STEERING AXLE

E2.2-3.5XN (E45-70XN) [A268];

E1.6-2.0XN (E30-40XN) [A269];
J2.2-3.5XN (J45-70XN) [A276];
J1.6-2.0XN (J30-40XN) [A935];
J4.0-5.0XN (J80-100XN) [A970];
E4.0-5.5XN, E5.0XNS (E80-120XN, E100XNS) [A099]

PART NO. 1688872 1600 SRM 1360

 SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• The Service Manuals are updated on a regular basis, but may not reflect recent design changes to the prod-
uct. Updated technical service information may be available from your local authorized Hyster® dealer. Service
Manuals provide general guidelines for maintenance and service and are intended for use by trained and expe-
rienced technicians. Failure to properly maintain equipment or to follow instructions contained in the Service
Manual could result in damage to the products, personal injury, property damage or death.

• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and that the load
being lifted is balanced. Make sure the crane, cables, and chains have the capacity to support the weight of the
load.

• Do not lift heavy parts by hand, use a lifting mechanism.

• Wear safety glasses.

• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift trucks.
Disconnect the battery ground cable on internal combustion lift trucks.

• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT TRUCK ON
BLOCKS in the Operating Manual or the Periodic Maintenance section.

• Keep the unit clean and the working area clean and orderly.

• Use the correct tools for the job.

• Keep the tools clean and in good condition.

• Always use HYSTER APPROVED parts when making repairs. Replacement parts must meet or exceed the
specifications of the original equipment manufacturer.

• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to remove parts.

• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the unit needs
repairs.

• Be sure to follow the WARNING and CAUTION notes in the instructions.

• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are flammable. Be sure
to follow the necessary safety precautions when handling these fuels and when working on these fuel systems.

• Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the area. Make
sure the area is well ventilated.

NOTE: The following symbols and words indicate safety information in this
manual:

WARNING
Indicates a hazardous situation which, if not avoided, could result in
death or serious injury.

CAUTION
Indicates a hazardous situation which, if not avoided, could result in
minor or moderate injury and property damage.

On the lift truck, the WARNING symbol and word are on orange back-
ground. The CAUTION symbol and word are on yellow background.
Steering Axle Table of Contents

TABLE OF CONTENTS

General ............................................................................................................................................................... 1
Steering Axle Assembly Repair......................................................................................................................... 2
Remove E2.2-3.5XN (E45-70XN) (A268), E1.6-2.0XN (E30-40XN) (A269) and E4.0-5.5XN,
E5.0XNS (E80-120XN, E100XNS) (A099) .................................................................................................... 2
Disassemble E2.2-3.5XN (E45-70XN) (A268), E1.6-2.0XN (E30-40XN) (A269) and E4.0-5.5XN,
E5.0XNS (E80-120XN, E100XNS) (A099) .................................................................................................... 4
Clean .............................................................................................................................................................. 7
Inspect ............................................................................................................................................................ 7
Assemble E2.2-3.5XN (E45-70XN) (A268), E1.6-2.0XN (E30-40XN) (A269) and E4.0-5.5XN,
E5.0XNS (E80-120XN, E100XNS) (A099) .................................................................................................... 7
Install E2.2-3.5XN (E45-70XN) (A268) ........................................................................................................ 8
Install E1.6-2.0XN (E30-40XN) (A269) ....................................................................................................... 9
Install E4.0-5.5XN, E5.0XNS (E80-120XN, E100XNS) (A099) ................................................................... 11
Remove J2.2-3.5XN (J45-70XN) (A276) and J4.0-5.0XN (J80-100XN) (A970) .......................................... 12
Disassemble J2.2-3.5XN (J45-70XN) (A276) and J4.0-5.0XN (J80-100XN) (A970)................................... 15
Clean .............................................................................................................................................................. 17
Inspect ............................................................................................................................................................ 17
Assemble J2.2-3.5XN (J45-70XN) (A276) and J4.0-5.0XN (J80-100XN) (A970)........................................ 17
Install J2.2-3.5XN (J45-70XN) (A276) and J4.0-5.0XN (J80-100XN) (A970)............................................. 18
Remove J1.6-2.0XN (J30-40XN) (A935) ....................................................................................................... 22
Disassemble J1.6-2.0XN (J30-40XN) (A935)................................................................................................ 23
Clean .............................................................................................................................................................. 24
Inspect ............................................................................................................................................................ 24
Assemble J1.6-2.0XN (J30-40XN) (A935)..................................................................................................... 24
Install J1.6-2.0XN (J30-40XN) (A935) ......................................................................................................... 25
Tie Rod Replacement ......................................................................................................................................... 26
Remove E2.2-E3.5XN (E45-70XN) (A268) and E4.0-5.5XN, E5.0XNS (E80-120XN, E100XNS)
(A099) ............................................................................................................................................................. 26
Clean .............................................................................................................................................................. 27
Inspect ............................................................................................................................................................ 27
Install E2.2-E3.5XN (E45-70XN) (A268) and E4.0-5.5XN, E5.0XNS (E80-120XN, E100XNS)
(A099) ............................................................................................................................................................. 27
Remove E1.6-2.0XN (E30-40XN) (A269) ...................................................................................................... 27
Clean .............................................................................................................................................................. 28
Inspect ............................................................................................................................................................ 28
Install E1.6-2.0XN (E30-40XN) (A269) ........................................................................................................ 28
Remove J2.0-3.5XN (J45-70XN) (A276) and J4.0-5.0XN (J80-100XN) (A970) .......................................... 29
Clean .............................................................................................................................................................. 29
Inspect ............................................................................................................................................................ 30
Install J2.0-3.5XN (J45-70XN) (A276) and J4.0-5.0XN (J80-100XN) (A970)............................................. 30
Remove J1.6-2.0XN (J30-40XN) (A935) ....................................................................................................... 30
Clean .............................................................................................................................................................. 31
Inspect ............................................................................................................................................................ 31
Install J1.6-2.0XN (J30-40XN) (A935) ......................................................................................................... 31
Spindle Repair.................................................................................................................................................... 31
Remove E2.2-3.5XN (E45-70XN) (A268) and E4.0-5.5XN, E5.0XNS (E80-120XN, E100XNS)
(A099) ............................................................................................................................................................. 31
Disassemble E2.2-3.5XN (E45-70XN) (A268) and E4.0-5.5XN, E5.0XNS (E80-120XN, E100XNS)
(A099) ............................................................................................................................................................. 33
Clean .............................................................................................................................................................. 33
Inspect ............................................................................................................................................................ 33

©2012 HYSTER COMPANY i

Table of Contents Steering Axle

TABLE OF CONTENTS (Continued)

Assemble E2.2-3.5XN (E45-70XN) (A268) and E4.0-5.5XN, E5.0XNS (E80-120XN, E100XNS)
(A099) ............................................................................................................................................................. 33
Install E2.2-3.5XN (E45-70XN) (A268) and E4.0-5.5XN, E5.0XNS (E80-120XN, E100XNS)
(A099) ............................................................................................................................................................. 34
Remove E1.6-2.0XN (E30-40XN) (A269) ...................................................................................................... 35
Disassemble E1.6-2.0XN (E30-40XN) (A269) .............................................................................................. 35
Clean .............................................................................................................................................................. 36
Inspect ............................................................................................................................................................ 36
Assemble E1.6-2.0XN (E30-40XN) (A269) ................................................................................................... 36
Install E1.6-2.0XN (E30-40XN) (A269) ........................................................................................................ 37
Remove J2.2-3.5XN (J45-70XN) (A276) and J4.0-5.0XN (J80-100XN) (A970) .......................................... 37
Disassemble J2.2-3.5XN (J45-70XN) (A276) and J4.0-5.0XN (J80-100XN) (A970)................................... 38
Clean .............................................................................................................................................................. 39
Inspect ............................................................................................................................................................ 39
Assemble J2.2-3.5XN (J45-70XN) (A276) and J4.0-5.0XN (J80-100XN) (A970)........................................ 39
Install J2.2-3.5XN (J45-70XN) (A276) and J4.0-5.0XN (J80-100XN) (A970)............................................. 40
Remove J1.6-2.0XN (J30-40XN) (A935) ....................................................................................................... 41
Disassemble J1.6-2.0XN (J30-40XN) (A935)................................................................................................ 42
Clean .............................................................................................................................................................. 42
Inspect ............................................................................................................................................................ 42
Assemble J1.6-2.0XN (J30-40XN) (A935)..................................................................................................... 43
Install J1.6-2.0XN (J30-40XN) (A935) ......................................................................................................... 43
Steering Cylinder Repair................................................................................................................................... 43
Remove E2.2-E3.5XN (E45XN-70XN) (A268) and J2.2-3.5XN (J45-70XN) (A276) ................................... 43
Disassemble E2.2-E3.5XN (E45XN-70XN) (A268) and J2.2-3.5XN (J45-70XN) (A276) ........................... 45
Clean .............................................................................................................................................................. 46
Inspect ............................................................................................................................................................ 46
Assemble E2.2-E3.5XN (E45XN-70XN) (A268) and J2.2-3.5XN (J45-70XN) (A276) ................................ 46
Install E2.2-E3.5XN (E45XN-70XN) (A268) and J2.2-3.5XN (J45-70XN) (A276) ..................................... 46
Remove E1.6-2.0XN (E30-40XN) (A269) ...................................................................................................... 47
Disassemble E1.6-2.0XN (E30-40XN) (A269) .............................................................................................. 48
Clean .............................................................................................................................................................. 50
Inspect ............................................................................................................................................................ 50
Assemble E1.6-2.0XN (E30-40XN) (A269) ................................................................................................... 50
Install E1.6-2.0XN (E30-40XN) (A269) ........................................................................................................ 50
Remove J1.6-2.0XN (J30-40XN) (A935) ....................................................................................................... 50
Disassemble J1.6-2.0XN (J30-40XN) (A935)................................................................................................ 51
Clean .............................................................................................................................................................. 52
Inspect ............................................................................................................................................................ 52
Assemble J1.6-2.0XN (J30-40XN) (A935)..................................................................................................... 52
Install J1.6-2.0XN (J30-40XN) (A935) ......................................................................................................... 53
Remove J4.0-5.0XN (J80-100XN) (A970) ..................................................................................................... 53
Disassemble J4.0-5.0XN (J80-100XN) (A970).............................................................................................. 54
Clean .............................................................................................................................................................. 55
Inspect ............................................................................................................................................................ 55
Assemble J4.0-5.0XN (J80-100XN) (A970)................................................................................................... 56
Install J4.0-5.0XN (J80-100XN) (A970) ....................................................................................................... 56
Remove E4.0-5.5XN, E5.0XNS (E80-120XN, E100XNS) (A099) ................................................................. 56
Disassemble E4.0-5.5XN, E5.0XNS (E80-120XN, E100XNS) (A099) ......................................................... 58
Clean .............................................................................................................................................................. 59
Inspect ............................................................................................................................................................ 59

ii
Steering Axle Table of Contents

TABLE OF CONTENTS (Continued)

Assemble E4.0-5.5XN, E5.0XNS (E80-120XN, E100XNS) (A099) .............................................................. 59
Install E4.0-5.5XN, E5.0XNS (E80-120XN, E100XNS) (A099) ................................................................... 59

This section is for the following models:

E2.2-3.5XN (E45-70XN) [A268];

E1.6-2.0XN (E30-40XN) [A269];
J2.2-3.5XN (J45-70XN) [A276];
J1.6-2.0XN (J30-40XN) [A935];
J4.0-5.0XN (J80-100XN) [A970];
E4.0-5.5XN, E5.0XNS (E80-120XN, E100XNS) [A099]

iii
"THE
QUALITY
KEEPERS"

HYSTER
APPROVED
PARTS
1600 SRM 1360 General

General
This section has the description and repair proce- in the frame mount when the lift truck travels over
dures for the steering axle. rough surfaces. See Figure 1.

The steering axle assembly includes an axle frame, The end caps of the steering cylinder also serve as
steering cylinder, two spindle assemblies, and two the axle mounts for the cylinder. The piston rod ex-
hub assemblies. The steering axle is articulated and tends from both ends of the cylinder and is connected
is connected to the frame by center pivot mounts. The to the tie rods which are connected to the spindle as-
center pivot mounts permit the steering axle to move semblies.

Figure 1. Steering Axle

1
Steering Axle Assembly Repair 1600 SRM 1360

Legend for Figure 1

NOTE: MOUNTS AND TIRES MAY BE DIFFERENT BETWEEN TRUCK MODELS.

A. CUSHION TRUCKS ONLY B. PNEUMATIC TRUCKS ONLY
1. AXLE FRAME 6. STEERING CYLINDER
2. STEERING DIRECTION SENSOR CABLE 7. TIE ROD
BRACKET 8. SPINDLE ASSEMBLY
3. STEERING DIRECTION SENSOR 9. MOUNT
4. MOUNT 10. CUSHION TIRE WHEEL ASSEMBLY
5. MOUNT BRACKET 11. PNEUMATIC HUB ASSEMBLY

Steering Axle Assembly Repair

REMOVE E2.2-3.5XN (E45-70XN) (A268), the Operating Manual or in one of the following
E1.6-2.0XN (E30-40XN) (A269) AND service manuals:
E4.0-5.5XN, E5.0XNS (E80-120XN, Periodic Maintenance 8000 SRM 1364 for lift
E100XNS) (A099) truck models
• E2.2-3.5XN (E45-70XN) (A268)
WARNING Periodic Maintenance 8000 SRM 1442 for lift
PUTTING THE LIFT TRUCK ON BLOCKS truck models
• E1.6-2.0XN (E30-40XN) (A269)
The lift truck must be put on blocks for some
types of maintenance and repair. The removal Periodic Maintenance 8000 SRM 1577 for lift
of the mast, drive axle, battery, or counter- truck models
weight assemblies will cause large changes • E4.0-5.5XN, E5.0XNS (E80-120XN, E100XNS)
in the center of gravity. When the lift truck (A099)
is put on blocks, put additional blocks in the
following positions: 2. Slide floor jack under steering axle. Raise floor
• If the mast and drive axle are removed, put jack until it holds the weight of the axle assembly.
blocks under the counterweight so the lift
truck cannot fall backward. NOTE: Tag hydraulic lines prior to disconnecting
• If the counterweight is removed, put blocks from steering cylinder to aid in the correct connec-
under the mast so that the lift truck cannot tion of hydraulic lines during installation.
fall forward.
3. Disconnect hydraulic hoses at steering cylinder.
Put the lift truck on blocks on a solid, even, and Install plug fittings in cylinder and put caps on
level surface. Verify the blocks or stands have hydraulic hoses. Plug fittings will prevent spin-
enough capacity to hold the lift truck. Use ad- dles from turning as axle is removed from under
ditional blocks next to the tires as necessary to the lift truck.
prevent movement of the lift truck. Verify the
4. Remove four capscrews that fasten the mount
lifting devices used during repairs can lift the
brackets under the rubber mounts.
weight of the parts and assemblies.
See Figure 2 for lift truck models
See the Operating Manual or Periodic Mainte-
• E2.2-3.5XN (E45-70XN) (A268)
nance section for your lift truck model, for the
procedures to put the lift truck on blocks. See Figure 3 for lift truck models
• E1.6-2.0XN (E30-40XN) (A269)
The steering axle can be removed without removing
the counterweight. See Figure 4 for lift truck models
• E4.0-5.5XN, E5.0XNS (E80-120XN, E100XNS)
1. Place the lift trucks on blocks. The procedure for
(A099)
placing the lift truck on blocks may be found in

2
1600 SRM 1360 Steering Axle Assembly Repair

1. CAPSCREW 5. STEER AXLE

2. WASHER 6. FRONT MOUNT
1. CAPSCREW 5. STEER AXLE 3. NUT BRACKET
2. WASHER 6. FRONT MOUNT 4. REAR MOUNT
3. NUT BRACKET BRACKET
4. REAR MOUNT
BRACKET Figure 4. Steer Axle Removal E4.0-5.5XN,
E5.0XNS (E80-120XN, E100XNS) (A099)
Figure 2. Steer Axle Removal E2.2-3.5XN
(E45-70XN) (A268) NOTE: The steering direction sensor is an op-
tional feature on E2.2-3.5XN (E45-70XN) (A268),
E1.6-2.0XN (E30-40XN) (A269) and E4.0-5.5XN,
E5.0XNS (E80-120XN, E100XNS) (A099) lift trucks.

5. Carefully lower the floor jack enough to discon-

nect, if installed, steering direction sensor cable
from the main wiring harness.

See Figure 5 for lift truck models

• E2.2-3.5XN (E45-70XN) (A268)

See Figure 6 for lift truck models

• E1.6-2.0XN (E30-40XN) (A269)

See Figure 7 for lift truck models

• E4.0-5.5XN, E5.0XNS (E80-120XN, E100XNS)
(A099)

6. Remove the steer axle from the under the lift

1. CAPSCREW 5. STEER AXLE
2. WASHER 6. FRONT MOUNT truck.
3. NUT BRACKET
4. REAR MOUNT
BRACKET

Figure 3. Steer Axle Removal E1.6-2.0XN

(E30-40XN) (A269)

3
Steering Axle Assembly Repair 1600 SRM 1360

DISASSEMBLE E2.2-3.5XN (E45-70XN) See Figure 5 for lift truck models

(A268), E1.6-2.0XN (E30-40XN) (A269) • E2.2-3.5XN (E45-70XN) (A268)
AND E4.0-5.5XN, E5.0XNS (E80-120XN, See Figure 6 for lift truck models
E100XNS) (A099) • E1.6-2.0XN (E30-40XN) (A269)
1. Place steering axle on blocks so the wheels just See Figure 7 for lift truck models
touch the floor. • E4.0-5.5XN, E5.0XNS (E80-120XN, E100XNS)
(A099)
2. Remove hub cap, cotter pin, castle nut, and
washer. Discard cotter pin.

1. HUB CAP 11. OIL SEAL

2. CASTLE NUT 12. AXLE ASSEMBLY
3. COTTER PIN 13. MOUNT
4. WASHER 14. CAPSCREW
5. OUTER BEARING CONE 15. BRACKET
6. OUTER BEARING CUP 16. WASHER
7. SOLID TIRE WHEEL 17. LOCKNUT
8. INNER BEARING CUP 18. STEERING DIRECTION SENSOR
9. INNER BEARING CONE 19. STEERING DIRECTION SENSOR CABLE
10. WEAR RING BRACKET

Figure 5. Steering Axle Assembly for E2.2-3.5XN (E45-70XN) (A268)

4
1600 SRM 1360 Steering Axle Assembly Repair

1. HUB CAP 9. INNER BEARING CONE

2. CASTLE NUT 10. OIL SEAL
3. COTTER PIN 11. AXLE ASSEMBLY
4. WASHER 12. MOUNT
5. OUTER BEARING CONE 13. CAPSCREW
6. OUTER BEARING CUP 14. BRACKET
7. SOLID TIRE WHEEL 15. WASHER
8. INNER BEARING CUP 16. LOCKNUT

Figure 6. Steering Axle Assembly for E1.6-2.0XN (E30-40XN) (A269)

5
Steering Axle Assembly Repair 1600 SRM 1360

1. HUB CAP 11. OIL SEAL

2. CASTLE NUT 12. AXLE ASSEMBLY
3. COTTER PIN 13. MOUNT
4. WASHER 14. CAPSCREW
5. OUTER BEARING CONE 15. BRACKET
6. OUTER BEARING CUP 16. WASHER
7. SOLID TIRE WHEEL 17. LOCKNUT
8. INNER BEARING CUP 18. STEERING DIRECTION SENSOR
9. INNER BEARING CONE 19. STEERING DIRECTION SENSOR CABLE
10. WEAR RING BRACKET

Figure 7. Steering Axle Assembly for Lift Trucks E4.0-5.5XN, E5.0XNS (E80-120XN, E100XNS) (A099)

NOTE: Identify and tag the outer and inner bearing See Figure 5 for lift truck models
cones so they can be reassembled in their original • E2.2-3.5XN (E45-70XN) (A268)
locations.
See Figure 6 for lift truck models
3. Remove outer bearing cone from the wheel. • E1.6-2.0XN (E30-40XN) (A269)

4. Remove wheel from spindle. See Figure 7 for lift truck models
• E4.0-5.5XN, E5.0XNS (E80-120XN, E100XNS)
NOTE: For correct orientation during installation, (A099)
note the position of the oil seal during removal.
6. Remove the mounts from the axle assembly.
NOTE: The wear ring may not be present on all steer-
ing axles. NOTE: Bearing cones are to be replaced as sets. If
one bearing cone has been determined to be unser-
5. Remove inner bearing cone, wear ring (if present) viceable, then both must be replaced.
and oil seal from spindle.

6
1600 SRM 1360 Steering Axle Assembly Repair

7. If the bearing cones are to be replaced, remove 5. Inspect spindle assemblies and tie rods for signs
the inner and outer bearing cups from the wheel of damage. Replace, if necessary, in accordance
using a brass drift pin. with Spindles, Bearings and Tie Rods Repair.

8. Repeat Step 1 through Step 7 for the other wheel. 6. Inspect the remainder of the axle assembly for
damage, and repair or replace as necessary.
CLEAN
ASSEMBLE E2.2-3.5XN (E45-70XN)
WARNING (A268), E1.6-2.0XN (E30-40XN) (A269)
Cleaning solvents can be flammable and toxic AND E4.0-5.5XN, E5.0XNS (E80-120XN,
and can cause skin irritation. When using E100XNS) (A099)
cleaning solvents, always follow the solvent
manufacturer’s recommended safety proce- 1. If bearing cups have been removed, use a press to
dures. install new bearing cups in wheel. See Figure 8.

WARNING
Compressed air is used for cleaning or drying
purposes, or for clearing restrictions. Wear
protective clothing (goggles/shield, gloves,
etc.) to avoid injury to personnel.

1. Clean bearing cones by placing them in a wire

basket and immersing in a container of fresh sol-
vent. Agitate the bearing cones in the solvent to
remove all traces of old lubricant.

2. Clean all remaining components, except the oil

seals and mounts, with solvent.

3. Clean the oil seals and rubber mounts in warm

soapy water. Rinse with clean warm water and
allow to air dry.

4. After cleaning, dry bearing cones with com-

pressed air. Take care to prevent spinning the
bearing cones when using a compressed air jet.

5. Immediately wrap bearing cones in a lint-free

cloth to protect them from dust and other foreign
matter.

INSPECT
1. WASHER 6. BEARING CUP
1. Inspect bearing cones for burned or damaged 2. HUB CAP 7. SPINDLE
rollers. If either condition exists, replace both 3. COTTER PIN 8. WEAR RING
sets of bearing cones and bearing cups. 4. CASTLE NUT 9. OIL SEAL
5. BEARING CONE
2. Inspect bearing cups for signs of overheating or
Figure 8. Bearing Arrangement for Lift
scoring. If either condition exists, replace both
Truck Models E2.2-3.5XN (E45-70XN) (A268),
sets of bearing cones and bearing cups.
E1.6-2.0XN (E30-40XN) (A269) and E4.0-5.5XN,
3. Inspect the rubber mounts for signs of damage or E5.0XNS (E80-120XN, E100XNS) (A099)
cracking. Replace, if necessary.

4. Inspect the oils seals and wear rings for any dam-
age. Replace, if damaged.

7
Steering Axle Assembly Repair 1600 SRM 1360

2. For specified lubricant see play, reassemble washer and repeat Step a
through Step c.
Periodic Maintenance 8000 SRM 1364 for lift
truck model 6. Install new cotter pin in castle nut. If cotter pin
• E2.2-3.5XN (E45-70XN) (A268) cannot be installed, tighten castle nut to the first
alignment position where the cotter pin can be
Periodic Maintenance 8000 SRM 1442 for lift installed.
truck model
• E1.6-2.0XN (E30-40XN) (A269) 7. Install hub cap.

Periodic Maintenance 8000 SRM 1577 for lift 8. Repeat Step 1 through Step 7 for other wheel.
truck models
• E4.0-5.5XN, E5.0XNS (E80-120XN, E100XNS) NOTE: Perform Step 9 through Step 11 for lift truck
(A099) models
• E4.0-5.5XN, E5.0XNS (E80-120XN, E100XNS)
Verify bearings are filled with grease. (A099)

3. Install oil seal, as noted during removal, wear 9. Install the castle nut as follows:
ring (if removed), and inner bearing cone on spin-
dle. a. Install castle nut and tighten to 203 N•m
(150 lbf ft) while rotating the wheel in both
directions to properly seat the bearings.
CAUTION
DO NOT damage the seals during installation. b. Back off castle nut until wheel turns freely
with no end play. Torque should be less than
4. Carefully slide wheel onto spindle. Install outer 27 N•m (238 lbf in).
bearing cone and install washer.
c. If there is excessive end play, reassemble
NOTE: Ensure that the washer is seated properly washer and repeat Step a and Step b.
against the bearing cone and not against the shaft
shoulder before tightening the castle nut. d. Re-torque castle nut to 34 N•m (25 lbf ft) and
lock in place at first alignment position which
NOTE: Perform Step 5 through Step 8 for lift truck occurs at or above 34 N•m (25 lbf ft).
models
• E2.2-3.5XN (E45-70XN) (A268) e. Install new cotter pin and bend one prong
• E1.6-2.0XN (E30-40XN) (A269) over castle nut. Bend other prong over spin-
dle and cut flush with end of spindle.
5. Install the castle nut as follows:
10. Install hub cap.
a. Install and tighten the castle nut to seat the
bearing, and back off completely. 11. Perform Step 1 through Step 4 and Step 9 and
Step 10 for other wheel.
b. Tighten castle nut to 68 N•m (50 lbf ft) while
rotating the wheel in both directions to prop- INSTALL E2.2-3.5XN (E45-70XN) (A268)
erly seat the bearings.
1. Install rubber mounts and top mount(s) on axle.
c. Loosen the castle nut 1/4 turn. Verify that the face of rubber mount with the
word "TOP" and the arrow (pointing up) is fac-
d. Tighten nut to 3 N•m (27 lbf in).
ing away from the steer axle. See Figure 9.
e. Pull on the wheel assembly to ensure that
there is no end play. If there is excessive end

8
1600 SRM 1360 Steering Axle Assembly Repair

1. CAPSCREW 5. STEER AXLE

2. WASHER 6. FRONT MOUNT
3. NUT BRACKET
4. REAR MOUNT
1. RUBBER MOUNT 3. STEER AXLE BRACKET
2. TOP MOUNT
Figure 10. Steer Axle Installation for Lift
Figure 9. Mount Installation for Lift truck Truck Model E2.2-3.5XN (E45-70XN) (A268)
Model E2.2-3.5XN (E45-70XN) (A268)
6. Remove plugs and caps and connect hydraulic
2. Apply lubricant (that is approved for use with lines to steering cylinder as noted during re-
rubber) to rubber mount. The lubricant is used moval.
to ease assembly of the rubber mounts into lift
truck frame and mount brackets. 7. Remove the floor jack from under the lift truck,
and remove the lift truck from the blocks.
3. Using a floor jack, position the steering axle un-
der the frame. 8. Operate steering system to remove air from sys-
tem. Turn steering wheel several times from one
4. If the lift truck is equipped with the steering di- stop to the other. Check for hydraulic leaks.
rection sensor option, connect steering direction
sensor cable to the main wiring harness. See Fig- INSTALL E1.6-2.0XN (E30-40XN) (A269)
ure 5.
1. Install rubber mounts and top mount(s) on axle.
5. Lift the steer axle into position on the lift truck Verify that the face of rubber mount with the
frame, and install the rear and front mount word "TOP" and the arrow (pointing up) is fac-
brackets, four washers, four capscrews, and four ing away from the steer axle. See Figure 11.
nuts. Tighten capscrews to 90 N•m (66 lbf ft).
See Figure 10.

9
Steering Axle Assembly Repair 1600 SRM 1360

1. RUBBER MOUNT 3. STEER AXLE

2. TOP MOUNT 1. CAPSCREW 5. STEER AXLE
2. WASHER 6. FRONT MOUNT
Figure 11. Mount Installation for Lift Truck 3. NUT BRACKET
4. REAR MOUNT
Model E1.6-2.0XN (E30-40XN) (A269) BRACKET
2. Apply lubricant (that is approved for use with Figure 12. Steer Axle Installation for Lift
rubber), to rubber mount. The lubricant is used Truck Model E1.6-2.0XN (E30-40XN) (A269)
to ease assembly of the rubber mounts into lift
truck frame and mount brackets. 6. Remove plugs and caps and connect hydraulic
lines to steering cylinder as noted during re-
3. Using a floor jack, position the steering axle un- moval.
der the frame.
7. Remove the floor jack from under the lift truck,
4. If the lift truck is equipped with the steering di- and remove the lift truck from the blocks.
rection sensor option, connect steering direction
sensor cable to the main wiring harness. See Fig- 8. Operate steering system to remove air from sys-
ure 6. tem. Turn steering wheel several times from one
stop to the other. Check for hydraulic leaks.
5. Lift the steer axle into position on the lift truck
frame, and install the rear and front mount
brackets, four washers, four capscrews, and four
nuts. Tighten capscrews to 41 to 49 N•m (30.2
to 36.1 lbf ft). See Figure 12.

10
1600 SRM 1360 Steering Axle Assembly Repair

INSTALL E4.0-5.5XN, E5.0XNS (E80-120XN, 5. Lift the steer axle into position on the lift truck
E100XNS) (A099) frame, and install the rear and front mount
brackets, eight washers, four capscrews, and
1. Install rubber mounts and top mount(s) on axle. four nuts. Tighten capscrews to 225 to 280 N•m
Verify that the face of rubber mount with the (166 to 207 lbf ft). See Figure 14.
word "TOP" and the arrow (pointing up) is fac-
ing away from the steer axle. See Figure 13. 6. Remove plugs and caps and connect hydraulic
lines to steering cylinder as noted during re-
2. Apply lubricant (that is approved for use with moval.
rubber) to rubber mount. The lubricant is used
to ease assembly of the rubber mounts into lift 7. Remove the floor jack from under the lift truck,
truck frame and mount brackets. and remove the lift truck from the blocks.

3. Using a floor jack, position the steering axle un- 8. Operate steering system to remove air from sys-
der the frame. tem. Turn steering wheel several times from one
stop to the other. Check for hydraulic leaks.
4. If the lift truck is equipped with the steering di-
rection sensor option, connect steering direction
sensor cable to the main wiring harness. See Fig-
ure 7.

1. CAPSCREW 5. STEER AXLE

2. WASHER 6. FRONT MOUNT
3. NUT BRACKET
4. REAR MOUNT
BRACKET

Figure 14. Steer Axle Installation, Lift Trucks

E4.0-5.5XN, E5.0XNS (E80-120XN, E100XNS)
1. RUBBER MOUNT 6. NUT (A099)
2. TOP MOUNTS 7. FRONT MOUNT
3. REAR MOUNT BRACKET
BRACKET 8. CAPSCREW
4. STEER AXLE
5. WASHER

Figure 13. Mount Installation, Lift Trucks

E4.0-5.5XN, E5.0XNS (E80-120XN, E100XNS)
(A099)

11
Steering Axle Assembly Repair 1600 SRM 1360

REMOVE J2.2-3.5XN (J45-70XN) (A276) Periodic Maintenance 8000 SRM 1372 for lift
AND J4.0-5.0XN (J80-100XN) (A970) truck models
• J2.2-3.5XN (J45-70XN) (A276)

WARNING Periodic Maintenance 8000 SRM 1541 for lift

PUTTING THE LIFT TRUCK ON BLOCKS truck models
• J4.0-5.0XN (J80-100XN) (A970)
The lift truck must be put on blocks for some
types of maintenance and repair. The removal 3. Slide floor jack under steering axle. Raise lifting
of the mast, drive axle, battery, or counter- device until it holds the weight of the axle assem-
weight assemblies will cause large changes bly.
in the center of gravity. When the lift truck
is put on blocks, put additional blocks in the NOTE: Tag hydraulic lines prior to disconnecting
following positions: from steering cylinder to aid in the correct connec-
• If the mast and drive axle are removed, put tion of the hydraulic lines during installation.
blocks under the counterweight so the lift
4. Disconnect hydraulic lines at steering cylinder.
truck cannot fall backward.
Install plug fittings in cylinder and put caps on
• If the counterweight is removed, put blocks
hydraulic lines. Plug fittings will prevent spin-
under the mast so that the lift truck cannot
dles from turning as axle is removed from under
fall forward.
the lift truck.
Put the lift truck on blocks on a solid, even, and
NOTE: Perform Step 5 and Step 6 for lift truck model
level surface. Verify the blocks or stands have
J2.2-3.5XN (J45-70XN) (A276) only.
enough capacity to hold the lift truck. Use ad-
ditional blocks next to the tires as necessary to 5. Remove two lower nuts, capscrews, and washers
prevent movement of the lift truck. Verify the from the battery box and front mount bracket.
lifting devices used during repairs can lift the See Figure 15.
weight of the parts and assemblies.
6. Remove the top capscrew and washer from the
See the Operating Manual or Periodic Mainte- battery box and front mount bracket. See Fig-
nance section for your lift truck model, for the ure 15.
procedures to put the lift truck on blocks.

The steering axle can be removed without removing

the counterweight.

1. Remove the battery from the lift truck. The pro-

cedure for removing the battery may be found in
the Operating Manual or in one of the follow-
ing service manuals:

Periodic Maintenance 8000 SRM 1372 for lift

truck models
• J2.2-3.5XN (J45-70XN) (A276)

Periodic Maintenance 8000 SRM 1541 for lift

truck models 1. CAPSCREW 4. FRONT MOUNT
• J4.0-5.0XN (J80-100XN) (A970) 2. WASHER BRACKET
3. BATTERY 5. NUT
2. Place the lift trucks on blocks. The procedure for COMPARTMENT
placing the lift truck on blocks may be found in
the Operating Manual or in one of the following Figure 15. Steer Axle Replacement J2.2-3.5XN
service manuals: (J45-70XN) (A276)

12
1600 SRM 1360 Steering Axle Assembly Repair

7. Remove two capscrews, washers, and rear mount • J2.2-3.5XN (J45-70XN) (A276)
bracket.
See Figure 17 for lift truck model
See Figure 16 for lift truck model • J4.0-5.0XN (J80-100XN) (A970)

1. WASHER 5. STEER AXLE

2. CAPSCREW 6. PNEUMATIC HUB
3. REAR MOUNT BRACKET 7. RUBBER MOUNTS
4. FRONT MOUNT BRACKET

Figure 16. Steer Axle Removal J2.2-3.5XN (J45-70XN) (A276)

13
Steering Axle Assembly Repair 1600 SRM 1360

Figure 17. Steer Axle Removal J4.0-5.0XN (J80-100XN) (A970)

14
1600 SRM 1360 Steering Axle Assembly Repair

Legend for Figure 17

1. WASHER 5. STEER AXLE
2. CAPSCREW 6. PNEUMATIC HUB
3. REAR MOUNT BRACKET 7. RUBBER MOUNTS
4. FRONT MOUNT BRACKET

NOTE: The front mount bracket may not be able to

be removed until the steering axle is lowered during
Step 9.

8. Remove two capscrews, washers, hydraulic hose

mounting brackets, and front mount bracket
from the counterweight.

See Figure 16 for lift truck models

• J2.2-3.5XN (J45-70XN) (A276)

See Figure 17 for lift truck models

• J4.0-5.0XN (J80-100XN) (A970)

NOTE: The steering direction sensor is standard on

J2.2-3.5XN (J45-70XN) (A276) and J4.0-5.0XN (J80-
100XN) (A970) lift trucks.

9. Carefully lower the floor jack enough to remove

capscrew and cover to disconnect steering direc-
tion sensor cable from the main wiring harness,
and remove the main wiring harness from the NOTE: MAJOR COMPONENTS NOT SHOWN FOR
conduit clip located on the steering axle. See Fig- CLARITY. STEERING DIRECTION SENSOR FOR
ure 18. Install cover and capscrew. Move the LIFT TRUCK MODELS J2.2-3.5XN (J45-70XN) (A276)
steer axle clear of the lift truck. SHOWN. STEERING DIRECTION SENSOR FOR LIFT
TRUCK MODELS J4.0-5.0XN (J80-100XN) (A970) IS
DISASSEMBLE J2.2-3.5XN (J45-70XN) SIMILAR.
(A276) AND J4.0-5.0XN (J80-100XN) (A970) 1. CAPSCREW
2. COVER
1. Place steering axle on blocks so the wheels just 3. MAIN WIRING HARNESS
touch the floor. 4. STEERING DIRECTION SENSOR
5. CONDUIT CLIP
2. Remove six lug nuts and wheel from the pneu- 6. STEERING AXLE
matic hub. See Figure 19.
Figure 18. Main Wiring Harness Disconnect

15
Steering Axle Assembly Repair 1600 SRM 1360

NOTE: STEERING AXLE FOR LIFT TRUCK MODELS J2.2-3.5XN (J45-70XN) (A276) SHOWN. STEERING AXLE
FOR LIFT TRUCK MODELS J4.0-5.0XN (J80-100XN) (A970) IS SIMILAR.
1. HUB CAP 11. MOUNT
2. CASTLE NUT 12. CAPSCREW
3. COTTER PIN 13. BRACKET
4. OUTER BEARING CONE 14. WASHER
5. OUTER BEARING CUP 15. PNEUMATIC HUB
6. INNER BEARING CUP 16. PNEUMATIC TIRE WHEEL
7. INNER BEARING CONE 17. LUG NUTS
8. WEAR RING 18. STEERING DIRECTION SENSOR
9. OIL SEAL 19. STEERING DIRECTION SENSOR CABLE
10. AXLE ASSEMBLY BRACKET

Figure 19. Steering Axle Assemblies for J2.2-3.5XN (J45-70XN) (A276)

3. Remove hub cap, cotter pin, castle nut, and pneu- 5. Remove the inner bearing cone and oil seal from
matic hub from the spindle. Discard cotter pin. the spindle assembly.

NOTE: Identify and tag the outer and inner bearing 6. Remove the mounts from the axle assembly.
cones so they can be reassembled in their original
locations. NOTE: Bearing cones are to be replaced as sets. If
one bearing cone has been determined to be unser-
4. Remove the outer bearing cone from the pneu- viceable, then both must be replaced.
matic hub.
7. If the bearing cones are to be replaced, remove
NOTE: Note the position of the oil seal during re- the inner and outer bearing cups from the pneu-
moval to ensure correct orientation during installa- matic hub using a brass drift pin.
tion.
8. Repeat Step 1 through Step 7 for the other wheel.

16
1600 SRM 1360 Steering Axle Assembly Repair

CLEAN 2. Inspect bearing cups for signs of overheating or

scoring. If either condition exists, replace both
WARNING sets of bearing cones and bearing cups.
Cleaning solvents can be flammable and toxic 3. Inspect the rubber mounts for signs of damage or
and can cause skin irritation. When using cracking. Replace, if necessary.
cleaning solvents, always follow the solvent
manufacturer’s recommended safety proce- 4. Inspect the oils seals and wear rings for any dam-
dures. age. Replace, if damaged.

5. Inspect spindle assemblies and tie rods for signs

WARNING
of damage. Replace, if necessary, in accordance
Compressed air is used for cleaning or drying with Spindles, Bearings and Tie Rods Repair.
purposes, or for clearing restrictions. Wear
protective clothing (goggles/shield, gloves, 6. Inspect the remainder of the axle assembly for
etc.) to avoid injury to personnel. damage, and repair or replace as necessary.
1. Clean bearing cones by placing them in a wire 7. For lift truck models J2.2-3.5XN (J45-70XN)
basket and immersing in a container of fresh sol- (A276) see Frame 100 SRM 1342 for procedures
vent. Agitate the bearing cones in the solvent to to inspect parts of the counterweight and bracket
remove all traces of old lubricant. mounts before installing the steering axle.
2. Clean all remaining components, except the oil ASSEMBLE J2.2-3.5XN (J45-70XN) (A276)
seals and mounts, with solvent.
AND J4.0-5.0XN (J80-100XN) (A970)
3. Clean the oil seals and rubber mounts in warm
1. If bearing cups have been removed, use a press to
soapy water. Rinse with clean warm water and
install new bearing cups in hub. See Figure 20.
allow to air dry.
2. Lubricate bearing cones with multipurpose
4. After cleaning, dry bearing cones with com-
grease.
pressed air. Take care to prevent spinning the
bearing cones when using a compressed air jet. See Periodic Maintenance 8000 SRM 1372 for
lift truck models
5. Immediately wrap bearing cones in a lint-free
• J2.2-3.5XN (J45-70XN) (A276)
cloth to protect them from dust and other foreign
matter. See Periodic Maintenance 8000 SRM 1541 for
lift truck models
6. For lift truck models J2.2-3.5XN (J45-70XN)
• J4.0-5.0XN (J80-100XN) (A970)
(A276) see Frame 100 SRM 1342 for procedures
to clean parts of the counterweight and bracket Verify bearings are filled with grease.
mounts before installing the steering axle.
3. Install oil seal, as noted during removal, and in-
INSPECT ner bearing cone on spindle.

1. Inspect bearing cones for burned or damaged

rollers. If either condition exists, replace both
sets of bearing cones and bearing cups.

17
Steering Axle Assembly Repair 1600 SRM 1360

d. Lock castle nut in place at first alignment

position when new cotter pin can be installed.

e. Install cotter pin in castle nut.

6. Install hub cap.

7. Repeat Step 1 through Step 6 for other wheel.

INSTALL J2.2-3.5XN (J45-70XN) (A276)

AND J4.0-5.0XN (J80-100XN) (A970)
1. Install rubber mounts and top mount(s) on axle.
Verify that the face of rubber mount with the
word "TOP" and the arrow (pointing up) is fac-
ing away from the steer axle.

See Figure 21 for lift truck models

1. SPINDLE 5. CASTLE NUT
2. HUB 6. BEARING CONE • J2.2-3.5XN (J45-70XN) (A276)
3. HUB CAP 7. BEARING CUP
4. COTTER PIN 8. OIL SEAL See Figure 22 for lift truck models
• J4.0-5.0XN (J80-100XN) (A970)
Figure 20. Bearing Arrangement for Lift Truck
Models J2.2-3.5 (J45-70) (A276) and J4.0-5.0XN 2. Apply lubricant, that is approved for use with
(J80-100XN) (A970) rubber, to rubber mount. The lubricant is used
to ease assembly of the rubber mounts into lift
truck frame and mount brackets.
CAUTION
DO NOT damage the seals during installation.

4. Carefully slide hub onto spindle. Install outer

bearing cone and install washer.

NOTE: Ensure that the washer is seated properly

against the bearing cone and not against the shaft
shoulder before tightening the castle nut.

5. Tighten the castle nut as follows:

a. Install the castle nut and tighten to 200 N•m

(147.5 lbf ft) while rotating the wheel in both
directions to properly seat the bearings.

b. Back off the castle nut until wheel turns

freely with no end play. Nut torque should
be less than 15 N•m (133 lbf in).

c. Retorque castle nut to:

1. RUBBER MOUNT 3. STEER AXLE
15 N•m (133 lbf in) for lift truck models 2. TOP MOUNT
• J2.2-3.5XN (J45-70XN) (A276)
Figure 21. Mount Installation for Lift Truck
40 to 60 N•m (30 to 44 lbf ft) for lift truck Model J2.2-3.5XN (J45-70XN) (A276)
models
• J4.0-5.0XN (J80-100XN) (A970)

18
1600 SRM 1360 Steering Axle Assembly Repair

3. Using a floor jack, position the steering axle un-

der the counterweight.

4. Raise the steering axle enough to connect steer-

ing direction sensor cable to the main wiring har-
ness.

5. Install the steering direction sensor cable cover

on the axle, and the main wiring harness into the
conduit clips on the top of the axle. See Figure 19.

6. Lift the steer axle into position on the lift truck

frame, and install the rear mount bracket, two
washers, and two capscrews. Tighten capscrews
to 225 to 280 N•m (166 to 207 lbf ft).

See Figure 23 for lift truck models

• J2.2-3.5XN (J45-70XN) (A276)
1. RUBBER MOUNT 3. STEER AXLE
2. TOP MOUNT See Figure 24 for lift truck models
• J4.0-5.0XN (J80-100XN) (A970)
Figure 22. Mount Installation for Lift Truck
Model J4.0-5.0XN (J80-100XN) (A970)

1. WASHER 5. STEER AXLE

2. CAPSCREW 6. PNEUMATIC HUB
3. REAR MOUNT BRACKET 7. RUBBER MOUNTS
4. FRONT MOUNT BRACKET

Figure 23. Steer Axle Installation for Lift Truck Model J2.2-3.5XN (J45-70XN) (A276)

19
Steering Axle Assembly Repair 1600 SRM 1360

Figure 24. Steer Axle Installation J4.0-5.0XN (J80-100XN) (A970)

20
1600 SRM 1360 Steering Axle Assembly Repair

Legend for Figure 24

1. WASHER 5. STEER AXLE
2. CAPSCREW 6. PNEUMATIC HUB
3. REAR MOUNT BRACKET 7. RUBBER MOUNTS
4. FRONT MOUNT BRACKET

NOTE: Perform Step 7 through Step 10 for lift truck

models J2.2-3.5XN (J45-70XN) (A276).

7. Using a jack, install the front mount bracket be-

tween the battery box and the front mount. In-
stall steering hose brackets, two washers, and
capscrews. Tighten capscrews 225 to 280 N•m
(166 to 207 lbf ft). See Figure 23.

8. From inside the battery box install the top

capscrew and washer. Tighten to 755 N•m
(557 lbf ft). See Figure 25.

9. After the front and rear mount brackets have

been installed, check to be sure there are no gaps 1. CAPSCREW 4. FRONT MOUNT
between the front and rear mount brackets and 2. WASHER BRACKET
the counterweight hexagon surfaces. See Fig- 3. BATTERY 5. NUT
ure 26. COMPARTMENT

Figure 25. Steer Axle Replacement for Lift

Truck Model J2.2-3.5XN (J45-70XN) (A276)

1. CAPSCREW 5. STEERING AXLE

2. WASHER 6. COUNTERWEIGHT
3. HEXAGON SURFACE 7. FRONT MOUNT BRACKET
4. REAR BULKHEAD 8. REAR MOUNT BRACKET

Figure 26. Clearance Between Mounting Brackets

21
Steering Axle Assembly Repair 1600 SRM 1360

10. From inside the battery box install the two lower The steering axle can be removed without removing
capscrews, washers and nuts. Tighten nuts to the counterweight.
755 N•m (557 lbf ft). See Figure 25.
1. Place the lift trucks on blocks. The procedure
NOTE: Perform Step 11 for lift truck models J4.0- for placing the lift truck on blocks may be found
5.0XN (J80-100XN) (A970). in the Operating Manual or Periodic Mainte-
nance 8000 SRM 1373.
11. Using a jack, install two capscrews, washers, hy-
draulic hose mounting brackets, and front mount 2. Slide floor jack under steering axle. Raise floor
bracket to the counterweight. Tighten capscrews jack until it holds the weight of the axle assembly.
225 to 280 N•m (166 to 207 lbf ft). See Figure 24.
3. Disconnect hydraulic hoses at steering cylinder.
12. Remove plugs and caps and connect hydraulic Install plug fittings in cylinder and put caps on
lines to steering cylinder as noted during re- hydraulic hoses. Plug fittings will prevent spin-
moval. dles from turning as axle is removed from under
the lift truck.
13. Remove the floor jack from under the lift truck
and remove the lift truck from the blocks. 4. Remove four capscrews that fasten the mount
brackets under the rubber mounts. See Fig-
14. Operate steering system to remove air from sys- ure 27.
tem. Turn steering wheel several times from one
stop to the other. Check for hydraulic leaks. 5. Carefully lower the floor jack enough to discon-
nect the steering direction sensor cable from the
REMOVE J1.6-2.0XN (J30-40XN) (A935) wiring harness. Remove the steer axle from the
under the lift truck.
WARNING
PUTTING THE LIFT TRUCK ON BLOCKS

The lift truck must be put on blocks for some

types of maintenance and repair. The removal
of the mast, drive axle, battery, or counter-
weight assemblies will cause large changes
in the center of gravity. When the lift truck
is put on blocks, put additional blocks in the
following positions:
• If the mast and drive axle are removed, put
blocks under the counterweight so the lift
truck cannot fall backward.
• If the counterweight is removed, put blocks
under the mast so that the lift truck cannot
fall forward.

Put the lift truck on blocks on a solid, even, and

level surface. Verify the blocks or stands have 1. FLANGE HEAD CAPSCREW
enough capacity to hold the lift truck. Use ad- 2. HYDRAULIC HOSES
ditional blocks next to the tires as necessary to 3. REAR MOUNT BRACKET
4. STEER AXLE
prevent movement of the lift truck. Verify the 5. FRONT MOUNT BRACKET
lifting devices used during repairs can lift the
weight of the parts and assemblies. Figure 27. Steer Axle Removal J1.6-2.0XN
(J30-40XN) (A935)
See the Operating Manual or Periodic Mainte-
nance section for your lift truck model, for the
procedures to put the lift truck on blocks.

22
1600 SRM 1360 Steering Axle Assembly Repair

DISASSEMBLE J1.6-2.0XN (J30-40XN) NOTE: Note the position of the oil seal during re-
(A935) moval to ensure correct orientation during installa-
tion.
1. Place steering axle on blocks so the wheels just
touch the floor. 5. Remove the inner bearing cone and oil seal from
the spindle assembly.
2. Remove five lug nuts and wheel from the hub.
See Figure 28. 6. Remove the mounts from the axle assembly.

3. Remove hub cap, cotter pin, castle nut, washer, NOTE: Bearing cones are to be replaced as sets. If
and hub from the spindle. Discard cotter pin. one bearing cone has been determined to be unser-
viceable, then both must be replaced.
NOTE: Identify and tag the outer and inner bearing
cones so they can be reassembled in their original 7. If the bearing cones are to be replaced, remove
locations. the inner and outer bearing cups from the hub
using a brass drift pin.
4. Remove the outer bearing cone from the hub.

1. LUG NUTS 10. INNER BEARING CUP

2. WHEEL 11. INNER BEARING CONE
3. HUB CAP 12. OIL SEAL
4. CASTLE NUT 13. STEERING DIRECTION SENSOR
5. COTTER PIN 14. AXLE ASSEMBLY
6. WASHER 15. MOUNT
7. OUTER BEARING CONE 16. BRACKET
8. OUTER BEARING CUP 17. FLANGE HEAD CAPSCREW
9. HUB

Figure 28. Steering Axle Assemblies for J1.6-2.0XN (J30-40XN) (A935)

23
Steering Axle Assembly Repair 1600 SRM 1360

8. Repeat Step 1 through Step 7 for the other wheel. 6. Inspect the remainder of the axle assembly for
damage, and repair or replace as necessary.
CLEAN
ASSEMBLE J1.6-2.0XN (J30-40XN) (A935)
WARNING 1. If bearing cups have been removed, use a press to
Cleaning solvents can be flammable and toxic install new bearing cups in hub. See Figure 29.
and can cause skin irritation. When using
cleaning solvents, always follow the solvent 2. Lubricate bearing cones with multipurpose
manufacturer’s recommended safety proce- grease. See Periodic Maintenance 8000 SRM
dures. 1373 for specified lubricant. Verify bearings are
filled with grease.
WARNING
3. Install oil seal, as noted during removal, and in-
Compressed air is used for cleaning or drying ner bearing cone on spindle.
purposes, or for clearing restrictions. Wear
protective clothing (goggles/shield, gloves,
etc.) to avoid injury to personnel. CAUTION
DO NOT damage the seals during installation.
1. Clean bearing cones by placing them in a wire
basket and immersing in a container of fresh sol- 4. Carefully slide hub onto spindle. Install outer
vent. Agitate the bearing cones in the solvent to bearing cone and install washer.
remove all traces of old lubricant.
NOTE: Ensure that the washer is seated properly
2. Clean all remaining components, except the oil against the bearing cone.
seals and mounts, with solvent.
5. Install the castle nut and tighten to 60 N•m
3. Clean the oil seals and rubber mounts in warm (44 lbf ft) while rotating the wheel three times
soapy water. Rinse with clean warm water and in both directions to properly seat the bearings.
allow to air dry. Loosen the castle nut and tighten nut to 20 N•m
(177 lbf in).
4. After cleaning, dry bearing cones with com-
pressed air. Take care to prevent spinning the
bearing cones when using a compressed air jet.

5. Immediately wrap bearing cones in a lint-free

cloth to protect them from dust and other foreign
matter.

INSPECT
1. Inspect bearing cones for burned or damaged
rollers. If either condition exists, replace both
sets of bearing cones and bearing cups.

2. Inspect bearing cups for signs of overheating or

scoring. If either condition exists, replace both
sets of bearing cones and bearing cups.

3. Inspect the rubber mounts for signs of damage or 1. HUB CAP 5. BEARING
2. COTTER PIN 6. HUB
cracking. Replace, if necessary. 3. CASTLE NUT 7. OIL SEAL
4. WASHER 8. SPINDLE
4. Inspect the oils seals and wear rings for any dam-
age. Replace, if damaged. Figure 29. Bearing Arrangement for Lift Truck
Models J1.6-2.0XN (J30-40XN) (A935)
5. Inspect spindle assemblies and tie rods for signs
of damage. Replace, if necessary, in accordance
with Spindles, Bearings and Tie Rods Repair.

24
1600 SRM 1360 Steering Axle Assembly Repair

6. Install new cotter pin in castle nut. If cotter pin 4. Raise the axle enough to connect steering direc-
cannot be installed, tighten castle nut to the first tion sensor cable to the wiring harness.
alignment position where the cotter pin can be
installed. 5. Lift the steer axle into position on the lift truck
frame. Install the rear and front mount brack-
7. Install hub cap. ets, and four flange head capscrews. Tighten cap-
screws to 90 N•m (66 lbf ft). See Figure 31.
8. Repeat Step 1 through Step 7 for other wheel.
6. Remove plugs and caps and connect hydraulic
INSTALL J1.6-2.0XN (J30-40XN) (A935) lines to steering cylinder as noted during re-
moval.
1. Install rubber mounts and top mount(s) on axle.
Verify that the face of rubber mount with the 7. Remove the floor jack from under the lift truck,
word "TOP" and the arrow (pointing up) is fac- and remove the lift truck from the blocks.
ing away from the steer axle. See Figure 30.
8. Operate steering system to remove air from sys-
2. Apply lubricant (that is approved for use with tem. Turn steering wheel several times from one
rubber) to rubber mount. The lubricant is used stop to the other. Check for hydraulic leaks.
to ease assembly of the rubber mounts into lift
truck frame and mount brackets.

3. Using a floor jack, position the steering axle un-

der the frame.

1. FLANGE HEAD CAPSCREW

2. HYDRAULIC HOSES
3. REAR MOUNT BRACKET
4. STEER AXLE
1. RUBBER MOUNT 3. STEER AXLE 5. FRONT MOUNT BRACKET
2. TOP MOUNT
Figure 31. Steer Axle Installation J1.6-2.0XN
Figure 30. Mount Installation for Lift Truck
(J30-40XN) (A935)
Model J1.6-2.0XN (J30-40XN) (A935)

25
Tie Rod Replacement 1600 SRM 1360

Tie Rod Replacement

REMOVE E2.2-E3.5XN (E45-70XN) (A268)
AND E4.0-5.5XN, E5.0XNS (E80-120XN,
E100XNS) (A099)

WARNING
PUTTING THE LIFT TRUCK ON BLOCKS

The lift truck must be put on blocks for some

types of maintenance and repair. The removal
of the mast, drive axle, battery, or counter-
weight assemblies will cause large changes
in the center of gravity. When the lift truck
is put on blocks, put additional blocks in the
following positions:
• If the mast and drive axle are removed, put
blocks under the counterweight so the lift 1. SPINDLE 6. BOOT
ASSEMBLY 7. SNAP RING
truck cannot fall backward. 2. COTTER PIN 8. STEERING
• If the counterweight is removed, put blocks 3. CASTLE NUT CYLINDER ROD
under the mast so that the lift truck cannot 4. TIE ROD 9. PIN
fall forward. 5. CLAMP

Put the lift truck on blocks on a solid, even, and Figure 32. Tie Rod Removal for Lift Truck
level surface. Verify the blocks or stands have Model E2.2-E3.5XN (E45-70XN) (A268) and
enough capacity to hold the lift truck. Use ad- E4.0-5.5XN, E5.0XNS (E80-120XN, E100XNS)
ditional blocks next to the tires as necessary to (A099)
prevent movement of the lift truck. Verify the
NOTE: It may be necessary to use a brass drift pin
lifting devices used during repairs can lift the
to remove the pin connecting the tie rod end to the
weight of the parts and assemblies.
steering cylinder rod.
See the Operating Manual or Periodic Mainte-
4. Remove snap ring and pin connecting the tie rod
nance section for your lift truck model, for the
end to the steering cylinder rod.
procedures to put the lift truck on blocks.
5. Remove cotter pin and castle nut from the tie rod.
1. Place the lift trucks on blocks. The procedure
Discard the cotter pin.
for placing the lift truck on blocks may be found
in the Operating Manual or Periodic Mainte-
nance for your lift truck. CAUTION
DO NOT hit the threads of the tie rod.
2. Remove the wheel and bearings. See Steering
Axle Assembly Repair. 6. Using a puller, remove the tie rod from the spin-
dle assembly.
3. Loosen two clamps and slide boot from the steer-
ing cylinder rod onto the tie rod end. See Fig- 7. If necessary to replace both tie rods, perform
ure 32. Step 1 through Step 6 for the other side of the
steering axle.

26
1600 SRM 1360 Tie Rod Replacement

CLEAN 8. Slide the boot over the tie rod end and steering
cylinder rod. Tighten the clamps on both ends of
CAUTION the boot.
DO NOT use cleaning solvent to clean the tie 9. Install the bearings and wheel. See Steering
rod assembly as it will destroy any rubber com- Axle Assembly Repair.
ponents of the assembly.
10. If the tie rod was removed from the other side,
Clean the tie rod assembly with warm soapy water. repeat Step 1 through Step 9.
Rinse with clear warm water, and air dry completely.
11. Remove the lift truck from blocks.
INSPECT
REMOVE E1.6-2.0XN (E30-40XN) (A269)
Inspect the tie rod assembly for damage (i.e. dam-
aged threads, bent rod etc.). If found to be damaged,
replace the tie rod assembly. WARNING
PUTTING THE LIFT TRUCK ON BLOCKS
INSTALL E2.2-E3.5XN (E45-70XN) (A268)
The lift truck must be put on blocks for some
AND E4.0-5.5XN, E5.0XNS (E80-120XN, types of maintenance and repair. The removal
E100XNS) (A099) of the mast, drive axle, battery, or counter-
weight assemblies will cause large changes
1. Install the tie rod assembly into the spindle as-
in the center of gravity. When the lift truck
sembly. See Figure 32.
is put on blocks, put additional blocks in the
NOTE: Perform Step 2 and Step 3 for lift trucks E2.2- following positions:
E3.5XN (E45-70XN) (A268). • If the mast and drive axle are removed, put
blocks under the counterweight so the lift
2. Install the castle nut onto the tie rod assembly. truck cannot fall backward.
Tighten to 163 N•m (120 lbf ft). See Figure 32. • If the counterweight is removed, put blocks
under the mast so that the lift truck cannot
3. Install new cotter pin in the castle nut. If the fall forward.
cotter pin cannot be installed, tighten the castle
nut to the next position that will allow the cotter Put the lift truck on blocks on a solid, even, and
pin to be installed. Bend one end of the cotter pin level surface. Verify the blocks or stands have
around the castle nut to the left and the other to enough capacity to hold the lift truck. Use ad-
the right. See Figure 32. ditional blocks next to the tires as necessary to
prevent movement of the lift truck. Verify the
NOTE: Perform Step 4 and Step 5 for lift trucks E4.0- lifting devices used during repairs can lift the
5.5XN, E5.0XNS (E80-120XN, E100XNS) (A099). weight of the parts and assemblies.
4. Install the castle nut onto the tie rod assembly. See the Operating Manual or Periodic Mainte-
Tighten castle nut to 163 to 200 N•m (120 to nance section for your lift truck model, for the
148 lbf ft) and advance the castle nut to the next procedures to put the lift truck on blocks.
slot in the nut to install cotter pin.
1. Place the lift trucks on blocks. The procedure
5. Install new cotter pin in castle nut. Bend one end for placing the lift truck on blocks may be found
of the cotter pin around castle nut to the left and in the Operating Manual or Periodic Mainte-
the other to the right. nance Manual for your lift truck.
6. Place the tie rod end into the steering cylinder 2. Remove the wheel and bearings. See Steering
rod end. Axle Assembly Repair
7. Install the pin that connects the tie rod end to the NOTE: It may be necessary to use a brass drift pin
steering cylinder rod, and install the snap ring on to remove the pin connecting the tie rod end to the
the pin. steering cylinder rod.

27
Tie Rod Replacement 1600 SRM 1360

3. Remove two snap rings and pin connecting tie rod CLEAN
end to steering cylinder rod. See Figure 33.

NOTE: It may be necessary to use a brass drift pin CAUTION

to remove the pin connecting tie rod end to spindle DO NOT use cleaning solvent to clean the tie
assembly. rod assembly as it will destroy any rubber com-
ponents of the assembly.
4. Remove two snap rings and pin connecting tie rod
end to spindle assembly. See Figure 33. Clean the tie rod assembly with warm soapy water.
Rinse with clear warm water, and air dry completely.
5. Remove tie rod and four belleville washers from
spindle and steering cylinder rod. See Figure 33. INSPECT
6. If necessary to replace both tie rods, perform Inspect the tie rod assembly for damage (i.e. dam-
Step 1 through Step 5 for the other side of the aged threads, bent rod etc.). If found to be damaged,
steering axle. replace the tie rod assembly.

INSTALL E1.6-2.0XN (E30-40XN) (A269)

1. Install four belleville washers and tie rod on
spindle assembly and steering cylinder rod. Fig-
ure 33.

2. Install pin and two snap rings connecting tie rod

to spindle assembly. See Figure 33.

3. Install pin and two snap rings connecting tie rod

to steering cylinder rod. See Figure 33.

4. Install bearings and wheel. See Steering Axle

Assembly Repair.

5. If the tie rod was removed from the other side,

repeat Step 1 through Step 4.
1. SPINDLE ASSEMBLY
2. SNAP RING 6. Remove the lift truck from blocks.
3. PIN
4. STEERING CYLINDER ROD
5. TIE ROD
6. BELLEVILLE WASHER

Figure 33. Tie Rod Removal for Lift Truck

Model E1.6-2.0XN (E30-40XN) (A269)

28
1600 SRM 1360 Tie Rod Replacement

REMOVE J2.0-3.5XN (J45-70XN) (A276)

AND J4.0-5.0XN (J80-100XN) (A970)

WARNING
PUTTING THE LIFT TRUCK ON BLOCKS

The lift truck must be put on blocks for some

types of maintenance and repair. The removal
of the mast, drive axle, battery, or counter-
weight assemblies will cause large changes
in the center of gravity. When the lift truck
is put on blocks, put additional blocks in the
following positions:
• If the mast and drive axle are removed, put
blocks under the counterweight so the lift
truck cannot fall backward.
• If the counterweight is removed, put blocks
under the mast so that the lift truck cannot
fall forward. NOTE: TIE ROD ASSEMBLY FOR LIFT TRUCK MOD-
ELS J2.2-3.5XN (J45-70XN) (A276) SHOWN. TIE ROD
Put the lift truck on blocks on a solid, even, and ASSEMBLY FOR LIFT TRUCK MODELS J4.0-5.0XN
level surface. Verify the blocks or stands have (J80-100XN) (A970) IS SIMILAR.
enough capacity to hold the lift truck. Use ad-
1. SPINDLE ASSEMBLY
ditional blocks next to the tires as necessary to 2. SNAP RING
prevent movement of the lift truck. Verify the 3. BELLEVILLE WASHER
lifting devices used during repairs can lift the 4. STEERING CYLINDER ROD
weight of the parts and assemblies. 5. PIN

See the Operating Manual or Periodic Mainte- Figure 34. Tie Rod Removal for Lift Truck
nance section for your lift truck model, for the Models J2.2-3.5XN (J45-70XN) (A276) and
procedures to put the lift truck on blocks. J4.0-5.0XN (J80-100XN) (A970)

1. Place the lift trucks on blocks. The procedure 4. Remove the snap ring and pin connecting the tie
for placing the lift truck on blocks may be found rod to the spindle assembly. See Figure 34.
in the Operating Manual or Periodic Mainte-
5. Remove the tie rod and belleville washers from
nance Manual for your lift truck.
the spindle and the steering cylinder rod.
2. Remove the wheel and bearings. See Steering
6. Repeat Step 1 through Step 5 for the other side.
Axle Assembly Repair.

NOTE: It may be necessary to use a brass drift pin CLEAN

to remove the pin connecting the tie rod end to the
steering cylinder rod and the pin connecting the tie CAUTION
rod end to the spindle. DO NOT use cleaning solvent to clean the tie
rod assembly as it will destroy any rubber com-
3. Remove the snap ring and pin connecting the tie
ponents of the assembly.
rod to the steering cylinder rod. See Figure 34.
Clean the tie rod assembly with warm soapy water.
Rinse with clear warm water, and air dry completely.

29
Tie Rod Replacement 1600 SRM 1360

INSPECT 1. Place the lift trucks on blocks. The procedure

for placing the lift truck on blocks may be found
Inspect the tie rod assembly for damage (i.e. bent in the Operating Manual or Periodic Mainte-
rod etc.). If found to be damaged, replace the tie rod nance Manual for your lift truck.
assembly.
2. Remove the wheel and bearings. See Steering
INSTALL J2.0-3.5XN (J45-70XN) (A276) Axle Assembly Repair.
AND J4.0-5.0XN (J80-100XN) (A970)
NOTE: It may be necessary to use a brass drift pin
1. Install the tie rod and belleville washers in the to remove the pin connecting the tie rod end to the
spindle and the steering cylinder rod. See Fig- steering cylinder rod and the pin connecting the tie
ure 34. rod end to the spindle.

2. Install the pin and snap ring connecting the tie 3. Remove the snap ring and pin connecting the tie
rod to the spindle assembly. See Figure 34. rod to the steering cylinder rod. See Figure 35.

3. Install the pin and snap ring connecting the tie 4. Remove the snap ring and pin connecting the tie
rod to the steering cylinder rod. See Figure 34. rod to the spindle assembly. See Figure 35.

4. Install the wheel and bearings. See Steering 5. Remove the tie rod and belleville washers from
Axle Assembly Repair. the spindle and the steering cylinder rod.

5. Repeat Step 1 through Step 4 for the other side. 6. Repeat Step 1 through Step 5 for the other side.

6. Remove the lift truck from blocks.

REMOVE J1.6-2.0XN (J30-40XN) (A935)

WARNING
PUTTING THE LIFT TRUCK ON BLOCKS

The lift truck must be put on blocks for some

types of maintenance and repair. The removal
of the mast, drive axle, battery, or counter-
weight assemblies will cause large changes
in the center of gravity. When the lift truck
is put on blocks, put additional blocks in the
following positions:
• If the mast and drive axle are removed, put
blocks under the counterweight so the lift
truck cannot fall backward.
• If the counterweight is removed, put blocks 1. LUBRICATION FITTING
under the mast so that the lift truck cannot 2. SNAP RING SPINDLE ASSEMBLY
3. STEERING CYLINDER ROD
fall forward. 4. BELLEVILLE WASHER
5. TIE ROD
Put the lift truck on blocks on a solid, even, and 6. PIN
level surface. Verify the blocks or stands have 7. SPINDLE
enough capacity to hold the lift truck. Use ad-
ditional blocks next to the tires as necessary to Figure 35. Tie Rod Removal for Lift Truck
prevent movement of the lift truck. Verify the Model J1.6-2.0XN (J30-40XN) (A935)
lifting devices used during repairs can lift the
weight of the parts and assemblies.

See the Operating Manual or Periodic Mainte-

nance section for your lift truck model, for the
procedures to put the lift truck on blocks.

30
1600 SRM 1360 Spindle Repair

CLEAN INSTALL J1.6-2.0XN (J30-40XN) (A935)

1. Install the tie rod and belleville washers in the
CAUTION spindle and the steering cylinder rod. See Fig-
DO NOT use cleaning solvent to clean the tie ure 35.
rod assembly as it will destroy any rubber com-
ponents of the assembly. 2. Install the pin and snap ring connecting the tie
rod to the spindle assembly. See Figure 35.
Clean the tie rod assembly with warm soapy water.
Rinse with clear warm water, and air dry completely. 3. Install the pin and snap ring connecting the tie
rod to the steering cylinder rod. See Figure 35.
INSPECT
4. Install the wheel and bearings. See Steering
Inspect the tie rod assembly for damage (i.e. bent Axle Assembly Repair.
rod etc.). If found to be damaged, replace the tie rod
assembly. 5. Repeat Step 1 through Step 4 for the other side.

6. Remove the lift truck from blocks.

Spindle Repair
REMOVE E2.2-3.5XN (E45-70XN) (A268) prevent movement of the lift truck. Verify the
AND E4.0-5.5XN, E5.0XNS (E80-120XN, lifting devices used during repairs can lift the
E100XNS) (A099) weight of the parts and assemblies.

See the Operating Manual or Periodic Mainte-

WARNING nance section for your lift truck model, for the
PUTTING THE LIFT TRUCK ON BLOCKS procedures to put the lift truck on blocks.

The lift truck must be put on blocks for some 1. Put the lift truck on blocks.
types of maintenance and repair. The removal
2. Remove the wheel and bearings. See Steering
of the mast, drive axle, battery, or counter-
Axle Assembly Repair.
weight assemblies will cause large changes
in the center of gravity. When the lift truck 3. Disconnect the tie rod from the spindle assembly.
is put on blocks, put additional blocks in the See Tie Rod Replacement.
following positions:
• If the mast and drive axle are removed, put NOTE: Step 4 through Step 8 are to be performed if
blocks under the counterweight so the lift the spindle assembly on the right side is being re-
truck cannot fall backward. paired and the optional steering direction sensor is
• If the counterweight is removed, put blocks installed.
under the mast so that the lift truck cannot
fall forward. NOTE: If the optional steering direction sensor is not
installed, go to Step 9.
Put the lift truck on blocks on a solid, even, and
level surface. Verify the blocks or stands have 4. Remove the capscrew and cover from the steer
enough capacity to hold the lift truck. Use ad- axle. See Figure 36.
ditional blocks next to the tires as necessary to

31
Spindle Repair 1600 SRM 1360

1. CAPSCREW 4. GREASE CAP

2. COVER 5. MAGNET
3. STEERING 6. MAGNET CARRIER
DIRECTION 7. STEER AXLE
SENSOR

Figure 36. Steering Direction Sensor for Lift

Truck Model E2.2-3.5XN (E40-70XN) (A268) and
E4.0-5.5XN, E5.0XNS (E80-120XN, E100XNS)
(A099) 1. SPINDLE LH 7. WEAR RING
2. GREASE CAP 8. SHIMS
5. Disconnect the steering direction sensor wiring 3. STEERING AXLE 9. O-RING
harness from the main wiring harness. 4. BEARING CUP 10. BEARING CAP
5. BEARING CONE 11. LUBRICATION
6. Remove two capscrews and steering direction 6. SEAL FITTING
sensor from the grease cap. 12. CAPSCREWS

7. Remove the grease cap from the steer axle. Figure 37. Spindle Repair E2.2-3.5XN
(E40-70XN) (A268) and E4.0-5.5XN, E5.0XNS
8. Remove the two magnets and magnet carrier (E80-120XN, E100XNS) (A099)
from the steering axle.
NOTE: Note the thickness of the shims during re-
9. Remove grease cap from top of steering axle. See moval to aid in installation.
Figure 37.
10. Remove three capscrews, bearing cap, and shims
from the bottom of the steering axle. See Fig-
ure 37.

11. Tilt the spindle and lift from the steering axle.

12. Remove the wear sleeve from the steering axle.

13. Repeat Step 2, Step 3 and Step 9 through Step 12

for the other spindle.

32
1600 SRM 1360 Spindle Repair

DISASSEMBLE E2.2-3.5XN (E45-70XN) 3. If lower bearing is found to be damaged, remove

(A268) AND E4.0-5.5XN, E5.0XNS the bearing cup from the bearing cap as shown in
(E80-120XN, E100XNS) (A099) Figure 38.

1. Remove and discard O-ring from the bearing cap. 4. Inspect all parts for dents, holes, bends, burrs,
See Figure 37. rust, corrosion, or marred finish.

2. Remove bearing cone, and seal from top of the 5. Replace any damaged parts.
spindle. Discard seal.
ASSEMBLE E2.2-3.5XN (E45-70XN) (A268)
3. Remove bearing cone, and seal from bottom of the AND E4.0-5.5XN, E5.0XNS (E80-120XN,
spindle. Discard seal. E100XNS) (A099)
CLEAN 1. If upper bearing cup was removed, using a press
install new bearing cup into the axle.
WARNING 2. If lower bearing was removed, using a press in-
Cleaning solvents can be flammable and toxic stall new bearing cup in the bearing cap.
and can cause skin irritation. When using
cleaning solvents, always follow the solvent NOTE: Coat all seals and O-rings with multipurpose
manufacturer’s recommended safety proce- grease prior to installation.
dures.
3. Install new seals on the top and bottom of spin-
dle.
WARNING
Compressed air is used for cleaning or drying
purposes, or for clearing restrictions. Wear
protective clothing (goggles/shield, gloves,
etc.) to avoid injury to personnel.

1. Clean bearings by placing them in a wire basket

and immersing in a container of fresh solvent.
Agitate the bearings in the solvent to remove all
traces of old lubricant.

2. After cleaning the bearings, dry them with clean

compressed air. Take care to prevent spinning
the bearings when using a compressed air jet.

3. Immediately wrap bearings in a lint-free cloth to

protect them from dust and other foreign matter.

4. Clean the spindle with solvent and air dry with

compressed air.

5. Clean the wear ring using warm soapy water and

dry with a lint free cloth.

INSPECT
1. Inspect for loose, missing, cracked, burned or
damaged hardware.

2. If upper bearing is found to be damaged, remove

1. PRY BAR 3. BEARING CAP
the bearing cup from the axle using a hammer 2. BEARING CUP 4. O-RING
and brass drift pin.
Figure 38. Bearing Removal

33
Spindle Repair 1600 SRM 1360

4. Pack each bearing cone with multipurpose

grease, and install the bearing cones on top and
bottom of spindle.

INSTALL E2.2-3.5XN (E45-70XN) (A268)

AND E4.0-5.5XN, E5.0XNS (E80-120XN,
E100XNS) (A099)
1. Install wear sleeve into steering axle. See Fig-
ure 37.

2. Tilt the spindle and install the spindle in the

steering axle.

3. Install the bearing cap without the shims. See

Figure 37. Install capscrews and tighten to 22 to
27.5 N•m (16 to 20 lbf ft). Measure the clearance
between the bearing cap and the axle. Remove
the bearing cap and install enough shims to give
a preload of 0.00 to 0.13 mm (0.000 to 0.005 in.).

NOTE: Perform Step 4 for lift truck models 1. CAPSCREW 4. GREASE CAP
E2.2-3.5XN (E45-70XN) (A268). 2. COVER 5. MAGNET
3. STEERING 6. MAGNET CARRIER
4. Install bearing cap and capscrews. Tighten the DIRECTION 7. STEER AXLE
capscrews to 44 to 55 N•m (32 to 41 lbf ft). SENSOR

NOTE: Perform Step 5 for lift truck models Figure 39. Steering Direction Sensor for Lift
E4.0-5.5XN, E5.0XNS (E80-120XN, E100XNS) Truck Model E2.2-3.5XN (E45-70XN) (A268)
(A099).
8. Install grease cap in the steer axle with the notch
5. Coat capscrew threads with Loctite® 242 or toward the grease fitting ±5°.
equivalent. Install bearing cap and capscrews.
Tighten capscrews to 52 N•m (38 lbf ft). 9. Using two capscrews, install steering direction
sensor on grease cap.
NOTE: If the optional steering direction sensor is
not installed, perform Step 6, and Step 12 through 10. Connect steering direction sensor wiring harness
Step 15. to main wiring harness.

NOTE: Step 7 through Step 15 are to be performed 11. Install cover and capscrew on steer axle.
if the spindle assembly on the left side is being re-
12. Connect the tie rod to the spindle assembly. See
paired and the optional steering direction sensor is
Tie Rod Replacement.
installed.
13. Install bearings and wheel. See Steering Axle
6. Install grease cap on the top of the steering axle.
Assembly Repair.
See Figure 37.
14. If required, repeat the procedure for the other
7. Install magnet carrier and two magnets into the
spindle.
steering axle. See Figure 39.
15. Remove the lift truck from the blocks.

34
1600 SRM 1360 Spindle Repair

REMOVE E1.6-2.0XN (E30-40XN) (A269) DISASSEMBLE E1.6-2.0XN (E30-40XN)

(A269)
WARNING 1. Remove and discard seal from bottom of spindle.
PUTTING THE LIFT TRUCK ON BLOCKS See Figure 40.
The lift truck must be put on blocks for some 2. Remove and discard seal from top of spindle. See
types of maintenance and repair. The removal Figure 40.
of the mast, drive axle, battery, or counter-
weight assemblies will cause large changes 3. Remove spacer from top of spindle. See Fig-
in the center of gravity. When the lift truck ure 40.
is put on blocks, put additional blocks in the
following positions: 4. Remove upper and lower bearing cones from
• If the mast and drive axle are removed, put spindle. See Figure 40.
blocks under the counterweight so the lift
5. Remove kingpin from spindle. See Figure 40.
truck cannot fall backward.
• If the counterweight is removed, put blocks
under the mast so that the lift truck cannot
fall forward.

Put the lift truck on blocks on a solid, even, and

level surface. Verify the blocks or stands have
enough capacity to hold the lift truck. Use ad-
ditional blocks next to the tires as necessary to
prevent movement of the lift truck. Verify the
lifting devices used during repairs can lift the
weight of the parts and assemblies.

See the Operating Manual or Periodic Mainte-

nance section for your lift truck model, for the
procedures to put the lift truck on blocks.

1. Put the lift truck on blocks.

2. Remove the wheel and bearings. See Steering

Axle Assembly Repair.

3. Disconnect the tie rod from the spindle assembly.

See Tie Rod Replacement.

4. Remove cotter pin, slotted nut, and sleeve from

spindle. Figure 40.
1. SPINDLE 6. SLEEVE
5. Remove pin from kingpin. See Figure 40. ASSEMBLY 7. SLOTTED NUT
2. SEAL 8. COTTER PIN
6. Tilt the spindle assembly and lift from the steer- 3. BEARING CONE 9. PIN
ing axle. See Figure 40. 4. BEARING CUP 10. STEERING AXLE
5. SPACER 11. KINGPIN
7. Repeat Step 2 through Step 6 for the other spin-
Figure 40. Spindle Repair E1.6-2.0XN
dle.
(E30-40XN) (A269)

35
Spindle Repair 1600 SRM 1360

CLEAN 2. If lower bearing cup was removed, using a press

install new bearing cup in spindle.
WARNING 3. Install kingpin in spindle. See Figure 40.
Cleaning solvents can be flammable and toxic
and can cause skin irritation. When using 4. Install upper and lower bearing cones on spindle.
cleaning solvents, always follow the solvent See Figure 40.
manufacturer’s recommended safety proce-
dures. 5. Install spacer on spindle. See Figure 40.

NOTE: Coat all seals and O-rings with multipurpose

WARNING grease prior to installation.
Compressed air is used for cleaning or drying
purposes, or for clearing restrictions. Wear 6. Install new seals on the top and bottom of the
protective clothing (goggles/shield, gloves, spindle. See Figure 40.
etc.) to avoid injury to personnel.
7. If necessary, repeat Step 1 through Step 6 for op-
1. Clean bearings by placing them in a wire basket posite side.
and immersing in a container of fresh solvent.
Agitate the bearings in the solvent to remove all
traces of old lubricant.

2. After cleaning the bearings, dry them with clean

compressed air. Take care to prevent spinning
the bearings when using a compressed air jet.

3. Immediately wrap bearings in a lint-free cloth to

protect them from dust and other foreign matter.

4. Clean the spindle with solvent and air dry with

compressed air.

5. Clean the wear ring using warm soapy water and

dry with a lint free cloth.

INSPECT
1. Inspect for loose, missing, cracked, burned or
damaged hardware.

2. If upper bearing is found to be damaged, remove

the bearing cup from the axle using a hammer
and brass drift pin.

3. If lower bearing is found to be damaged, remove

the bearing cup from the bearing cap as shown in
Figure 41.
1. PRY BAR 3. BEARING CAP
4. Inspect all parts for dents, holes, bends, burrs, 2. BEARING CUP 4. O-RING
rust, corrosion, or marred finish.
Figure 41. Bearing Removal
5. Replace any damaged parts.

ASSEMBLE E1.6-2.0XN (E30-40XN) (A269)

1. If upper bearing cup was removed, using a press
install the new bearing cup in spindle.

36
1600 SRM 1360 Spindle Repair

INSTALL E1.6-2.0XN (E30-40XN) (A269) 2. Remove the wheel and bearings. See Steering
Axle Assembly Repair.
1. Tilt the spindle assembly and install the spindle
in the steering axle. 3. Disconnect the tie rod from the spindle assembly.
See Tie Rod Replacement.
2. Install pin on kingpin. See Figure 40.
NOTE: Step 4 through Step 9 are to be performed
3. Install sleeve, slotted nut, and cotter pin on spin- if the kingpin assembly on the left side is being re-
dle. See Figure 40. paired.
4. Connect the tie rod to the spindle assembly. See 4. Remove capscrew and cover from the steer axle.
Tie Rod Replacement.
5. Disconnect the wiring harness from the steering
5. Install bearings and wheel. See Steering Axle direction sensor.
Assembly Repair.
6. Remove two capscrews and steering direction
6. If required, repeat the procedure for the other sensor from the steer axle. See Figure 42.
spindle.

7. Remove the lift truck from the blocks.

REMOVE J2.2-3.5XN (J45-70XN) (A276)

AND J4.0-5.0XN (J80-100XN) (A970)

WARNING
PUTTING THE LIFT TRUCK ON BLOCKS

The lift truck must be put on blocks for some

types of maintenance and repair. The removal
of the mast, drive axle, battery, or counter-
weight assemblies will cause large changes
in the center of gravity. When the lift truck
is put on blocks, put additional blocks in the
following positions:
• If the mast and drive axle are removed, put
blocks under the counterweight so the lift
truck cannot fall backward.
• If the counterweight is removed, put blocks
under the mast so that the lift truck cannot
fall forward.
NOTE: STEERING DIRECTION SENSOR FOR LIFT
Put the lift truck on blocks on a solid, even, and TRUCK MODELS J2.2-3.5XN (J45-70XN) (A276)
level surface. Verify the blocks or stands have SHOWN. STEERING DIRECTION SENSOR FOR
enough capacity to hold the lift truck. Use ad- LIFT TRUCK MODELS J4.0-5.0XN (J80-100XN)
ditional blocks next to the tires as necessary to (A970) IS SIMILAR.
prevent movement of the lift truck. Verify the
1. CAPSCREW 5. GREASE CAP
lifting devices used during repairs can lift the 2. COVER 6. MAGNET
weight of the parts and assemblies. 3. STEERING 7. MAGNET CARRIER
DIRECTION 8. STEER AXLE
See the Operating Manual or Periodic Mainte- SENSOR
nance section for your lift truck model, for the 4. INSERT
procedures to put the lift truck on blocks.
Figure 42. Steering Direction Sensor for Lift
1. Put the lift truck on blocks. Truck Models J2.2-3.5XN (J45-70XN) (A276)
and J4.0-5.0XN (J80-100XN) (A970)

37
Spindle Repair 1600 SRM 1360

7. Remove the insert from the steering direction

sensor.

8. Remove the grease cap from the steer axle.

9. Remove the magnets and magnet carrier from

the steer axle.

10. Remove grease cap from top of steer axle. See

Figure 43.

NOTE: Note the thickness of the shims during re-

moval to aid in installation.

11. Remove three capscrews, bearing cap, and shims

from the bottom of the steering axle. See Fig-
ure 43.

12. Tilt the spindle and lift from the steering axle.

13. Remove the wear sleeve from the steering axle.

14. Repeat Step 2 through Step 13 for the other spin-

dle.

DISASSEMBLE J2.2-3.5XN (J45-70XN)

(A276) AND J4.0-5.0XN (J80-100XN) (A970)
1. Remove and discard the O-ring from the bearing
cap. See Figure 43.

2. Remove bearing cone and seal from the top of the

spindle. Discard seal.

3. Remove bearing cone and seal from the bottom of NOTE: SPINDLE ASSEMBLY FOR LIFT TRUCK
the spindle. Discard seal. MODELS J2.2-3.5XN (J45-70XN) (A276) SHOWN.
SPINDLE ASSEMBLY FOR LIFT TRUCK MODELS
J4.0-5.0XN (J80-100XN) (A970) IS SIMILAR.
1. SPINDLE LH 7. WEAR RING
2. GREASE CAP 8. SHIMS
3. STEERING AXLE 9. O-RING
4. BEARING CUP 10. BEARING CAP
5. BEARING CONE 11. LUBRICATION
6. SEAL FITTING
12. CAPSCREWS

Figure 43. Spindle Repair for Lift Truck

Models J2.2-3.5XN (J45-70XN) (A276) and
J4.0-5.0XN (J80-100XN) (A970)

38
1600 SRM 1360 Spindle Repair

CLEAN

WARNING
Cleaning solvents can be flammable and toxic
and can cause skin irritation. When using
cleaning solvents, always follow the solvent
manufacturer’s recommended safety proce-
dures.

WARNING
Compressed air is used for cleaning or drying
purposes, or for clearing restrictions. Wear
protective clothing (goggles/shield, gloves,
etc.) to avoid injury to personnel.

1. Clean bearings by placing them in a wire basket

and immersing in a container of fresh solvent.
Agitate the bearings in the solvent to remove all
traces of old lubricant.

2. After cleaning the bearings, dry them with clean

compressed air. Take care to prevent spinning
the bearings when using a compressed air jet.

3. Immediately wrap bearings in a lint-free cloth to

protect them from dust and other foreign matter.

4. Clean the spindle with solvent and air dry with 1. PRY BAR 3. BEARING CAP
compressed air 2. BEARING CUP 4. O-RING

5. Clean the wear ring using warm soapy water and Figure 44. Bearing Removal
dry with a lint free cloth.
ASSEMBLE J2.2-3.5XN (J45-70XN) (A276)
INSPECT AND J4.0-5.0XN (J80-100XN) (A970)
1. Inspect for loose, missing, cracked, burned or 1. If upper bearing cup was removed, using a press
damaged hardware. install new bearing cup into the axle.

2. If upper bearing is found to be damaged, remove 2. If lower bearing cup was removed, using a press
the bearing cup from the axle using a hammer install new bearing cup in the bearing cap.
and brass drift pin.
NOTE: Coat all seals and O-rings with multipurpose
3. If lower bearing is found to be damaged, remove grease prior to installation.
the bearing cup from the bearing cap as shown in
3. Install new seals on top and bottom of spindle.
Figure 44.
4. Pack each bearing cone with multipurpose
4. Inspect all parts for dents, holes, bends, burrs,
grease, and Install bearing cones on top and
rust, corrosion, or marred finish.
bottom of spindle.
5. Replace any damaged parts.

39
Spindle Repair 1600 SRM 1360

INSTALL J2.2-3.5XN (J45-70XN) (A276) 14. If required, repeat procedure for the other spin-
AND J4.0-5.0XN (J80-100XN) (A970) dle.

1. Install wear sleeve into steering axle. See Fig- 15. Remove lift truck from the blocks.
ure 43.

2. Tilt spindle and install spindle in the steering

axle.

3. Install the bearing cap without shims. See

Figure 43. Install capscrews and tighten 22 to
27.5 N•m (16 to 20 lbf ft). Measure clearance
between bearing cap and axle. Remove bearing
cap and install enough shims to give a preload of
0.00 to 0.13 mm (0.000 to 0.005 in.).

4. Install bearing cap and capscrews. Tighten cap-

screws 44 to 55 N•m (32 to 41 lbf ft).

NOTE: If performing install procedures on the right

side of steer axle, go to Step 6; otherwise perform
Step 5 and then go to Step 12.

5. Install grease cap on the top of the steering axle.

See Figure 43.

6. Install magnet carrier and magnets into the steer

axle. See Figure 45.
NOTE: STEERING DIRECTION SENSOR FOR LIFT
7. Install grease cap into steer axle with the notch TRUCK MODELS J2.2-3.5XN (J45-70XN) (A276)
toward grease fitting within ±5°. SHOWN. STEERING DIRECTION SENSOR FOR
LIFT TRUCK MODELS J4.0-5.0XN (J80-100XN)
8. Install insert into steering direction sensor. (A970) IS SIMILAR.
9. Install steering direction sensor and two cap- 1. CAPSCREW 4. INSERT
screws into steer axle. 2. COVER 5. GREASE CAP
3. STEERING 6. MAGNET
10. Connect wiring harness to steering direction sen- DIRECTION 7. MAGNET CARRIER
sor. SENSOR 8. STEER AXLE

11. Install cover and capscrew on steer axle Figure 45. Steering Direction Sensor for Lift
Truck Models J2.2-3.5XN (J45-70XN) (A276)
12. Connect tie rod to spindle assembly. See Tie Rod and J4.0-5.0XN (J80-100XN) (A970)
Replacement.

13. Install bearings and wheel. See Steering Axle

Assembly Repair.

40
1600 SRM 1360 Spindle Repair

REMOVE J1.6-2.0XN (J30-40XN) (A935) 6. Remove two capscrews and steering direction
sensor from kingpin cover. See Figure 46.
WARNING
PUTTING THE LIFT TRUCK ON BLOCKS

The lift truck must be put on blocks for some

types of maintenance and repair. The removal
of the mast, drive axle, battery, or counter-
weight assemblies will cause large changes
in the center of gravity. When the lift truck
is put on blocks, put additional blocks in the
following positions:
• If the mast and drive axle are removed, put
blocks under the counterweight so the lift
truck cannot fall backward.
• If the counterweight is removed, put blocks
under the mast so that the lift truck cannot
fall forward.

Put the lift truck on blocks on a solid, even, and

level surface. Verify the blocks or stands have
enough capacity to hold the lift truck. Use ad-
ditional blocks next to the tires as necessary to
prevent movement of the lift truck. Verify the
lifting devices used during repairs can lift the
weight of the parts and assemblies.

See the Operating Manual or Periodic Mainte-

nance section for your lift truck model, for the
procedures to put the lift truck on blocks.

1. Put the lift truck on blocks. NOTE: RIGHT HAND SPINDLE SHOWN.
2. Remove the wheel and bearings. See Steering 1. CAPSCREW
Axle Assembly Repair. 2. PLATE
3. STEERING AXLE WIRING HARNESS
3. Disconnect the tie rod from the spindle. See Tie 4. STEERING DIRECTION SENSOR
5. KIN PIN COVER
Rod Replacement. 6. STEERING AXLE
NOTE: Step 4 and Step 6 are to be performed if the Figure 46. Steering Direction Sensor for Lift
kingpin assembly on the right side is being repaired. Truck Model J1.6-2.0XN (J30-40XN) (A935)
4. Remove capscrew and two plates from steering
axle. See Figure 46.

5. Disconnect steering axle wiring harness from the

steering direction sensor. See Figure 46.

41
Spindle Repair 1600 SRM 1360

DISASSEMBLE J1.6-2.0XN (J30-40XN) 6. Remove the needle bearings from the steering
(A935) axle.

1. Remove three capscrews, three washers and the 7. Remove and discard the kingpin seals from the
upper kingpin cover from the steering axle. See steering axle.
Figure 47.
CLEAN
2. Remove three capscrews, washers, and the lower
kingpin cover from the steering axle. WARNING
3. Remove the grub screw and kingpin from the Cleaning solvents can be flammable and toxic
spindle. and can cause skin irritation. When using
cleaning solvents, always follow the solvent
4. Remove the thrust bearing from between the manufacturer’s recommended safety proce-
steering axle and spindle. dures.

5. Remove the spindle from the steering axle.

WARNING
Compressed air is used for cleaning or drying
purposes, or for clearing restrictions. Wear
protective clothing (goggles/shield, gloves,
etc.) to avoid injury to personnel.

1. Clean bearings by placing them in a wire basket

and immersing in a container of fresh solvent.
Agitate the bearings in the solvent to remove all
traces of old lubricant.

2. After cleaning the bearings, dry them with clean

compressed air.

3. Immediately wrap bearings in a lint-free cloth to

protect them from dust and other foreign matter.

4. Clean the spindle and kingpin with solvent and

air dry with compressed air.

INSPECT
1. Inspect bearings for any damage. (i.e. burned
or corroded bearings). If any damage is found,
replace the bearings.

2. Inspect the kingpin for straightness by placing

a ruler or other known true straight edge along
the length of the kingpin. Replace the kingpin if
found to be bent.

1. CAPSCREW 7. THRUST BEARING 3. Inspect all other parts for, burrs, rust, corrosion,
2. WASHER 8. SPINDLE or marred finish.
3. UPPER KINGPIN 9. GRUB SCREW.
COVER 10. KINGPIN 4. Replace any damaged parts.
4. NEEDLE BEARING 11. LOWER KINGPIN
5. STEERING AXLE COVER 5. If removed, inspect the steering direction sensor
6. KINGPIN SEAL
and its attaching parts for damage. If damaged,
Figure 47. Spindle Repair J1.6-2.0XN replace either the steering direction sensor or the
(J30-40XN) (A935) damaged parts.

42
1600 SRM 1360 Steering Cylinder Repair

ASSEMBLE J1.6-2.0XN (J30-40XN) (A935) 7. Install the lower kingpin cover, three capscrews,
and washers on the steering axle.
NOTE: Coat kingpin seals with multipurpose grease
prior to installation. 8. Install the upper kingpin cover, three capscrews,
and washers on the steering axle.
1. Install new kingpin seals into steering axle. See
Figure 47 INSTALL J1.6-2.0XN (J30-40XN) (A935)
2. Coat needle bearings with multipurpose grease NOTE: Step 1 and Step 3 are to be performed if the
and install needle bearings into steering axle. kingpin assembly on the right side is being repaired.
3. Install the spindle into steering axle. 1. Install the steering direction sensor and two cap-
screws in kingpin cover. See Figure 46.
4. Fill thrust bearing with multipurpose grease,
and install thrust bearing between the steering 2. Connect steering axle wiring harness to steering
axle and spindle. direction sensor. See Figure 46.
NOTE: There is an indentation in the kingpin for 3. Install two plates and capscrew to steering axle.
the installation of the grub screw. While performing See Figure 46.
Step 5, ensure that the indentation is lined up on the
grub screw hole in the spindle. 4. Connect the tie rod to the spindle assembly. See
Tie Rod Replacement.
5. Coat the kingpin with multipurpose grease, and
install the kingpin in the steering axle and spin- 5. Install the wheel. See Steering Axle Assembly
dle assembly. Repair.

6. Install and tighten the grub screw in the spindle. 6. If required, repeat the procedure for the other
Check the kingpin to ensure there is no vertical spindle.
movement.

Steering Cylinder Repair

REMOVE E2.2-E3.5XN (E45XN-70XN)
(A268) AND J2.2-3.5XN (J45-70XN) (A276)
NOTE: The end caps of the steering cylinder are held
in the shell by the installation of cylinder mount cap-
screws into the axle frame. To prevent oil leaks at the
caps, hold the caps on the shell during removal.

1. Disconnect and tag hydraulic lines at steering

cylinder. Install plugs in fittings on steering
cylinder and put caps on hydraulic lines.

See Figure 48 for lift truck models

• E2.2-3.5XN (E45-70XN) (A268)

See Figure 49 for lift truck models

• J2.2-3.5XN (J45-70XN) (A276)

1. HYDRAULIC HOSE

Figure 48. Steering Cylinder Hoses for Lift

Truck Model E2.2-3.5XN (E45-70XN) (A268)

43
Steering Cylinder Repair 1600 SRM 1360

2. Loosen four clamps and move two boots from the

tie rods to the steering cylinder rod. See Fig-
ure 50.

WARNING
The steering cylinder weighs 13.7 kg (30 lb),
and to prevent possible injury, may require
two people to remove the steering cylinder
from the steering axle.

3. Remove two snap rings, two pins, four capscrews,

and steering cylinder from the steering axle and
tie rods. See Figure 50.

4. Remove two boots and four clamps from the

steering cylinder rod.

1. HYDRAULIC HOSE

Figure 49. Steering Cylinder Hoses for Lift

Truck Model J2.2-3.5XN (J45-70XN) (A276)

Figure 50. Steering Cylinder Removal for Lift Truck Models E2.2-E3.5XN (E45XN-70XN) (A268)
and J2.2-3.5XN (J45-70XN) (A276)

44
1600 SRM 1360 Steering Cylinder Repair

Legend for Figure 50

1. CLAMP 4. SNAP RING 7. STEERING CYLINDER
2. BOOT 5. PIN 8. CAPSCREW
3. STEERING AXLE 6. TIE ROD 9. STEERING CYLINDER ROD
DISASSEMBLE E2.2-E3.5XN
CAUTION (E45XN-70XN) (A268) AND J2.2-3.5XN
Disposal of lubricants and fluids must meet lo-
(J45-70XN) (A276)
cal environmental regulations.
1. Remove one end cap from cylinder shell and slide
5. Hold end of steering cylinder over a container.
off of cylinder rod. See Figure 51.
Remove plug for hydraulic fitting from each end
cap. Push rod toward end of shell that is over 2. Remove the rod wiper, seal, O-ring, backup ring,
container. Oil will drain from cylinder. Repeat and O-ring from the end cap. Discard rod wiper,
procedure for other end. seal, and O-rings. See Figure 51.

Figure 51. Steering Cylinder Disassembly

45
Steering Cylinder Repair 1600 SRM 1360

Legend for Figure 51

1. ROD WIPER 4. O-RING 7. PISTON
2. SEAL 5. BACKUP RING 8. CYLINDER ROD
3. END CAP 6. PISTON SEAL 9. CYLINDER SHELL

3. Pull cylinder rod out of cylinder shell, to prevent

possible damage to the cylinder shell, keep cylin- CAUTION
der rod centered in cylinder shell during removal. DO NOT damage the O-rings, seals, or wipers
See Figure 51. during installation.

4. Remove and discard piston seal from the piston. 2. Install new O-ring, backup ring, O-ring, seal, and
See Figure 51. wiper on both end caps. See Figure 51.

5. Repeat Step 1 and Step 2 for the opposite end cap. 3. Install one end cap on cylinder shell. See Fig-
ure 51.
CLEAN
4. Install new piston seal on piston. See Figure 51.

WARNING 5. Carefully slide cylinder rod into cylinder shell

Cleaning solvents can be flammable and toxic and end cap. Keep cylinder rod aligned in cen-
and can cause skin irritation. When using ter of shell during installation so the parts are
cleaning solvents, always follow the solvent not damaged.
manufacturer’s recommended safety proce-
dures. 6. Install remaining end cap into cylinder shell. In-
stall plugs in hydraulic fittings on end caps.
WARNING INSTALL E2.2-E3.5XN (E45XN-70XN)
Compressed air is used for cleaning or drying (A268) AND J2.2-3.5XN (J45-70XN) (A276)
purposes, or for clearing restrictions. Wear
protective clothing (goggles/shield, gloves, 1. Hold end caps and install steering cylinder on
etc.) to avoid injury to personnel. steering axle using four capscrews. Tighten cap-
screws 225 to 280 N•m (166 to 206 lbf ft). See
Clean all metal parts in solvent. Dry with com- Figure 50.
pressed air.
2. Install two clamps and one boot on each end of
INSPECT the cylinder rod. See Figure 50.
1. Inspect cylinder rod for grooves or damage. Re- 3. Install tie rods into the steering cylinder ends.
move small scratches with fine emery cloth.
4. Install two pins into the steering cylinder rod/tie
2. Inspect cylinder bore for damage. rod combination and install a snap ring on
each pin. Move the rubber covers over each
3. Inspect end caps for cracks. tie rod/steering cylinder rod combination and
tighten clamps.
ASSEMBLE E2.2-E3.5XN (E45XN-70XN)
(A268) AND J2.2-3.5XN (J45-70XN) (A276) 5. Remove plugs and caps and connect hydraulic
lines as tagged during removal, to steering cylin-
1. Coat seals, rod wipers, and O-rings with pack- der. Operate steering system to remove air from
ing lubricant Hyster P/N 186061 prior to instal- cylinders and system. Turn steering wheel sev-
lation. eral times from one stop to the other. Check that
the steer cylinder operates lock to lock.

46
1600 SRM 1360 Steering Cylinder Repair

REMOVE E1.6-2.0XN (E30-40XN) (A269)

NOTE: The end caps of the steering cylinder are held
in the shell by the installation of cylinder mount cap-
screws into the axle frame. To prevent oil leaks at the
caps, hold the caps on the shell during removal.

1. Disconnect and tag hydraulic lines at steering

cylinder. Install plugs in fittings on steering
cylinder and put caps on hydraulic lines. See
Figure 52.

WARNING
The steering cylinder weighs 13.7 kg (30 lb),
and to prevent possible injury, may require
two people to remove the steering cylinder
from the steering axle.

2. Remove four snap rings, two pins, four cap-

screws, and steering cylinder from the steering
axle and tie rods. See Figure 53.

1. HYDRAULIC HOSE

Figure 52. Steering Cylinder Hoses for Lift

Truck Model E1.6-2.0XN (E30-40XN) (A269)

47
Steering Cylinder Repair 1600 SRM 1360

1. STEERING AXLE 5. STEERING CYLINDER

2. SNAP RING 6. CAPSCREW
3. PIN 7. STEERING CYLINDER ROD
4. TIE ROD

Figure 53. Steering Cylinder for Lift Truck Models E1.6-2.0XN (E30-40XN) (A269)
DISASSEMBLE E1.6-2.0XN (E30-40XN)
CAUTION (A269)
Disposal of lubricants and fluids must meet lo-
cal environmental regulations. 1. Remove one end cap from cylinder shell and slide
off of cylinder rod. See Figure 54.
3. Hold end of steering cylinder over a container.
Remove plug for hydraulic fitting from each end 2. Remove the rod wiper, seal, O-ring, backup ring,
cap. Push rod toward end of shell that is over and O-ring from the end cap. Discard rod wiper,
container. Oil will drain from cylinder. Repeat seal, and O-rings. See Figure 54.
procedure for other end.

48
1600 SRM 1360 Steering Cylinder Repair

1. ROD WIPER 6. PISTON SEAL

2. SEAL 7. PISTON
3. END CAP 8. CYLINDER ROD
4. O-RING 9. CYLINDER SHELL
5. BACKUP RING

Figure 54. Steering Cylinder Disassembly

3. Pull cylinder rod out of cylinder shell. To prevent 4. Remove and discard piston seal from the piston.
possible damage to the cylinder shell, keep cylin-
der centered in cylinder shell during removal. 5. Repeat Step 1 and Step 2 for the opposite end cap.

49
Steering Cylinder Repair 1600 SRM 1360

CLEAN INSTALL E1.6-2.0XN (E30-40XN) (A269)

1. Hold end caps and install steering cylinder on
WARNING steering axle using four capscrews. Tighten cap-
Cleaning solvents can be flammable and toxic screws to 225 to 280 N•m (166 to 206 lbf ft). See
and can cause skin irritation. When using Figure 53.
cleaning solvents, always follow the solvent
manufacturer’s recommended safety proce- 2. Install tie rods into the steering cylinder ends.
dures. See Figure 53.

3. Install two pins into steering cylinder rod and tie

WARNING
rod combination. Install two snap rings on each
Compressed air is used for cleaning or drying pin.
purposes, or for clearing restrictions. Wear
protective clothing (goggles/shield, gloves, 4. Remove plugs and caps and connect hydraulic
etc.) to avoid injury to personnel. lines as tagged during removal, to steering cylin-
der. Operate steering system to remove air from
Clean all metal parts in solvent. Dry with com- cylinders and system. Turn steering wheel sev-
pressed air. eral times from one stop to the other. Check that
the steer cylinder operates lock to lock.
INSPECT
1. Inspect cylinder rod for grooves or damage. Re- REMOVE J1.6-2.0XN (J30-40XN) (A935)
move small scratches with fine emery cloth. 1. Disconnect and tag hydraulic lines at the steer-
2. Inspect cylinder bore for damage. ing cylinder. See Figure 55. Install plugs in the
cylinder fittings and caps on the hydraulic lines
3. Inspect end caps for cracks. to prevent possible contamination.

ASSEMBLE E1.6-2.0XN (E30-40XN) (A269)

1. Coat seals, rod wipers, and O-rings with pack-
ing lubricant Hyster P/N 186061 prior to instal-
lation.

CAUTION
DO NOT damage the O-rings, seals, or wipers
during installation.

2. Install new O-ring, backup ring, O-ring, seal, and

wiper on both end caps. See Figure 54.

3. Install one end cap on cylinder shell. See Fig-

ure 54.

4. Install new piston seal on piston. See Figure 54.

5. Carefully slide cylinder rod into cylinder shell

and end cap. Keep cylinder rod aligned in cen-
ter of shell during installation so the parts are 1. HYDRAULIC HOSE
not damaged.
Figure 55. Steering Cylinder Hose Removal
6. Install remaining end cap into cylinder shell. In- J1.6-2.0XN (J30-40XN) (A935)
stall plugs in hydraulic fittings on end caps.

50
1600 SRM 1360 Steering Cylinder Repair

2. Remove two dowel pins, two snap rings, two pins, DISASSEMBLE J1.6-2.0XN (J30-40XN)
four socket head screws, and two grub screws. To (A935)
remove the steering cylinder, rotate one of the
hubs out of the way and pull the steering cylinder 1. Remove the snap ring from the collar. See Fig-
from the steer axle frame. See Figure 56. ure 57.

2. Push the collar into the cylinder shell approxi-

CAUTION mately 25.4 mm (1 in.) and remove the split ring
Disposal of lubricants and fluids must meet lo- from the cylinder shell.
cal environmental regulations.
3. To remove the collar from the cylinder shell pull
3. While holding one end of the steering cylinder the cylinder rod until the piston pushes the collar
over a suitable container, remove the plug from from the cylinder shell.
the fitting and push the rod toward the end over
the container. This will push any fluid on that 4. Repeat Step 1 through Step 3 to remove the collar
end of the cylinder out and into the container. from the opposite end of the steer cylinder.
Repeat for the opposite end.

1. SNAP RING 5. DOWEL

2. PIN 6. STEERING CYLINDER
3. STEER AXLE FRAME 7. GRUB SCREW
4. HUB 8. SOCKET HEAD SCREWS

Figure 56. Steering Cylinder Removal J1.6-2.0XN (J30-40XN) (A935)

51
Steering Cylinder Repair 1600 SRM 1360

5. Remove and discard the rod wiper, inner seal, come in contact with the inner surface of the
outer seal, and backup ring from each collar. See cylinder shell possibly scoring the inner surface.
Figure 57.
7. Remove and discard two wear rings and the pis-
6. Remove the cylinder rod from the cylinder shell ton seal from the piston. See Figure 57.
using care not to allow the cylinder rod end to

1. SNAP RING 5. SPLIT RING 9. OUTER SEAL

2. CYLINDER ROD 6. ROD WIPER 10. PISTON
3. CYLINDER SHELL 7. INNER SEAL 11. WEAR RING
4. COLLAR 8. BACKUP RING 12. PISTON SEAL

Figure 57. Steering Cylinder Repair

CLEAN ASSEMBLE J1.6-2.0XN (J30-40XN) (A935)

1. Coat seals, rod wipers, and O-rings with pack-
WARNING ing lubricant Hyster P/N 186061 prior to instal-
Cleaning solvents can be flammable and toxic lation.
and can cause skin irritation. When using
cleaning solvents, always follow the solvent
manufacturer’s recommended safety proce- CAUTION
dures. Do not damage the O-rings, seals, or wipers
during installation.
WARNING 2. Install two new wear rings and a new piston seal
Compressed air is used for cleaning or drying on the piston. See Figure 57.
purposes, or for clearing restrictions. Wear
protective clothing (goggles/shield, gloves, 3. Install the cylinder rod in the cylinder shell using
etc.) to avoid injury to personnel. care not to allow the cylinder rod end to come
in contact with the inner surface of the cylinder
Clean all metal parts in solvent. Dry with com- shell possibly scoring the inner surface.
pressed air.
4. Install a new backup ring, outer seal, inner seal,
INSPECT and rod wiper on each collar. See Figure 57.

1. Inspect cylinder rod for grooves or damage. Re- 5. Install the collar on the cylinder rod and push the
move small scratches with fine emery cloth. collar about 25.4 mm (1 in.) from the cylinder
shell end and install the split ring in the cylinder
2. Inspect cylinder bore for damage. shell.
3. Inspect collars for damage.

52
1600 SRM 1360 Steering Cylinder Repair

6. Use the rod to push the collar back to the end of

the cylinder shell enough to allow installation of
the snap ring. Install the snap ring on the collar
with the snap ring plier tabs at the top of the
cylinder shell.

7. Repeat Step 5 and Step 6 to install the collar into

the opposite end of the steering cylinder. See Fig-
ure 57.

INSTALL J1.6-2.0XN (J30-40XN) (A935)

1. Rotate one of the hubs out of the way and install
the steering cylinder on the steer axle frame. See
Figure 56.

2. Install four socket head screws and two grub

screws in steering cylinder and steer axle frame.
Tighten socket head and grub screws to 130 N•m
(95 lbf ft).

3. Connect the tie rod to the steering cylinder rod

with a pin and dowel. Figure 56.

4. Repeat Step 3 for opposite side tie rod.

5. Connect the hydraulic hoses to the steering cylin-

der as tagged during removal.

6. Operate the steering system to remove air from

the steering system and steering cylinder. Check
that the steering cylinder operates from stop to
stop by turning the steering wheel several times
from one stop to the other.
1. HYDRAULIC HOSE 2. STEERING AXLE
REMOVE J4.0-5.0XN (J80-100XN) (A970) Figure 58. Steering Cylinder Hoses for Lift
Truck Model J4.0-5.0XN (J80-100XN) (A970)
NOTE: The end caps of the steering cylinder are held
in the shell by the installation of cylinder mount cap-
screws into the axle frame. To prevent oil leaks at the WARNING
caps, hold the caps on the shell during removal. The steering cylinder is heavy. To prevent pos-
sible injury, two people may be required to re-
1. Disconnect and tag hydraulic lines at steering move the steering cylinder from the steering
cylinder. Install plugs in fittings on steering axle.
cylinder and put caps on hydraulic lines. See
Figure 58. 2. Remove four snap rings, two pins, eight cap-
screws, and steering cylinder from the steering
axle and tie rods. See Figure 59.

53
Steering Cylinder Repair 1600 SRM 1360

1. SNAP RING 5. STEERING CYLINDER

2. PIN 6. CAPSCREW
3. TIE ROD 7. PIN AND SNAP RINGS
4. STEERING CYLINDER ROD

Figure 59. Steering Cylinder Removal for Lift Truck Models J4.0-5.0XN (J80-100XN) (A970)
DISASSEMBLE J4.0-5.0XN (J80-100XN)
CAUTION (A970)
Disposal of lubricants and fluids must meet lo-
cal environmental regulations. 1. Remove one end cap from cylinder shell and slide
off of cylinder rod. See Figure 60.
3. Hold end of steering cylinder over a container.
Remove plug for hydraulic fitting from each end 2. Remove the rod wiper, seal, O-ring, backup ring,
cap. Push rod toward end of shell that is over and O-ring from the end cap. Discard rod wiper,
container. Oil will drain from cylinder. Repeat seal, and O-rings. See Figure 60.
procedure for other end.

54
1600 SRM 1360 Steering Cylinder Repair

1. ROD WIPER 6. PISTON SEAL

2. SEAL 7. CYLINDER SHELL
3. END CAP 8. CYLINDER ROD
4. O-RING 9. PISTON
5. BACKUP RING

Figure 60. Steering Cylinder Disassembly

3. Pull cylinder rod out of cylinder shell, to prevent

WARNING
possible damage to the cylinder shell, keep cylin-
der rod centered in cylinder shell during removal. Compressed air is used for cleaning or drying
See Figure 60. purposes, or for clearing restrictions. Wear
protective clothing (goggles/shield, gloves,
4. Remove and discard piston seal from the piston. etc.) to avoid injury to personnel.
See Figure 60.
Clean all metal parts in solvent. Dry with com-
5. Repeat Step 1 and Step 2 for the opposite end cap. pressed air.

CLEAN INSPECT
1. Inspect cylinder rod for grooves or damage. Re-
WARNING move small scratches with fine emery cloth.
Cleaning solvents can be flammable and toxic
and can cause skin irritation. When using 2. Inspect cylinder bore for damage.
cleaning solvents, always follow the solvent
manufacturer’s recommended safety proce- 3. Inspect end caps for cracks.
dures.

55
Steering Cylinder Repair 1600 SRM 1360

ASSEMBLE J4.0-5.0XN (J80-100XN) (A970) REMOVE E4.0-5.5XN, E5.0XNS

(E80-120XN, E100XNS) (A099)
1. Coat seals, rod wipers, and O-rings with pack-
ing lubricant Hyster P/N 186061 prior to instal- 1. The end caps of the steering cylinder are held in
lation. the shell by the installation of cylinder mount
capscrews into the axle frame. To prevent oil
CAUTION leaks at the caps, hold the caps on the shell dur-
DO NOT damage the O-rings, seals, or wipers ing removal.
during installation.
Disconnect and tag hydraulic lines at steering
2. Install new O-ring, backup ring, O-ring, seal, and cylinder. Install plugs in fittings on steering
wiper on both end caps. See Figure 60. cylinder and put caps on hydraulic lines. See
Figure 61.
3. Install one end cap on cylinder shell. See Fig-
ure 60. 2. Loosen four clamps and move two boots from the
tie rods to the steering cylinder rod. See Fig-
4. Install new piston seal on piston. See Figure 60. ure 62.

5. Carefully slide cylinder rod into cylinder shell

and end cap. Keep cylinder rod aligned in cen-
ter of shell during installation so the parts are
not damaged.

6. Install remaining end cap into cylinder shell. In-

stall plugs in hydraulic fittings on end caps.

INSTALL J4.0-5.0XN (J80-100XN) (A970)

1. Hold end caps and install steering cylinder on
steering axle using eight capscrews. Tighten cap-
screws 225 to 280 N•m (166 to 206 lbf ft). See
Figure 59.

2. Install tie rods into the steering cylinder ends.

1. HYDRAULIC HOSE
3. Install two pins into the steering cylinder rod/tie
rod combination and install two snap rings on Figure 61. Steering Cylinder Hoses for Lift
each pin. See Figure 59. Trucks E4.0-5.5XN, E5.0XNS (E80-120XN,
E100XNS) (A099)
4. Remove plugs and caps and connect hydraulic
lines as tagged during removal, to steering cylin-
der. Operate steering system to remove air from
cylinders and system. Turn steering wheel sev-
eral times from one stop to the other. Check that
the steer cylinder operates lock to lock.

56
1600 SRM 1360 Steering Cylinder Repair

1. CLAMP 6. TIE ROD

2. BOOT 7. STEERING CYLINDER
3. STEERING AXLE 8. CAPSCREW
4. SNAP RING 9. STEERING CYLINDER ROD
5. PIN

Figure 62. Steering Cylinder Removal, Lift Truck Models E4.0-5.5XN, E5.0XNS (E80-120XN,
E100XNS) (A099)

WARNING CAUTION
The steering cylinder weighs 17.1 kg (38 lb), Disposal of lubricants and fluids must meet lo-
To prevent possible injury, two people may be cal environmental regulations.
required to remove the steering cylinder from
the steering axle. 5. Hold end of steering cylinder over a container.
Remove plug for hydraulic fitting from each end
3. Remove two snap rings, two pins, eight cap- cap. Push rod toward end of shell that is over
screws, and steering cylinder from the steering container. Oil will drain from cylinder. Repeat
axle and tie rods. See Figure 62. procedure for other end.
4. Remove two boots and four clamps from the
steering cylinder rod.

57
Steering Cylinder Repair 1600 SRM 1360

DISASSEMBLE E4.0-5.5XN, E5.0XNS 3. Pull cylinder rod out of cylinder shell, to prevent
(E80-120XN, E100XNS) (A099) possible damage to the cylinder shell, keep cylin-
der rod centered in cylinder shell during removal.
1. Remove one end cap from cylinder shell and slide See Figure 63.
off of cylinder rod. See Figure 63.
4. Remove and discard piston seal from the piston.
2. Remove the rod wiper, seal, O-ring, backup ring,
and O-ring from the end cap. Discard rod wiper, 5. Repeat Step 1 through Step 4 for the opposite end
seal, and O-rings. See Figure 63. cap.

1. ROD WIPER 6. PISTON SEAL

2. SEAL 7. PISTON
3. END CAP 8. CYLINDER ROD
4. O-RING 9. CYLINDER SHELL
5. BACKUP RING

Figure 63. Steering Cylinder Disassembly

58
1600 SRM 1360 Steering Cylinder Repair

CLEAN 3. Install new O-ring, backup ring, O-ring, seal, and

wiper on both end caps. See Figure 63.
WARNING 4. Install one end cap on cylinder shell.
Cleaning solvents can be flammable and toxic
and can cause skin irritation. When using 5. Install new piston seal on piston. See Figure 63.
cleaning solvents, always follow the solvent
manufacturer’s recommended safety proce- 6. Carefully slide cylinder rod into cylinder shell
dures. and end cap. Keep cylinder rod aligned in cen-
ter of shell during installation so the parts are
not damaged.
WARNING
Compressed air can move particles so that they 7. Install remaining end cap into cylinder shell.
cause injury to the user or to other personnel.
Make sure that the path of the compressed air 8. Install plugs in hydraulic fittings on end caps.
is away from all personnel. Wear protective
goggles or a face shield to prevent injury to the INSTALL E4.0-5.5XN, E5.0XNS (E80-120XN,
eyes. E100XNS) (A099)
Clean all metal parts in solvent and dry with com- 1. Hold end caps and install steering cylinder on
pressed air. steering axle using eight capscrews.

INSPECT 2. Tighten capscrews 225 N•m (166 lbf ft) See Fig-
ure 62.
1. Inspect cylinder rod for grooves or damage. Re-
move small scratches with fine emery cloth. 3. Install two clamps and one boot on each end of
the cylinder rod. See Figure 62.
2. Inspect cylinder bore for damage.
4. Install tie rods into the steering cylinder ends.
3. Inspect end caps for cracks.
5. Install two pins into the steering cylinder rod/tie
ASSEMBLE E4.0-5.5XN, E5.0XNS rod combination and install a snap ring on
(E80-120XN, E100XNS) (A099) each pin. Move the rubber covers over each
tie rod/steering cylinder rod combination and
1. Coat the internal surfaces of the cylinder shell tighten clamps.
with anti-rust compound (Rust Veto 377 or equiv-
alent). See Figure 63. 6. Remove plugs and caps and connect hydraulic
lines as tagged during removal, to steering cylin-
2. Coat seals, rod wipers, and O-rings with packing der. Operate steering system to remove air from
lubricant (Hyster P/N 186061) prior to installa- cylinders and system. Turn steering wheel sev-
tion. eral times from one stop to the other. Check that
the steer cylinder operates lock to lock.
CAUTION
DO NOT damage the O-rings, seals, or wipers
during installation.

59
 NOTES

____________________________________________________________

____________________________________________________________

____________________________________________________________

____________________________________________________________

____________________________________________________________

____________________________________________________________

____________________________________________________________

____________________________________________________________

____________________________________________________________

____________________________________________________________

____________________________________________________________

____________________________________________________________

____________________________________________________________

____________________________________________________________

____________________________________________________________

____________________________________________________________

____________________________________________________________

____________________________________________________________

____________________________________________________________

____________________________________________________________

60
 TECHNICAL PUBLICATIONS

1600 SRM 1360 12/12 (8/12)(3/12)(1/11)(2/10)(9/09)(1/09)(7/08) Printed in United Kingdom