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STEERING SYSTEM

H8.00-12.00XM (H170-280HD)
[F007, G007, H007];
H13.00-14.00XM (H300-330HD)
[E019, F019, G019];
H16.00XM-6 (H360HD) [E019, F019,
G019]; H10.00-12.00XM-12EC (H360HD-EC)
[E019, F019, G019]

PART NO. 1494140 1600 SRM 936


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 Mainte-
nance 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 Table of Contents

TABLE OF CONTENTS

General ............................................................................................................................................................... 1
Description ......................................................................................................................................................... 1
Steering Wheel and Column Assembly............................................................................................................. 3
General ........................................................................................................................................................... 3
Steering Wheel and Horn.............................................................................................................................. 3
Remove....................................................................................................................................................... 3
Install ......................................................................................................................................................... 3
Steering Control Unit Repair ............................................................................................................................ 5
General ........................................................................................................................................................... 5
Description ..................................................................................................................................................... 5
Operation ....................................................................................................................................................... 5
Remove ........................................................................................................................................................... 6
Disassemble ................................................................................................................................................... 6
Clean .............................................................................................................................................................. 9
Assemble and Install ..................................................................................................................................... 9
Steering System Air Removal ........................................................................................................................... 15
Steering Relief Pressure Check......................................................................................................................... 16
Troubleshooting.................................................................................................................................................. 16

This section is for the following models:

H8.00-12.00XM (H170-280HD) [F007, G007, H007];


H13.00-14.00XM (H300-330HD) [E019, F019, G019];
H16.00XM-6 (H360HD) [E019, F019, G019];
H10.00-12.00XM-12EC (H360HD-EC) [E019, F019, G019]

©2007 HYSTER COMPANY i


"THE
QUALITY
KEEPERS"

HYSTER
APPROVED
PARTS
1600 SRM 936 Description

General
This section has the description and repair proce- the parts of the steering axle are in the section Steer-
dures for the parts of the steering system. Descrip- ing Axle 1600 SRM 326. Repair information for the
tion and repair information is given for the steer- steering hydraulic pump is in the section Hydraulic
ing wheel and column assembly, the steering control System 1900 SRM 938.
unit, and the priority valve. Repair information for

Description
These lift trucks use a hydraulic steering system. When the engine is not running, a check valve closes
See Figure 1 and Figure 2. The hydraulic system has and permits the steering control unit to control the
a tandem, gear-type pump. The two sections have a steering system. The lift truck is difficult to steer
common inlet and separate outlets. The small sec- when the steering pump is not operating, but the
tion of the pump supplies oil to the steering system. steering control unit can make steering possible.
When the steering wheel is not turned, most of the
hydraulic oil from the small pump goes to the main
control valve via the priority valve for the lift, tilt,
and auxiliary circuits.

1. STEERING CYLINDER 4. HYDRAULIC TANK


2. MANIFOLD BLOCK 5. PILOT VALVE
3. STEERING PRIORITY VALVE 6. HYDRAULIC PUMP

Figure 1. Steering System Diagram

1
Description 1600 SRM 936

1. HYDRAULIC TANK 6. STEERING CONTROL UNIT


2. SMALL HYDRAULIC PUMP 7. STEERING CYLINDER
3. LARGE HYDRAULIC PUMP 8. TO MAIN CONTROL VALVE
4. STEERING LINE RELIEF VALVE 9. TO PILOT BLOCK VALVE
5. STEERING PRIORITY VALVE

Figure 2. Steering System Schematic Diagram

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1600 SRM 936 Steering Wheel and Column Assembly

Steering Wheel and Column Assembly


GENERAL 1. Disconnect battery. Remove horn button from
steering wheel. See Figure 3.
The steering column, located in the cab, is mounted
to a support bracket and the floor of the cab. See 2. Remove electrical wire from horn button. Re-
Figure 3. The steering column is fitted to the steering move large nut and pull steering wheel from
control unit through the cab floor. The steering wheel steering shaft.
is held on the splines of the steering column with a
large nut. The steering control unit has splines that 3. See Steering Control Unit Repair for more disas-
engage with the lower end of the steering column. sembly procedures.
The steering control unit is fastened to the underside
of the cab floor with four bolts. Install
1. Install steering wheel and large nut onto steering
STEERING WHEEL AND HORN
shaft. See Figure 3. Tighten nut to 35 to 45 N•m
This procedure describes the replacement of the (26 to 33 lbf ft).
steering wheel and horn actuator assembly. Disas-
2. Attach electrical wire from horn switch to horn
semble the parts as required to make repairs.
button. Install horn button.
Remove

WARNING
To prevent electrical arcs when removing
cover, disconnect negative battery cable.

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Steering Wheel and Column Assembly 1600 SRM 936

1. SCREW 10. UPPER STEERING COLUMN COVER


2. WASHER 11. LH STEERING COVER COLUMN
3. SCREW 12. RH STEERING COVER COLUMN
4. WASHER 13. LH STEERING COVER COLUMN
5. SOCKET 14. RH STEERING COVER COLUMN
6. HORN BUTTON 15. COLUMN ASSEMBLY - STEERING
7. SPINNER KNOB 16. BOOT
8. STEERING WHEEL 17. LIGHT
9. HARNESS

Figure 3. Steering Wheel and Steering Column Assembly

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1600 SRM 936 Steering Control Unit Repair

Steering Control Unit Repair


GENERAL from pump flows through the steering control unit
to the main control valve. To return the tires to the
This section has a description section, an operation straight position, the steering wheel must be rotated
section, and repair procedures for the steering con- in the opposite direction. The steering control unit
trol unit. will operate as described, but all parts will rotate in
the opposite direction.
DESCRIPTION
The steering control unit has a pilot-operated relief
The steering control unit is a hydrostatic unit con- valve and an additional port for a pilot line. A prior-
trolled by the steering wheel. See Figure 4. It is ity valve is also used in the system and is connected
mounted on the underside of the cab floor. The steer- to the hydraulic pump.
ing control unit has a shaft assembly, control section,
and a metering section. The hydraulic hoses for the The demand for steering is sensed at the LS port in
steering system are fastened to a manifold block. the steering control unit. The pilot line from the LS
port is connected to the priority valve. The priority
Turning the steering wheel actuates three main valve has a pilot-operated spool. While steering, a
parts of the steering control unit: (1) the spool for spring and pilot pressure from the load sensing (LS)
the control section, (2) the sleeve for the control line hold the spool open for steering. When there is
section, and (3) the rotor in the metering section. no pressure in the LS line (no steering), pilot pres-
When the steering wheel is not moving, the spool sure from the hydraulic pump shifts 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.

OPERATION
As the steering wheel is turned, the spool just begins
to rotate. See Figure 4. 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 one side of the steering cylinder. Oil
from the other side of the steering cylinder flows back 1. CONTROL SECTION
to the control section of the steering control unit. 2. METERING SECTION
3. CHECK BALL (MANUAL OPERATION)
When the steering wheel stops moving, the metering 4. SLEEVE
action in the metering section also stops. The neutral 5. NEUTRAL POSITION SPRINGS
6. SPOOL
position springs return the sleeve to the neutral po-
sition. When this action occurs, the pressure stays in Figure 4. Steering Control Unit
the steering cylinder to keep the tires in position. Oil

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Steering Control Unit Repair 1600 SRM 936

REMOVE 3. Remove four capscrews that fasten steering con-


trol unit to underside of cab floor and remove
1. Raise operator’s cab. See the section Operators steering control unit from end of steering column.
Cab for your lift truck. See Figure 3.
2. Put tags on hydraulic lines at manifold block.
Disconnect hydraulic lines and put caps on open-
ings.

DISASSEMBLE
NOTE: Tag location of all component parts to help in assembly of control unit.

NOTE: Do not disassemble manifold block. Check valve cannot be removed. Relief valve is set by manufacturer.

STEP 1.
Put 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. O-RING
2. COVER
3. CAPSCREW

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1600 SRM 936 Steering Control Unit Repair

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

1. O-RING
2. CENTER SHAFT
3. PORT PLATE
4. STATOR
5. ROTOR
6. SPACER

STEP 4.
Remove retainer for check ball. Remove check ball.

1. RETAINER

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Steering Control Unit Repair 1600 SRM 936

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. SPOOL AND SLEEVE ASSEMBLY 5. NEUTRAL POSITION SPRINGS


2. RING 6. CENTER PIN
3. SPOOL 7. THRUST BEARING
4. SLEEVE 8. THRUST WASHER

STEP 6.
Remove relief valve assembly and dust seal from
housing. Do not disassemble relief valve cartridge.

1. DUST SEAL
2. RELIEF VALVE ASSEMBLY
3. HOUSING

8
1600 SRM 936 Steering Control Unit Repair

CLEAN manufacturer’s recommended safety precau-


tions.
WARNING Clean all parts in solvent. Dry parts with compressed
Cleaning solvents can be flammable and toxic air. Do not dry parts with a cloth. Make sure all
and can cause skin irritation. When using surfaces are free of scratches and sharp edges.
cleaning solvents, always follow the solvent

ASSEMBLE AND INSTALL


NOTE: Use new seals, O-rings, and neutral position springs during assembly. Lubricate all parts with clean
hydraulic oil.

STEP 1.
Carefully assemble spool and sleeve. Make sure spool
rotates freely in sleeve. Make sure alignment marks
are aligned.

1. SPOOL
2. SLEEVE

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Steering Control Unit Repair 1600 SRM 936

STEP 2.
Assemble neutral position springs, then push them
into position in spool. Make sure flat springs are
installed to outside of curved springs. Install center
pin. Install ring on sleeve (over neutral position
springs). Ring must turn freely on sleeve.

1. SPOOL
2. NEUTRAL POSITION SPRINGS (FLAT)
3. NEUTRAL POSITION SPRINGS (CURVED)
4. CENTER PIN
5. RING

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1600 SRM 936 Steering Control Unit Repair

STEP 3.
Put spool on workbench; then put housing onto spool
as shown. Install guide ring with O-ring on end of
spool. Put a large thrust washer (see STEP 4) on top
of guide ring and O-ring assembly. Use socket or tube
to push on washer and install O-ring and guide ring
in housing. Carefully remove washer, tube, and spool
from housing.

1. HOUSING
2. WASHER
3. O-RING
4. GUIDE RING
5. SPOOL
6. TUBE

STEP 4.
Install thrust washers and thrust bearing on spool.
Make sure chamfer on inner thrust washer is next to
sleeve.

1. THRUST BEARING
2. THRUST WASHER
3. SPOOL
4. SLEEVE

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Steering Control Unit Repair 1600 SRM 936

STEP 5.
Install spool and sleeve assembly in housing. Care-
fully rotate spool and sleeve assembly during in-
stallation to make sure spool fits correctly in seal
installed in STEP 3. Make sure center pin on spool
and sleeve assembly is horizontal (parallel to surface
with ports).

1. HOUSING
2. SPOOL AND SLEEVE ASSEMBLY

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

1. CHECK BALL RETAINER


2. O-RING
3. PORT PLATE
4. HOUSING

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1600 SRM 936 Steering Control Unit Repair

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

1. CENTER SHAFT 4. STATOR


2. CENTER PIN 5. O-RING
3. ROTOR

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Steering Control Unit Repair 1600 SRM 936

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

1. CHECK BALL 4. O-RING


2. RETAINER 5. COVER
3. CAPSCREW 6. SPACER

STEP 9.
Install dust seal in housing. When used, install relief
valve assembly.

1. DUST SEAL
2. RELIEF VALVE ASSEMBLY

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1600 SRM 936 Steering System Air Removal

STEP 10.
Install manifold block and O-rings on steering con-
trol unit. Tighten capscrews for manifold block to
40 N•m (30 lbf ft).

1. MANIFOLD BLOCK
2. O-RING
3. STEERING CONTROL UNIT

WARNING
After making repairs, do not extend hands or arms through steering wheel. If control unit was not
assembled correctly or lines not connected correctly, steering wheel can rotate with a strong force
and cause injury. If this action occurs, disassemble control unit or check lines to correct problem.

STEP 11.
See Figure 3. Install steering column and steering control unit on brackets. Connect hydraulic lines at manifold
block. Start engine and operate steering wheel. Check for correct operation.

Steering System Air Removal


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

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Troubleshooting 1600 SRM 936

Steering Relief Pressure Check


NOTE: The relief valve is in the steering control unit. 6. If relief pressure is not correctly set, remove
The relief pressure is set at the factory. plug and adjust pressure by turning adjustment
screw. If you cannot correctly adjust relief pres-
1. Tilt operator’s cab. See the section Operator’s sure, replace parts of relief valve.
Cab for your lift truck.
7. When checks are complete, remove gauge and in-
2. Connect 0 to 20 MPa (0 to 3000 psi) gauge to test stall cap on fitting.
port. See Figure 5.

3. Start engine. Operate hydraulic system until


temperature of hydraulic oil is 55 to 65 C (130 to
150 F). Run engine at approximately 2500 rpm
when checking pressure.

4. Steer in one direction until wheels will not turn


further. Keep steering wheel fully turned and
read gauge. Correct relief pressure is 16.5 MPa
(2400 psi).

5. If relief pressure is not correct, remove plug and


adjust pressure by turning screw.

WARNING 1. STEERING RELIEF VALVE PLUG


The adjustment screw compresses a spring. 2. MANIFOLD BLOCK
Use caution and wear eye protection when Figure 5. Manifold Block, Steering Control
adjusting relief valve. Unit

Troubleshooting

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

No action when steering No oil or not enough oil in hydraulic Fill tank to correct level.
wheel is turned. tank.

Lines are loose at control unit or Tighten fittings.


manifold block.

Sleeve and spool in control unit will Repair steering control unit.
not move.

Steering cylinder leaks. Repair steering cylinder.

Spacer for center pin is not installed. Assemble steering control unit cor-
rectly.

16
1600 SRM 936 Troubleshooting

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

Lift truck steers slowly. Oil level is low. There is no oil in Fill tank to correct level.
Steering wheel is hard to tank.
turn.

Lines to control unit are damaged. Repair oil lines.

Sleeve and spool in control unit are Repair steering control unit.
worn.

Parts of metering section are worn. Repair steering control unit.

Check valve in control unit does not Clean or repair steering control unit.
open.

Check valve or relief valve in man- Clean or replace manifold block.


ifold block is damaged or is not ad-
justed correctly.

Priority valve is not operating cor- Clean or repair priority valve.


rectly.

Steering relief pressure is too low. Adjust relief pressure.

Engine idle speed is too low. Adjust idle speed to specifications.

Steering wheel turns tires in Lines at control unit are not correctly Connect lines correctly.
wrong direction. connected.

Tires continue to turn after Neutral position springs are broken. Repair steering control unit.
steering wheel stops.

Sleeve or spool has damage. Repair steering control unit.

Steering wheel kicks back in Center shaft is not correctly aligned Assemble steering control unit cor-
both directions. with metering section. rectly.

17
NOTES

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TECHNICAL PUBLICATIONS

1600 SRM 936 3/07 (9/03)(2/01)(1/95) Printed in U.S.A.

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