 lbf ft
59 to 69 N m (43 to 51 lbf ft)
46 to 49 N.m (34 to 36 lbf ft)
HYDRAULIC CONTROL VALVE
Through Bolts
5/16 in
3/8 in
19 N.m (14 lbf ft)
45 N.m (33 lbf ft)
MAST
Mast Hanger to Mast Capscrews
Mast Hanger Cap Capscrews
555 N.m (410 lbf ft)
66 N.m (50 lbf ft)
TILT CYLINDERS
Rod End capscrews 42 N.m (31 lbf ft)

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8. 1
INTRODUCTION
GENERAL
This section has the description and repair procedures
for the steering axle. See the following sections for addi-
tional information on the steering system.
THE STEERING CONTROL UNIT,
1600 SRM 54
THE STEERING CONTROL UNIT,
1600 SRM 257
THE HYDRAULIC SYSTEM AND GEAR
PUMP ASSEMBLY, 1900 SRM 130
DESCRIPTION (See FIGURE 1.)
The steering axle assembly includes an axle frame,
steering cylinder, and two spindle and hub assemblies.
The steering axle is articulated and is connected to the
frame by a center pivot pin. The pivot pin permits the
steering axle to rotate at the frame mount when the lift
truck travels over rough surfaces.
The ends of the piston rod extend from both ends of the
steeringcylindershell.Asinglepistonandthesealarein
the center of the rod. Oil pressure on one side of the pis-
ton moves the piston in the bore. The piston pushes an
equal amount of oil from the opposite side of the cylin-
der.
A relief valve in the hydraulic pump controls the oil
pressure when the piston reaches the end of the stroke.
The tie rods that connect the spindle arms to the cylinder
are not adjustable.
Each spindle turns on two tapered roller bearings. The
spindle and bearings are held in the axle frame by a king
pin. The preload on the bearings is controlled by a nut on
the bottom of the king pin.
The wheel hubs rotate on two tapered roller bearings
and are held on the spindles by a castle nut. The bearing
preload of the wheel hubs is adjusted by the castle nut.
The grease seals protect the bearings from dirt and wa-
ter. Wear sleeves protect the hub from wear by the seals.
1
2 3
45
6
7
8
1. STEERING AXLE
FRAME
2. FRAME MOUNT
3. PIVOT PINS
4. STEERING CYLINDER
5. TIE ROD
6. SPINDLE ASSEMBLY
7. KING PIN
8. WHEEL HUB
12620
FIGURE 1. STEERING AXLE ASSEMBLY

9. 2
REPAIRS
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: upright, drive axle, engine and
transmission, and the counterweight. when the lift
truck is put on blocks, put additional blocks in the
following positions:
a. Before removing the upright and drive axle, put
blocks under the counterweight so that the lift
truck can not fall backward.
b. Before removing the counterweight, put blocks
under the upright assembly so that the lift truck
can not fall 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.
Make sure the lift truck is in a position of stability
before making repairs. Make sure the lifting devices
used during repairs can lift the weight of the parts
and assemblies.
NOTE: Some lift trucks have lifting eyes. These lift
pointscanbeusedtoraisethelifttrucksothatblockscan
be installed.
The following examples are given to help you make an
estimate of the weight that will be lifted.
1. The approximate weight of a lift truck on the steering
axle:
S1.25XL (S25XL) 1315 kg (2900 lb)
S1.50XL (S30XL) 1555 kg (3430 lb)
S1.75XL (S35XL) 1790 kg (3950 lb)
H1.25XL (H25XL)1365 kg (3010 lb)
H1.50XL (H30XL)1575 kg (3470 lb)
H1.75XL (H35XL)1825 kg (4025 lb)
H2.00XL (H40XL)1700 kg (3800 lb)
H2.50XL (H50XL)2080 kg (4600 lb)
H3.00XL (H60XL)2555 kg (5630 lb)
H2.00J (H40J) 1860 kg (4100 lb)
H2.50J (H50J) 2150 kg (4740 lb)
H3.00JS (H60JS) 2700 kg (6000 lb)
2. The weight of a steering axle without wheels is
approximately 95 kg (210 lb).
NOTE: The wheels, hubs, bearings, spindles, cylinder,
and tie rods can be removed with the axle in the lift
truck.
STEERING AXLE
Removal (See FIGURE 2.)
Put the back of the lift truck on blocks. Remove the
counterweight. Disconnect the hydraulic lines and
install caps on the cylinder fittings and the open hydrau-
lic lines. The caps will prevent the spindle from turning
astheaxleisremovedfromunderthelifttruck.Putalift-
ing device under the axle. Remove the bolt that holds the
pivot pin in the frame mount. Remove the pivot pin from
the frame mount. The end of the pivot pin has an M12 x
1.75 threaded hole. Install a threaded puller in the pivot
pin. Pull the pivot pin out of the frame. Use the access
hole in the counterweight if equipped. Lower the axle
from the frame and move the axle from the lift truck.
1
2
3
45
6
1. FRAME MOUNT
2. PIVOT PIN
3. BUSHING
4. STEERING AXLE
5. GREASE FITTING
6. THREADED HOLE (M12 x 1.75)
9670
FIGURE 2. PIVOT ASSEMBLY

10. 3
Installation
Check that the pivot pin bushings are in good condition.
If the bushings are worn or damaged, replace them. Use
a floor jack or another lift truck to lift the steering axle
into the correct position. Align the axle with the frame
mount. Apply grease to the pivot pin for easier installa-
tion. Install the pivot pin and the bolt that holds the pivot
pin in the frame mount. Tighten the bolt to 66 N.m (50
lbf ft). Connect the hydraulic lines. Install the counter-
weight. Remove the air from the system by turning the
steering wheel several times from stop to stop when the
engine is running.
STEERING CYLINDER
Removal (See FIGURE 2.)
Disconnect the hydraulic lines at the steering cylinder.
Rotate the ends of the hydraulic lines away from the
steering cylinder. Disconnect the tie rods at the ends of
the cylinder rod. Remove the capscrews that fasten the
steering cylinder to the axle. Remove the steering cylin-
der from the axle. Make a note of any shim arrangement
under the steering cylinder mounts.
1
2,5
3
3
2,4
2,6
2,5
3
1. STEERING CYLINDER
2. MOUNT BOLTS
STEERING CYLINDER
3. FRAME, STEERING AXLE
4. TIGHTEN TO 130 Nm (96 lb ft)
5. TIGHTEN TO 225 Nm (166 lb ft)
6. TIGHTEN TO 165 Nm (120 lb ft)
EARLY UNITS – 4 BOLT MOUNT
LATE UNITS – 8 BOLT MOUNT LATE UNITS – 4 BOLT MOUNT
1
3
1
3
FIGURE 3. STEERING CYLINDER MOUNT
12639

11. 4
1
2 3
4
5
6
7
8
9
10
FIGURE 4. STEERING CYLINDER
6 7
3 4 5 2 8 9
1
10
1. ROD
2. CYLINDER SHELL
3. END CAP
4. BACK–UP RING
5. O–RING
6. WIPER RING
7. ROD SEAL
8. PISTON
9. PISTON SEAL
10.SQUARE RING
LATE MODELS
EARLY MODELS
9561
12638
Service (See FIGURE 4.)
On early cylinders, use a spanner to remove the end
caps. On later models, pull the end caps from the cylin-
der shell. Repair the cylinder as necessary. Use new
seals and O–rings. Make sure the arrangement of the
seals and O–rings is correct. (See FIGURE 4.) On early
models, tighten the end caps to 407 to 475 N.m (300 to
350 lbf ft).
Installation (See FIGURE 4.)
Install the steering cylinder on the axle. On early units,
install the shims under the bottom steering cylinder
mount from which they were removed. Tighten the
capscrews as shown in FIGURE 4. Connect the tie rods
to the end of the cylinder rod. Connect the hydraulic
lines. Remove air from the hydraulic system. Turn the
steering wheel several times from stop to stop when the
engine is running.
HUBS (See FIGURE 5.)
Removal
Remove the wheels to service the hubs (except for the
“S” series lift trucks). Remove the grease cap in the hub
for access to the bearings. Remove the nut, the outer
bearing assembly, and the hub. Check for damage or
wear on the bearings. If the bearings or the seals are to be
replaced, use a brass driver to remove the inner bearing
assembly from the hub.

12. 5
2 3 4
5
6
7
8
9
10
11
12
13
14
15
17
18
19
20
21
22
23
24
16
9777
19.FRAME
20.TIE ROD
21.BUSHING
22.TIE ROD PIN
23.BELLEVILLE WASHER
24.STUD
FIGURE 5. SPINDLE AND HUB ASSEMBLY
H1.25–1.75XL
(H25–35XL) ONLY
18
1
24
16
15
1. GREASE CUP
2. CASTLE NUT
3. OUTER BEARING
4. HUB
5. INNER BEARING
6. WEAR SLEEVE
7. SEAL
8. SPINDLE
9. PIN
10.KING PIN
11.O–RING
12.SPINDLE SEAL
13.BEARING
14.BEARING CUP
15.SEAL
16.SPACER
17.CASTLE NUT
18.COTTER PIN
Installation
Lubricate the two hub bearings with multi–purpose
grease. Install the seal and the inner bearing in the hub.
Install the hub on the spindle. Install the outer bearing,
washer and nut. Tighten the nut to 200 N.m (150 lbf ft)
while rotating the hub. Loosen the nut until the hub ro-
tates freely. Tighten the nut to 34 N.m (25 lbf ft). Lock
the nut in position with a cotter pin at the first alignment
slot that occurs at approximately 34 N.m (25 lbf ft)
NOTE: On H1.25–1.75XL (H25–35 XL) units, install
the studs with Loctite® and tighten to 30 to 50 N.m (22
to 37 lbf ft).
SPINDLES (See FIGURE 5.)
Removal
Remove the wheels from the steering axle to service the
spindles. Remove the hubs. Disconnect the tie rods from
the spindle. Remove the cotter pin and nut from the bot-
tom of the king pin. Use a driver to remove the king pin.
Remove the sleeve and then the spindle from the axle.
Use a driver to remove the bearings and seals from the
spindle.
NOTE: Dirt and corrosion can make the spacer difficult
to remove from the steering axle frame. A machined
space is put in the top of the spacer so that the spacer can
be removed with a bearing puller.