STEERING SYSTEM YARDMASTER

HR45-25, HR45-27, HR45-31, HR45-40S, HR45-36L, HR45-40LS, HR45-45LSX [A227, B227, C227]

PART NO. 1470230

1600 SRM 786

SAFETY PRECAUTIONS MAINTENANCE AND REPAIR

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 condition that can cause immediate death or injury!

CAUTION
Indicates a condition that can cause property damage!

Steering System YardMaster

Table of Contents

TABLE OF CONTENTS
General ............................................................................................................................................................... Description ......................................................................................................................................................... Steering Control Unit Repair ............................................................................................................................ Description ..................................................................................................................................................... Operation ....................................................................................................................................................... Load-Sensing Steering .................................................................................................................................. Remove ........................................................................................................................................................... Disassemble ................................................................................................................................................... Clean .............................................................................................................................................................. Assemble ........................................................................................................................................................ Install ............................................................................................................................................................. Steering Axle Repair.......................................................................................................................................... Description ..................................................................................................................................................... Remove ........................................................................................................................................................... Install ............................................................................................................................................................. Steering Cylinder Repair................................................................................................................................... Remove ........................................................................................................................................................... Clean and Inspect .......................................................................................................................................... Assemble ........................................................................................................................................................ Install ............................................................................................................................................................. Hubs Repair ....................................................................................................................................................... Remove ........................................................................................................................................................... Clean .............................................................................................................................................................. Install ............................................................................................................................................................. Spindles Repair .................................................................................................................................................. Remove ........................................................................................................................................................... Install ............................................................................................................................................................. System Air Removal .......................................................................................................................................... Relief Valve Adjustment for Steering System .................................................................................................. Antitipping Device Adjustment......................................................................................................................... Troubleshooting.................................................................................................................................................. This section is for the following models: HR45-25, HR45-27, HR45-31, HR45-40S, HR45-36L, HR45-40LS, HR45-45LSX [A227, B227, C227] 1 1 3 3 3 3 4 5 8 8 13 14 14 15 15 15 15 15 15 15 16 16 16 16 17 17 17 17 17 18 19

2007 HYSTER COMPANY

"THE QUALITY KEEPERS" HYSTER APPROVED PARTS

1600 SRM 786

Description

General
This section has the description and repair procedures for the parts of the steering system.

Description
These vehicles use a hydraulic steering system. See Figure 1 and Figure 2. The oil for the steering system is supplied by the main hydraulic pump. Oil from the pump flows to the main control valve, past a relief valve, then to the steering control unit. The relief valve for the steering system is set at 220 bar (3200 psi). When the engine is not running, a check valve closes and permits the steering control unit to operate as a hydraulic motor. The vehicle is difficult to steer when the steering pump is not operating, but steering is possible. When the steering wheel is turned, a pilot line (LS) from the steering control unit shifts a shuttle valve in the main control valve. The shuttle valve moves to send all of the oil from the pump to the steering control unit. The other four lines at the steering control unit connect the supply, return, left, and right steering cylinder ports. Return flow from the steering system is sent to the hydraulic tank.

1. STEERING CONTROL UNIT

2. MAIN CONTROL VALVE Figure 1. Steering System Diagram

3. STEERING CYLINDER

Description

1600 SRM 786

1. 2. 3. 4.

STEERING CONTROL UNIT MANIFOLD BLOCK STEERING CYLINDER MAIN CONTROL VALVE

5. 6. 7. 8.

TO MAIN CONTROL VALVE FROM HYDRAULIC TANK MAIN HYDRAULIC PUMP TO HYDRAULIC TANK

Figure 2. Steering System Schematic Diagram

1600 SRM 786

Steering Control Unit Repair

Steering Control Unit Repair

DESCRIPTION
The steering control unit is a hydrostatic unit controlled by the steering wheel. See Figure 3. It is mounted in the steering housing. The steering control unit has a shaft assembly, control section, and a metering section. The hydraulic hoses for the steering system are fastened to a manifold block. As the steering wheel is turned, the spool just begins to rotate. The springs try to move the sleeve to keep the NEUTRAL position between the spool and sleeve. However, the force necessary to turn the rotor is greater than the pressure of the springs. The springs begin to bend, letting the spool move a small amount within the sleeve. The spool stops moving when it touches the center pin. In this position, the holes in the sleeve and the spool are aligned. Oil coming into the control unit flows to the metering section. More rotation of the steering wheel causes the spool to rotate the pin. This action causes the rotation of the sleeve and the rotor in the metering section. The oil then flows to the flow amplifier and then to one side of the steering cylinder. Oil from the other side of the steering cylinder flows back through the flow amplifier and the control section of the steering control unit. When the steering wheel stops moving, the metering action in the metering section also stops. The NEUTRAL position springs return the sleeve to the NEUTRAL position. When this action occurs, the pressure stays in the steering cylinder to keep the tires in position. Oil from the pump flows through the steering control unit to the tank or other parts of the system. To return the tires to the straight position, the steering wheel must be rotated in the opposite direction. The steering control unit will operate as described, but all parts will rotate in the opposite direction.

1. 2. 3. 4. 5. 6.

CONTROL SECTION METERING SECTION CHECK BALL (MANUAL OPERATION) SLEEVE NEUTRAL POSITION SPRINGS SPOOL Figure 3. Steering Control Unit

LOAD-SENSING STEERING
The demand for steering is sensed at the load-sensing (LS) port in the steering control unit. The pilot line from the LS port is connected to the priority valve in the main control valve. While steering, a spring and pilot pressure from the LS line hold the regulator spool open for steering. When there is no pressure in the LS line (no steering), pilot pressure from the hydraulic pump shifts the spool. In this position, most of the oil for steering system goes to the hydraulic system.

OPERATION
Turning the steering wheel actuates three main parts of the steering control unit (see Figure 3): (1) the spool for the control section, (2) the sleeve for the control section, and (3) the rotor in the metering section. When the steering wheel is not moving, the spool and sleeve are held in the NEUTRAL (center) position by springs. During this time, oil flows freely through the steering control unit. The oil does not flow to the steering cylinder.

Steering Control Unit Repair

1600 SRM 786 2. Remove steering column from steering control unit. See Figure 4. Remove capscrews that fasten steering control unit to bracket and remove steering control unit.

REMOVE
1. Remove cover from steering housing. Put tags on hydraulic lines at manifold block. Disconnect hydraulic lines and put caps on openings.

1. STEERING WHEEL 2. STEERING COLUMN 3. RUBBER BOOT

4. STEERING CONTROL UNIT 5. MANIFOLD BLOCK Figure 4. Steering Column Assembly

1600 SRM 786

Steering Control Unit Repair

DISASSEMBLE
STEP 1. Put the control unit in a vise with soft jaws. Make an identification mark on length of control unit. Remove manifold block.

1. STEERING CONTROL UNIT 2. VISE STEP 2. Remove cover on bottom of steering control unit.

1. CAPSCREW 2. COVER 3. O-RING

Steering Control Unit Repair STEP 3. Remove spacer, stator, rotor, and port plate. Put a mark on stator so the same side is toward body of control unit. Remove O-rings. Remove center shaft.

1600 SRM 786

1. 2. 3. 4. 5. 6. STEP 4. Remove screw for check ball. Remove check ball.

SPACER STATOR ROTOR PORT PLATE O-RING CENTER SHAFT

1. SCREW

1600 SRM 786

Steering Control Unit Repair

STEP 5. Remove spool and sleeve assembly. Remove thrust bearing assembly from spool. Push center pin from sleeve. Carefully remove spool from sleeve. (Rotate spool slowly during removal.) Remove ring from sleeve. Remove NEUTRAL position springs from spool.

1. 2. 3. 4.

SPOOL AND SLEEVE ASSEMBLY THRUST WASHER THRUST BEARING CENTER PIN

5. 6. 7. 8.

SLEEVE SPOOL RING NEUTRAL POSITION SPRINGS

STEP 6. Remove dust seal from housing.

1. HOUSING 2. DUST SEAL

Steering Control Unit Repair

1600 SRM 786

CLEAN WARNING
Cleaning solvents can be flammable and toxic and can cause skin irritation. When using cleaning solvents, always follow the solvent manufacturers recommended safety precautions.

WARNING
Compressed air can move particles so they cause injury to the user or to other personnel. Make sure the path of the compressed air is away from all personnel. Wear protective goggles or a face shield to prevent injury to the eyes. Clean all parts in solvent. Dry parts with compressed air. Do not dry parts with a cloth. Make sure all surfaces are free of scratches and sharp edges.

ASSEMBLE
NOTE: Use new seals, O-rings, and NEUTRAL position springs during assembly. Lubricate all parts with clean hydraulic oil. STEP 1. Install new dust seal in housing.

1. HOUSING 2. DUST SEAL

1600 SRM 786 STEP 2. Put spool on workbench, then put housing onto spool as shown. Install guide ring with O-ring on the end of spool. Put a large thrust washer (see STEP 5) on top of guide ring and O-ring assembly. Use a deep socket or tube to push on washer, and install O-ring and guide ring in housing. Carefully remove washer, tube, and spool from housing.

Steering Control Unit Repair

1. 2. 3. 4. 5. 6. STEP 3. Carefully assemble spool and sleeve. Make sure spool rotates freely in sleeve.

O-RING GUIDE RING SPOOL WASHER TUBE HOUSING

1. SPOOL 2. SLEEVE

Steering Control Unit Repair

1600 SRM 786

STEP 4. Assemble NEUTRAL position springs, then push them into position in spool. Make sure flat springs are installed to the outside of curved springs. Install center pin. Install ring on sleeve (over NEUTRAL position springs). The ring must turn freely on the sleeve.

1. NEUTRAL POSITION SPRINGS (FLAT) 2. NEUTRAL POSITION SPRINGS (CURVED) 3. CENTER PIN

4. SPOOL 5. RING

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1600 SRM 786 STEP 5. Install thrust washers and thrust bearing on spool. Make sure chamfer on inner thrust washer is toward sleeve. Install spool and sleeve assembly in housing. Carefully rotate spool and sleeve assembly during installation to make sure spool fits correctly in seal installed in STEP 2. Make sure center pin in spool and sleeve assembly is horizontal (parallel to port surface).

Steering Control Unit Repair

1. 2. 3. 4. 5. 6.

HOUSING SPOOL AND SLEEVE ASSEMBLY THRUST WASHER THRUST BEARING SPOOL SLEEVE

STEP 6. Install check ball and sleeve. Make sure the sleeve is even with or below the surface of the housing. Lubricate O-ring and install O-ring and port plate. Align holes in port plate with holes in housing.

1. CHECK BALL SLEEVE 2. HOUSING

3. O-RING 4. PORT PLATE

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Steering Control Unit Repair

1600 SRM 786

STEP 7. Install center shaft so it engages with center pin in spool and sleeve assembly. Make sure the center pin is still parallel to the port surface. Install rotor on center shaft. Make sure a valley in the rotor aligns with slot (center pin) in center shaft. Install O-ring and stator. Make sure to align the marks made during disassembly.

1. CENTER SHAFT 2. CENTER PIN 3. ROTOR

4. STATOR 5. O-RING

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1600 SRM 786

Steering Control Unit Repair

STEP 8. Install spacer. Install O-ring and cover. Tighten capscrews for the cover, in the sequence shown, to 17 Nm (150 lbf in). Then tighten them to 30 Nm (265 lbf in). Make sure the capscrew with the pin fits in the hole for the check ball.

1. SPACER 2. O-RING 3. COVER

4. CAPSCREW 5. CHECK BALL

STEP 9. Install manifold block and O-rings on steering control unit.

INSTALL WARNING
After making repairs, do not extend the hands or arms through the center of the steering wheel. If the control unit was not assembled correctly, or hoses are not connected correctly, it can rotate with a strong force and cause

injury. If this action occurs, disassemble the control unit and correct the problem. 1. Install control unit on bracket. See Figure 4. Connect lines at manifold block and steering control unit. 2. Connect steering column. Install housing.

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Steering Axle Repair

1600 SRM 786

Steering Axle Repair

DESCRIPTION
The steering axle assembly includes an axle frame, a steering cylinder, and two spindle and hub assemblies. See Figure 5. The axle assembly is connected to the frame with two pivot shafts. The ends of the axle and steer wheels can move up and down when the vehicle travels over rough surfaces. The ends of the piston rod extend from both ends of the steering cylinder shell. Tie rods connect the spindle arms to the cylinder rod. Oil pressure on one side of the piston moves the piston in the bore. The piston pushes an equal amount of oil from the opposite side of the cylinder. A relief valve in the steering system controls the oil pressure when the piston reaches the end of the cylinder.

1. 2. 3. 4.

HUB LOCK RING BUSHING PIN

5. 6. 7. 8.

PLATE PIVOT PIN PIVOT BUSHING AXLE FRAME

9. 10. 11. 12.

TIE ROD STEERING CYLINDER WASHER SET WASHER

Figure 5. Steering Axle Assembly

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1600 SRM 786

Steering Cylinder Repair 2. Put a lifting device under the axle. Remove plates that hold pivot pins in frame. Remove pivot pins. Lower axle from frame and remove axle.

REMOVE WARNING
Put the rear of the vehicle on blocks. Follow the procedures for raising the vehicle in the Operating Manual or Periodic Maintenance section. The surface must be solid, even, and level. Make sure any blocks used to support the vehicle are solid, one piece units. Make sure the lifting devices used during repairs can lift the weight of the parts. 1. Remove counterweight. [The counterweight weighs approximately 17,000 kg (37,500 lb).] See Figure 5. When removing axle, disconnect hydraulic lines and install caps on cylinder fittings. The caps will prevent cylinder rod from moving as axle is removed.

INSTALL
1. When installing axle, make sure washer sets and bushing are in correct position. See Figure 5. Lubricate bushings and pivot shafts with multipurpose grease. Raise axle into frame mounts. Install pivot shafts and plates. Install counterweight. [The counterweight weighs approximately 17,000 kg (37,500 lb).] 2. Check the operation of the antitipping device as described in Antitipping Device Adjustment.

Steering Cylinder Repair

REMOVE WARNING
Make sure the lifting devices used during repairs can lift the weight of the parts. [The counterweight 1. Remove counterweight. weighs approximately 17,000 kg (37,500 lb).] Disconnect hydraulic lines and install caps on cylinder fittings. See Figure 5. 2. Disconnect tie rods at cylinder. Remove capscrews that hold cylinder to axle frame. Remove cylinder. Clean all parts in solvent. Dry parts with compressed air. Make sure all surfaces are free of scratches and sharp edges. 1. Inspect piston rod for grooves or damage. 2. Inspect brackets on cylinder for cracks.

ASSEMBLE
1. Repair cylinder as necessary using new seals and O-rings. Lubricate parts with hydraulic oil during assembly. 2. Install retainers at ends of cylinder.

CLEAN AND INSPECT WARNING

Cleaning solvents can be flammable and toxic, and can cause skin irritation. When using cleaning solvents, always follow the solvent manufacturers recommended safety precautions.

INSTALL WARNING
Make sure the lifting devices used during repairs can lift the weight of the parts. 1. Install hydraulic fittings on cylinder. Install cylinder and mounting blocks on axle frame. Tighten capscrews that hold cylinder to axle frame to 500 Nm (370 lbf ft). 2. Connect tie rods to cylinder. (See Figure 5.) [The counterweight 3. Install counterweight. weights approximately 17,000 kg (37,500 lb).]

WARNING
Compressed air can move particles so they cause injury to the user or to other personnel. Make sure the path of the compressed air is away from all personnel. Wear protective goggles or a face shield to prevent injury to the eyes.

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Hubs Repair

1600 SRM 786

Hubs Repair
REMOVE
Remove hub cover. See Figure 6. Remove adjustment nuts and lock ring. Remove hub. If the bearings or the seals are replaced, use a brass drift to remove inner bearing assembly from hub. Check for damage or wear on bearings.

INSTALL
1. Lubricate bearings with multipurpose grease. See Figure 6. Install the inner bearing and seal. Install hub, outer bearing, washer, and adjustment nut on spindle. Tighten adjustment nut while rotating hub. 2. Install lock ring against adjustment nut. Tighten adjusting nut a small amount until tab on lock ring aligns with a notch in adjustment nut. Bend tab on lock ring to lock adjustment nut. 3. Install outer adjustment nut and tighten it. Bend tab on lock ring to lock the nut. 4. Fill hub with multipurpose grease. Install hub cover.

CLEAN WARNING
Cleaning solvents can be flammable and toxic and can cause skin irritation. When using cleaning solvents, always follow the solvent manufacturers recommended safety procedures. Clean all parts with solvent. Make sure bearings are clean.

1. 2. 3. 4.

HUB COVER LOCK RING WASHER HUB

5. 6. 7. 8.

SPINDLE SEAL BEARING CAP CAP

9. 10. 11. 12.

BUSHING KING PIN CAPSCREW AXLE FRAME

13. BEARING 14. ADJUSTMENT NUT

Figure 6. Hub and Spindle

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1600 SRM 786

Relief Valve Adjustment for Steering System

Spindles Repair
REMOVE WARNING
Completely remove the air pressure from the tires before removing the wheels from the vehicle. Air pressure in the tires can cause the tire and rim parts to explode, causing serious injury or death. Always wear safety glasses. 1. Remove wheels from steering axle to service spindles. See Figure 6. Remove hubs. Disconnect tie rod from spindle. Remove caps for spindle. 2. Connect lifting device to spindle. Remove capscrews that hold bearing caps to axle frame. 3. Remove spindle assembly from axle.

INSTALL
1. Lubricate thrust washers and bushings with multipurpose grease. See Figure 6. Install thrust washers and seals on spindle. Install bushings on spindle. 2. Install spindle assembly in axle frame. Install bearing cap and capscrews. Tighten capscrews. 3. Install caps for spindle. 4. Connect tie rod to spindle. (See Figure 5.) Install hubs as described in Hubs Repair.

System Air Removal

Air can enter the system when a hydraulic line is disconnected. If the operation is rough, start the engine and rotate the steering wheel stop to stop several times in each direction. The air will be removed without disconnecting any lines. If the operation is still rough, air can be entering the system at a loose fitting.

Relief Valve Adjustment for Steering System

WARNING
Before disconnecting any hydraulic lines or fittings, release pressure from the hydraulic circuit as follows: 1. Shut the engine off and completely lower the boom. 2. Operate the joystick and the brake pedals until the hydraulic pressure is released. The relief valve for the steering system is in the main control valve. See Figure 7. Adjust the setting of the relief valve for the steering system as follows: 1. Install pressure gauge of 600 bar (8700 psi) at main pressure test port (M) on main control valve. 2. Start engine. Operate hydraulic system until temperature of hydraulic oil is 55 to 65 C (130 to 150 F). 3. With engine at full throttle, adjust main regulators to 420 bar (6100 psi). With the steering cylinder at full stroke, adjust relief valve (P2) to obtain 220 bar (3200 psi).

1. STEERING RELIEF VALVE 220 bar (3200 psi) 2. MAIN PRESSURE TEST PORT 3. MAIN CONTROL VALVE Figure 7. Steering Relief Valve 17

Antitipping Device Adjustment

1600 SRM 786

Antitipping Device Adjustment

NOTE: At 75% of the tipping load, the complete vehicle lifts up except the steering axle. The steering axle equals 25% of the tipping load. 1. Pick up load of approximately 12 to 15 metric ton (26,000 to 33,000 lb). 2. Raise load 75 mm (3 in.) from ground. Extend boom slowly to shift weight forward and remove weight from steering axle. Lower load to ground and make sure steering tires contact the ground. 3. Remove cover for switch. See Figure 8. Loosen lock nut for the adjustment bolt. Turn adjustment bolt clockwise until spring bracket is loose. Check that clearance between switch and adjustment bolt is 2 to 3 mm (0.08 to 0.12 in.). (When switch is open, warning light is on and alarm sounds.) Tighten lock nut. Install cover. 4. Release load on vehicle and antitipping mechanism will return to its normal position.

1. 2. 3. 4. 5.

LINK SUPPORT LOCK NUT SWITCH COVER

6. 7. 8. 9.

ADJUSTMENT BOLT SPRING SPRING BRACKET STEERING AXLE

Figure 8. Antitipping Device

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1600 SRM 786

Troubleshooting

Troubleshooting
PROBLEM There is no action when the steering wheel is turned. POSSIBLE CAUSE Oil level is low. There is no oil in tank. Lines are loose at control unit or manifold block. Sleeve and spool in control unit will not move. The vehicle steers slowly. The steering wheel is hard to turn. Oil level is low. There is no oil in tank. Lines to control unit are damaged. Sleeve and spool in control unit are worn. Parts of metering section are worn. Check valve in control unit does not open. PROCEDURE OR ACTION Fill tank to correct level. Tighten oil lines. Replace control unit.

Fill tank to correct level.

Replace oil lines. Replace control unit. Replace control unit. Replace control unit.

The steering wheel turns the tires in the wrong direction.

Lines at control unit are not correctly connected. Metering rotor in control unit is not correctly aligned.

Connect lines correctly. Assemble control unit correctly.

The tires continue to turn after the steering wheel stops.

NEUTRAL position springs in control unit are broken. Sleeve or spool in control unit has damage.

Repair or replace control unit. Replace control unit.

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NOTES ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________

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TECHNICAL PUBLICATIONS
1600 SRM 786 7/06 (11/03)(1/00) Printed in United Kingdom