Hyster A216 (J50XM2) Forklift Service Repair Manual

SERVICE REPAIR J40XM2 J50XM2 J60XM2 [A216]

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.

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 traction 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)

1. DIFFERENTIAL 2. SPINDLE (AXLE HOUSING)

3. AXLE MOUNT 4. SPEED REDUCER 5. TRACTION MOTOR

3. AXLE MOUNT 4. SPEED REDUCER 5. TRACTION MOTOR

Figure 2. Drive Unit Assembly J2.00-3.20XM (J40-65Z) (A416)

Figure 1. Drive Unit Assembly J2.00-3.20XM (J40-60XM, J40-60XM 2) (A216)

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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 separate 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 counterweight. When the lift truck is put on blocks, put additional blocks in the following positions: a. Before removing the drive axle, put blocks under the counterweight so the lift truck cannot tip backward. b. Before removing the battery or counterweight, put blocks under the mast assembly 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.

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 (removal) 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.

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

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Figure 3. Put Lift Truck on Blocks

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 cylinder, and threaded rod through the alignment pin from the frame side.

Operate the hydraulic cylinder in the

A. REMOVAL

B. INSTALLATION

1. FRAME 2. AXLE MOUNT 3. BOLT

4. SPACER (CUP) 5. ALIGNMENT PIN

direction away from the frame and pull the pin out of (removal) or into (installation) the axle mount and frame members.

6. HYDRAULIC CYLINDER (WITH HOLLOW PISTON)

Figure 5. Axle Mount Arrangement (Method 2)

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Drive Axle, Speed Reducer, and Differential Repair

DISASSEMBLE 1. Remove the axle shafts. See Figure 6 and Figure 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. Remove the axle mounts from the axle housing.

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OIL LEVEL PLUG DRIVE AXLE HOUSING O-RING SPINDLE RH AXLE MOUNT ALIGNMENT PIN

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1400 SRM 575 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 reducer housing to the differential housing. Separate 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.

WASHER ISOLATOR SPACER SPEED REDUCER HOUSING NUTS AND BOLT (MOTOR SUPPORT)

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DC TRACTION MOTOR LH AXLE MOUNT GREASE FITTING BUSHING DIFFERENTIAL HOUSING BREATHER

Figure 6. Drive Unit Parts J2.00-3.20XM (J40-60XM, J40-60XM 2) (A216)

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1400 SRM 575

Drive Axle, Speed Reducer, and Differential Repair

6. Remove the gears, bearings, and shims from the speed reducer housing.

8. Remove the drive gear from the differential case.

See Figure 8. If necessary, disassemble the differential. See Figure 9.

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.

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OIL LEVEL PLUG DRIVE AXLE HOUSING O-RING SPINDLE RH AXLE MOUNT ALIGNMENT PIN WASHER ISOLATOR SPACER

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SPEED REDUCER HOUSING NUTS AND BOLT (MOTOR SUPPORT) AC TRACTION MOTOR LH AXLE MOUNT GREASE FITTING BUSHING DIFFERENTIAL HOUSING BREATHER

Figure 7. Drive Unit Parts J2.00-3.20XM (J40-65Z) (A416)

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Drive Axle, Speed Reducer, and Differential Repair

CLEAN WARNING Always wear safety glasses.

Cleaning solvents may be flammable and toxic and can cause severe skin irritation. When using cleaning solvents, always comply with the solvent manufacturer’s recommended safety precautions.

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DRIVE GEAR DIFFERENTIAL DIFFERENTIAL BEARING CAP ADJUSTMENT NUT CAPSCREW AND LOCK PLATE 6. SPEED REDUCER HOUSING

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1400 SRM 575 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 solvent. Dry the parts with compressed air.

BEARING CUP BEARING CONE CLUSTER GEAR SHIMS BEARING CAP O-RING REDUCTION GEAR

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PINION ALIGNMENT PIN DIFFERENTIAL HOUSING EXPANSION PLUG LOCK NUT LOCK RING BEARING LOCK NUT

Figure 8. Speed Reducer and Differential Assembly

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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. Inspect the cross for wear where the gears turn.

The cross and the holes for the cross in the differential case must fit tightly.

2. Inspect the bearings and bearing surfaces for damage.

3. The mounts must turn freely on the axle housing. The splines for the axle shafts must not be damaged.

(82 lbf ft). Make sure the drive gear is in the correct 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 Figure 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 differential 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. 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 differential 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 hardened washers. Tighten the capscrews to 111 N•m

1. SIDE GEAR 2. THRUST WASHER 3. DIFFERENTIAL CASE Figure 10. Install Side Gear and Thrust Washer

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Drive Axle, Speed Reducer, and Differential Repair

1400 SRM 575 8. Install the two bearing adjustment nuts into position 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).

1. SPIDER, DIFFERENTIAL PINIONS, AND THRUST WASHERS Figure 11. Spider (Cross), Pinions, and Thrust Washers Installation

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 differential housing. Apply a bead of sealant (Loctite® 515 or equivalent) to the flange of the differential housing. Install the speed reducer housing to the differential housing. Tighten the capscrews to 52 N•m (38 lbf ft).

1. DIFFERENTIAL CASE 2. ALIGNMENT MARKS Figure 12. Second Half of Differential Case Installation

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).

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 lubricant on the outer diameter of the bearing cups or the bearing bores of the housing.

14. Install the bearings and the cluster gear and pinion 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 capscrews to 38 N•m (28 lbf ft).

7. Install the differential assembly into the housing. The bearing cups must fit correctly into the bores of the housing.

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

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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 average of the three measurements. Add 0.15 mm (0.006 in.) to the average measurement. Subtract this dimension from 2.54 mm (0.100 in.) to

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BEARING CAP PINION SPEED REDUCER HOUSING CLUSTER GEAR O-RING BEARING CUP (ALIGNMENT)

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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.

REDUCTION GEAR BEARING LOCK NUT LOCK RING LOCK NUT EXPANSION PLUG ADJUSTMENT NUT

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DIFFERENTIAL BEARING CAP DIFFERENTIAL DRIVE GEAR BEARING CUP SHIMS

Figure 13. Speed Reducer and Differential 17. Apply a bead of sealant (Loctite 515 or equivalent) 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).

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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 reducer.

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 NeverSeez 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).

1. BEARING CAP 2. ALIGNMENT MARKS Figure 14. Bearing Caps Installation

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.

Figure 15. New O-Rings Installation 21. Align the holes in the speed reducer and the motor 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

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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 until 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.

1400 SRM 575

Torque Specifications 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 described 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 differential housing with SAE 90 EP gear oil through the fill hole until the oil level is even with the bottom of the fill hole. Install the plug.

Figure 16. Lock Plate Installation 6. Apply a bead of sealant (Loctite 515 or equivalent) on the flange of the axle shaft. Install the axle shafts and capscrews. Tighten the capscrews to 98 N•m (72 lbf ft).

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 Differential Bearings 95 to 110 N•m (70 to 81 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 Differential 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)

Bearing Cap Capscrews for Speed Reducer 19 N•m (14 lbf ft) Differential Case Halves 50 N•m (37 lbf ft)

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Troubleshooting

1400 SRM 575

Troubleshooting PROBLEM The lift truck will not move.

The drive axle has leaks.

The drive axle makes noise.

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POSSIBLE CAUSE

PROCEDURE OR ACTION

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 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 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 torque.

Speed reducer gears are damaged.

Install new gears.

capscrews

to

specified

1600 SRM 485

General

General There are two different steering systems available: Power Steering and Power Steering with On-Demand. The difference in the components for each system can be found in Figure 1 and Figure 2. This section covers the description, disassembly, assembly, 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.

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 assembly of the steering control unit used in the A1.001.50XL (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 control unit are not used.

Additional information for the components of the steering system is found in the Master Drive Unit

A. THREE WHEEL UNITS

B. MANY FOUR WHEEL UNITS

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STEERING WHEEL OPTICAL ENCODER ACTIVATOR STEERING CONTROL UNIT STEERING PUMP MOTOR STEERING PUMP PRESSURE SWITCH [EXCEPT A1.00-1.50XL (A20-30XL)]

HYDRAULIC STEERING MOTOR STEERING CHAIN MASTER DRIVE UNIT STEERING CYLINDER STEERING AXLE FROM TANK TO TANK

*E3.50-5.50XL (E70-120XL, E70-120XL 3) ONLY. #POWER STEERING WITH ON-DEMAND ONLY. Figure 1. Power Steering Components

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General

1600 SRM 485

Figure 2. Power Steering Components E1.50-2.00XMS (E25-40XMS, E25-40XM 2S)

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1600 SRM 485

Description Legend for Figure 2

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6. PRESSURE SWITCH (ON-DEMAND STEERING ONLY) 7. RETURN TO HYDRAULIC TANK 8. FROM HYDRAULIC TANK 9. MOUNT FOR STEERING MOTOR

STEERING CYLINDER TO STEERING CONTROL UNIT PRESSURE CHECK FITTING PUMP MOTOR STEERING PUMP

Description The steering system used on these lift trucks is a hydraulic system that does not have a mechanical 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 steering 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.

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MOTOR STEERING PUMP PRESSURE TEST PORT STEERING CONTROL UNIT STEERING WHEEL

When the steering wheel is rotated to steer the lift truck, the hydraulic oil is routed to the steering motor 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.

STEERING CYLINDER OR MOTOR PRESSURE TEST PORT* HYDRAULIC TANK FILTER

*PRESSURE SWITCH FOR ON-DEMAND STEERING OPTION ONLY. REPLACES CHECK PORT. Figure 3. Steering System Hydraulic Schematic

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Steering Wheel and Column Assembly Repair 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 completes 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 steering control unit is also operated by the steering wheel to direct oil to the steering cylinder or hydraulic 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 optical 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 activator assembly. The activator assembly completes

1600 SRM 485 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 linkage 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 possible.

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 engage 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 position 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 clearance 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.

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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 components 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 CONNECT 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. Remove key switch. Make an identification of the electrical wires and disconnect them from the key switch.

1600 SRM 485

Steering Wheel and Column Assembly Repair

Figure 4. Steering Wheel and Steering Column Assembly (Early XL Units)

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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

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TRUCK WIRE HARNESS SNAP RING PLASTIC TUBE PIN STEERING SHAFT SOCKET HEAD SCREW KEY SWITCH CLAMP BRACKET STEERING CONTROL UNIT

3. Remove the instrument display panel or instrument display meters and gauges. Early model lift trucks can have either an instrument display cluster that wraps around the steering column, near the steering wheel, or instrument display meters and gauges that are located on both sides of and near the bottom of the steering column. See the service manual sections Instrument 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. Disconnect 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 steering column. Make an identification of the electrical 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

6

LATCH BRACKET OPTICAL ENCODER AND BRACKET DRIVE GEAR AND SETSCREW ENCODER/ACTIVATOR WIRE HARNESS ACTIVATOR INPUT OUTPUT LEFT TURN RIGHT TURN 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 brackets. 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 identification 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 connected 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 column from the lift truck. Make sure the electrical wires and the hydraulic hoses are not damaged as the steering column is removed.

1600 SRM 485

Steering Wheel and Column Assembly Repair

NOTE: PETRI STEERING WHEEL SHOWN. 1.

2.

3.

4.

5.

6.

7.

8.

9.

LATCH PIVOT PIN COTTER PIN BRACKET HORN SWITCH PIN PUSH ROD INTERNAL SNAP RING STEERING WHEEL NUT LOCK RING

10.

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SOCKET HEAD SCREW ADJUSTER SPOOL NUT HORN COVER BASE PLATE STEERING WHEEL EXTERNAL SNAP RING BEARING STEERING SHAFT PLASTIC TUBE

19.

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PLASTIC WASHER SPRING BRACKET STEERING CONTROL UNIT STEERING COLUMN LATCH SOCKET HEAD SCREW

Figure 5. Steering Wheel and Steering Column Assembly (Later XL Units)

7

Steering Wheel and Column Assembly Repair

1600 SRM 485

Figure 6. Steering Wheel and Steering Column Assembly (Early Model XM Units)

8

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.

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18.

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22.

11. Remove the steering shaft as follows:

1. Install the steering column on the cowl mounts.

Lubricate the pivots with multipurpose grease and install the capscrews into the housing.

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 engages 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 return spring, washer, and tube are removed at the same time as the steering shaft and bearing are removed. Use a small pry bar at the bottom of the steering shaft near the steering 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 steering control unit and the bracket to the steering column. Remove the four capscrews or nuts that fasten the steering control unit to the bracket.

PLATE ALLEN HEAD CAPSCREW PIVOT SHAFT RETURN SPRING FRONT COVER BRACKET OPTICAL ENCODER AND BRACKET DRIVE GEAR AND SETSCREW ENCODER/ACTIVATOR WIRE HARNESS ACTIVATOR (UNDER INSTRUMENT PANEL TO LEFT OF STEERING COLUMN) 23. TRUCK WIRE HARNESS 24. LATCH

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.

ASSEMBLY COMPONENTS, INSTALL

5. If removed, install the wires on the key switch as identified during removal. Install the key switch.

NOTE: This procedure is for the installation of all components of the steering column assembly. Usually it is not necessary to install all of the components. Do only those steps of the procedure necessary to install the component you need to install.

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

Steering Wheel and Column Assembly Repair

1600 SRM 485

Figure 7. Steering Wheel and Steering Column Assembly (Later Model XM Units)

10

1600 SRM 485

Steering Wheel and Column Assembly Repair Legend for Figure 7

1.

2.

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4.

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6.

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ON-DEMAND STEERING COMPONENTS FRONT COVER BRACKET PIVOT (STEERING) SHAFT PLATE LOCKWASHER CAPSCREW LOCK NUT SCREW STATIC GROUND PATCH REAR COVER COLUMN TILT LEVER PUSH ROD LATCH SPRING WASHER

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.

17.

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COTTER PIN PIN STEERING CONTROL UNIT PLUG (WITHOUT TURN SIGNAL) OPTICAL ENCODER HOUSING AND BRACKET DRIVE GEAR AND SETSCREW OPTICAL ENCODER HORN SYSTEM STEERING WHEEL STEERING COLUMN RETURN SPRING LARGE HEX NUT INPUT RIGHT TURN LEFT TURN RETURN

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 system will not operate as expected. This operation that is not expected can cause damage or personal injury. Connect the hoses as identified during removal.

11. Connect the hydraulic hoses to the steering control unit, the cowl, the control valve, or the steering 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

Power Steering Motor and Pump

1600 SRM 485

Power Steering Motor and Pump DESCRIPTION NOTE: See the section Hydraulic System for your lift truck model for additional information on the power steering pump.

The power steering motor and pump assembly is under the floor plate on all units except the J2.00-3.20XM (J40-60XM, J40-60XM 2), E1.50-2.00XMS (E25-40XMS, E25-40XM 2S), and E3.50-5.50XL (E70-120XL, E70-120XL 3) units. The

E1.50-2.00XMS (E25-40XMS, E25-40XM 2S) and the E3.50-5.50XL (E70-120XL, E70-120XL 3) units have the motor and pump assembly under the battery compartment. The J2.00-3.20XM (J40-60XM, J40-60XM 2) units have the motor and pump assembly mounted behind the battery compartment. The power steering motor and pump operate as described in Description in front part of this manual. See Figure 8, Figure 9, and Figure 10.

A. E1.25-3.00XL (E25-60XL), J2.00-3.00XL (J40-60XL), E2.00-3.20XM (E45-65XM, E45-65XM 2), N30XMH, N30XM 2H AND E3.50-5.50XL (E70-120XL, XL 3 B. A1.00-1.50XL (A20-30XL) 1.

2.

3.

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POWER STEERING MOTOR CLAMP MOUNT AND BRACKET POWER STEERING PUMP LIFT TRUCK FRAME

5. FROM HYDRAULIC TANK 6. TO STEERING CONTROL UNIT 7. STRAP AND MOUNT BRACKET

Figure 8. Power Steering Motor and Pump

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1600 SRM 485

1.

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4.

5.

6.

LIFT TRUCK FRAME STEERING MOTOR STEERING PUMP O-RING MOUNTING BRACKET PRESSURE SWITCH

Power Steering Motor and Pump

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FROM HYDRAULIC TANK TO STEERING CONTROL UNIT PUMP MOUNTING BOLT BRACKET MOUNTING BOLT MOTOR MOUNTING BOLT

Figure 9. Power Steering Motor and Pump J2.00-3.20XM (J40-60XM, J40-60XM 2)

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Power Steering Motor and Pump

1.

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3.

4.

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MOTOR HYDRAULIC PUMP - STEERING WASHER RUBBER BUSHINGS CAPSCREW AND NUT

1600 SRM 485

6.

7.

8.

9.

MOUNT BRACKET FRAME BRACKET MOUNT PIN MOTOR BASE

Figure 10. Power Steering Pump Motor E1.50-2.00XMS (E25-40XMS, E25-40XM 2S)

REMOVE AND DISASSEMBLE, MODELS E1.25-3.00XL (E25-60XL), J2.00-3.00XL (J40-60XL), E2.00-3.20XM (E45-65XM, E45-65XM 2), N30XMH, AND N30XM 2H, NOTE: On some units, the power steering motor must be removed from the mounts on the frame to replace the brushes. Other motors require removal of the end bell to replace the brushes.

1. Disconnect the battery and attach a tag on the truck battery connector, stating DO NOT CONNECT BATTERY. 2. Remove the floor plate.

3. Install identification tags on the power cables and disconnect them from the power steering motor.

4. Attach identification tags on the electrical wires and disconnect them from the pressure switch.

14

5. Put a drain pan under the pump. Install identification tags on the hydraulic hoses and disconnect them from the power steering pump. See Figure 8. Quickly put plugs in the ends of the hoses and the pump ports to keep oil from draining and dirt from entering the system.

6. Remove the two clamp capscrews and nuts, the washers, and the two mounts. Remove the motor, pump, and bracket as an assembly. See Figure 8.

7. Check the motor brushes. See the sections Periodic Maintenance (for your truck model) and DC Motor Maintenance 620 SRM 294 for additional information for inspection of the brushes and commutator.

8. If the motor must be disassembled for cleaning or repairs, remove the pump so that a new oil seal can be installed. Before disassembling the motor, make match marks for alignment on the end plates and the motor housing. These marks are necessary to assemble the motor correctly. To disassemble the motor, see Figure 8, Figure 11, and Figure 12.

1600 SRM 485

1.

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6.

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THROUGH BOLT END PLATE SPRING WASHER BEARING BRUSH HOLDER MOUNT SCREW BRUSH HOLDER ASSEMBLY BRUSH TERMINAL AND WIRE BRUSH SPRING TERMINAL AND WIRE INSULATOR WASHER BUSHING SPACER

Power Steering Motor and Pump

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INSULATOR WASHER WASHER WASHER NUT STATOR COVER GASKET CORE ARMATURE BALL BEARING END PLATE SHAFT SEAL

Figure 11. Power Steering Pump Motor E/J1.50-3.20XM (E/J25-65XM, E/J25-65XM 2), N30XMH and N30XM 2H

15

Power Steering Motor and Pump

Figure 12. Power Steering Pump Motor

16

1600 SRM 485

1600 SRM 485

Power Steering Motor and Pump Legend for Figure 12

A. E1.25-3.00XL (E25-60XL), E3.50-5.50XL (E70-120XL, E70-120XL 3), AND J2.00-3.00XL (J40-60XL) B. A1.00-1.50XL (A20-30XL) 1.

2.

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12.

COUPLING DRIVE END PLATE SEAL RETAINING RING BEARING HOUSING SCREW RETAINING RING MOTOR HOUSING ARMATURE POWER TERMINAL BRUSH BRUSH HOLDER

9. Make a note of the position of the inlet and outlet ports of the pump for correct alignment to the motor during assembly. Remove the capscrews that fasten the pump to the motor and carefully remove the pump. Remove the O-ring at the pump shaft. See Power Steering Pump, Repair to disassemble the pump.

REMOVE AND DISASSEMBLE, MODELS E3.50-5.50XL (E70-120XL, E70-120XL 3) 1. Remove the battery and put the lift truck on blocks as described in the Operating Manual or the section Periodic Maintenance 8000 SRM 291 for E3.50-5.50XL (E70-120XL) models or 8000 SRM 915 for E3.50-5.50XL (E70-120XL 3) models.

2. Install identification tags on the power cables and disconnect them from the pump motor.

3. Attach identification tags on the electrical wires and disconnect them from the pressure switch.

4. Put a drain pan under the pump. Install identification tags on the hydraulic hoses and disconnect them from the power steering pump. Quickly put plugs in the ends of the hoses and the pump ports to keep oil from draining and dirt from entering the system.

13.

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23.

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PLATE NUT BRUSH PLATE COMMUTATOR COVER BEARING DISK COMMUTATOR END PLATE SHIM FAN FAN COVER BRUSH PLATE SCREWS FAN COVER SCREW SPRING WASHER

5. The capscrews for the motor mount are accessible from under the truck. Remove the mount capscrews and the motor and pump as one assembly.

6. Check the motor brushes. See the sections, Periodic Maintenance 8000 SRM 291 for E3.50-5.50XL (E70-120XL) models or 8000 SRM 915 for E3.50-5.50XL (E70-120XL 3) models and DC Motor Maintenance 620 SRM 294 for additional information for inspection of the brushes and commutator.

7. If the motor must be disassembled for cleaning or repairs, remove the pump so that a new oil seal can be installed. Before disassembling the motor, make match marks for alignment on the end plates and the motor housing. These marks are necessary to assemble the motor correctly. To disassemble the motor, see Figure 8 and Figure 12.

8. Make a note of the position of the inlet and outlet ports of the pump for correct alignment to the motor during assembly. Remove the capscrews that fasten the pump to the motor and carefully remove the pump. Remove the O-ring at the pump shaft. See Power Steering Pump, Repair to disassemble the pump.

17

Power Steering Motor and Pump

REMOVE AND DISASSEMBLE, MODELS J2.00-3.20XM (J40-60XM, J40-60XM 2) WARNING Put the lift truck on blocks on a solid, even, and level surface. Make sure the blocks or stands have enough capacity to hold the lift truck. Use additional blocks next to the tires as necessary to prevent movement of the lift truck. Make sure the lifting devices used during repairs can lift the weight of the parts and assemblies.

Completely deflate the tires before removing them from the lift truck. Air pressure in the tires can cause the tire and rim parts to explode causing serious injury or death.

NOTE: The J2.00-3.20XM (J40-60XM, J40-60XM 2) units must be on blocks and a wheel removed to remove the steering motor and pump. Put the lift truck on blocks as described in the Operating Manual or the section Periodic Maintenance 8000 SRM 552.

1. Turn the key to the OFF position and remove the key. Remove the left steer wheel using the following procedure: a. Put the steer axle on blocks so that the tires are raised from the floor b. Remove the grease cap c. Remove the cotter pin and the castle nut d. Remove the outer bearing cone e. Slide the wheel from the spindle f.

Remove the inner bearing cone and the seal from the spindle

2. Remove the fender shield that is located above the steer wheel on the left side.

WARNING Never put tools or other metal objects on the battery. Metal on the battery can cause a short circuit and possible damage or injury.

3. Open the hood and install a cardboard or plywood cover on the top of the battery to prevent accidental short circuits.

4. Remove the cover panel from the left side of the battery.

18

1600 SRM 485 5. Remove the cover from the top of the counterweight.

6. Remove the suction hose at the pump. Quickly put plugs in the end of the hose and the pump port to keep oil from draining and dirt from entering the system.

7. Disconnect the pressure hose from the steering pump. Install a plug at the fitting for the hose and the pump port.

8. If installed, disconnect the electrical plug at the pressure switch on the bottom of the pump.

9. Attach identification tags on the electrical cables.

Disconnect the cables from the pump.

10. Install a sling around the steering pump and motor assembly. Connect a crane to the sling and raise the crane so that it supports the assembly.

The pump and motor assembly weighs approximately 18.5 kg (41 lb) or more.

11. Remove the capscrews that fasten the mounting bracket to the lift truck frame. See Figure 9.

12. Remove the pump and motor as an assembly. Remove the pump from the motor.

13. Check the motor brushes. See the sections Periodic Maintenance 8000 SRM 552 and DC Motor Maintenance 620 SRM 294 for additional information for inspection of the brushes and commutator.

14. If the motor must be disassembled for cleaning or repairs, remove the pump so that a new oil seal can be installed. Before disassembling the motor, make match marks for alignment on the end plates and the motor housing. These marks are necessary to assemble the motor correctly. To disassemble the motor, see Figure 11.

15. Make a note of the position of the inlet and outlet ports of the pump for correct alignment to the motor during assembly. Remove the capscrews that fasten the pump to the motor and carefully remove the pump. Remove the O-ring at the pump shaft. See Power Steering Pump, Repair to disassemble the pump.

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