STEERING HOUSING

AND STEERING

CONTROL UNIT

J1.60XMT-Plus, J1.80XMT-Plus,

J2.00XMT-Plus [G160]

PART NO. 897983

1600 SRM 655

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 Housing and Steering Control Unit

Table of Contents

TABLE OF CONTENTS

General ...............................................................................................................................................................

1

Description .........................................................................................................................................................

1

Operation............................................................................................................................................................

2

Steering Housing Repair ...................................................................................................................................

2

Remove and Disassemble ..............................................................................................................................

2

Clean ..............................................................................................................................................................

2

Assemble and Install .....................................................................................................................................

4

Steering Control Unit Repair ............................................................................................................................

4

Remove ...........................................................................................................................................................

4

Disassemble ...................................................................................................................................................

4

Clean ..............................................................................................................................................................

4

Assemble ........................................................................................................................................................

6

Install .............................................................................................................................................................

6

System Air Removal ..........................................................................................................................................

6

Troubleshooting..................................................................................................................................................

7

This section is for the following models:

J1.60XMT-Plus, J1.80XMT-Plus,

J2.00XMT-Plus [G160]

©2002 HYSTER COMPANY

i

"THE

QUALITY

KEEPERS"

HYSTER

APPROVED

PARTS

1600 SRM 655

Description

General

This section has the description and repair procedures for the steering housing and the steering control unit.
Additional information on parts of the steering system are in the sections Steering Axle 1600 SRM 532 and
Hydraulic System 1900 SRM 539.

Description

The steering housing has the mounts for the steer-
ing column and the steering control unit. See Fig-
ure 1. The steering wheel is installed on the steer-
ing column. The housing is adjustable and is held
in position by a latch. The position of the housing
can be changed for different operator requirements.
The steering housing is also the mount for the con-
trol levers and the instrument cluster.

The steering system is a hydraulic system that does
not have a mechanical connection between the steer-
ing wheel and the steering axle. The control of the
steering is through a hydraulic circuit.

If the main hydraulic pump does not operate, a check
ball permits the steering control unit to control the
steering system. The lift truck is difficult to steer
when the hydraulic pump is not operating, but the
steering control unit can operate the steering cylin-
der and make steering possible.

1. STEERING WHEEL

2. STEERING

COLUMN

3. STEERING

CONTROL UNIT

4. KNOB

5. LATCH

6. COVER

7. COWL

8. MOUNT

Figure 1. Steering Housing Assembly

1

Steering Housing Repair

1600 SRM 655

Operation

The steering control unit is a rotary valve that is op-
erated by the steering wheel. During the steering op-
eration, the steering control unit controls the direc-
tion of flow and amount of oil that flows to the steer-
ing axle. The steering cylinder actuates the steering
linkage to move the steering tires. Hydraulic oil re-
turns from the steering cylinder to the steering con-
trol unit and then returns to the hydraulic tank. See
Figure 2 and Figure 3.

Turning the steering wheel actuates three main
parts of the steering control unit: (1) The spool for
the control section, (2) the sleeve for the control
section, and (3) the gearwheel set 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.

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 gearwheel
set 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 gearwheel set in the metering
section. The oil then flows to one side of the steer-
ing cylinder. Hydraulic oil from the other side of the
steering cylinder returns through 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 po-
sition. When this action occurs, the pressure stays in
the steering cylinder to keep the steering tires in po-
sition. Oil from the pump flows through the steering
control unit to the tank or other parts of the system.
To return the steering 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 di-
rection.

Steering Housing Repair

REMOVE AND DISASSEMBLE

1. Disconnect the negative battery cable at the bat-

tery. Remove the rear cover for the steering hous-
ing. See Figure 2. Remove the instrument clus-
ter. Remove the front cover for the steering hous-
ing.

2. Put tags for identification on the hydraulic hoses

at the steering control unit so that they can be
connected correctly during assembly. Disconnect
the hydraulic hoses at the bottom of the steering
control unit. Install plugs at all hose ports to
prevent dirt from entering the steering hydraulic
system.

3. Remove the horn button. Disconnect the wire at

the horn button. Remove nut and steering wheel.

4. Remove the capscrews and nuts that hold the

steering column and the control unit to the

bracket. Remove the steering column and the
control unit. Remove the parts from the housing
as necessary.

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 precau-
tions and procedures.

Clean all the parts in solvent. Dry the parts with
compressed air. Do not dry the parts with a cloth.
Make sure all surfaces are free of scratches and sharp
edges.

2

1600 SRM 655

Steering Housing Repair

WARNING

The hydraulic hoses MUST be connected to the correct ports; or the steering system will not operate as
expected, which can cause damage or personal injury. Make sure the hoses are identified and connected
correctly.

1. FRONT COVER

2. REAR COVER

3. HORN BUTTON

4. NUT

5. STEERING WHEEL

6. CAPSCREW

7. LOCKWASHER

8. WASHER

9. BRACKET

10. STEERING COLUMN

11. STEERING CONTROL UNIT

12. MOUNT

13. PIVOT SHAFT

14. PLATE

15. CAPSCREW

16. SPRING

17. SCREW

18. KNOB

19. LATCH

20. ROD

21. WASHER

22. SPRING

23. COTTER PIN

24. PIN

25. SOCKET HEAD SCREW

Figure 2. Steering Housing Disassembly

3

Steering Control Unit Repair

1600 SRM 655

ASSEMBLE AND INSTALL

1. Install the steering column and steering control

unit in the bracket. Install the steering wheel
and nut. See Figure 2. Tighten the nut to 40 to
54 N•m (30 to 40 lbf ft). Connect the wire at the
horn button and install the horn button.

2. Install the mount on the cowl. Install the latch on

the bracket, using the pin and cotter pin. Install

the bracket on the mount with the pivot shaft
and spring. Install the plates and capscrews that
hold the bracket to the shaft. Install the spring
washer and rod for the latch. Install the knob on
the latch. Install the socket head screw and nut.

3. Install the instrument cluster on the front cover

and make the necessary wiring connections. In-
stall the covers on the bracket. Connect the hy-
draulic lines to the steering control unit.

Steering Control Unit Repair

REMOVE

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 the hoses were not connected
correctly, it can rotate with a strong force and
cause serious injury.

If this action occurs,

disassemble the control unit and correct the
existing problem.

1. Disconnect the negative battery cable at the bat-

tery. See Figure 2. Remove the rear cover for the
steering housing. Remove the instrument clus-
ter. Remove the front cover for the steering hous-
ing.

2. Put tags for identification on the hydraulic hoses

at the steering control unit so that they can be
connected correctly during assembly. Disconnect
the hydraulic hoses at the bottom of the steering
control unit. Install plugs at all hose ports to
prevent dirt from entering the steering hydraulic
system.

3. Remove the horn button. Disconnect the wire at

the horn button. Remove nut and steering wheel.

4. Remove the capscrews and nuts that hold the

steering column and the control unit to the
bracket. Remove the steering column and the
control unit.

DISASSEMBLE

1. Make an identification mark on the length of the

steering control unit. In assembling the housing,
the distributor plate and the gearwheel set will
be in line with the end cover. See Figure 3.

CAUTION

The special screws and O-rings have to be re-
placed into the ports they came out of for the
steering control unit to work correctly.

2. Remove the special screws. Mark the screws at

the control unit so that they can be assembled
correctly.

3. Remove the end cover on the bottom of the steer-

ing control unit.

4. Remove the cardan spool, the spacer, the distrib-

utor plate, and the gearwheel set. Remove the
O-rings.

5. Remove the dust seal ring. Remove the spool

and sleeve assembly. Remove the bearing as-
sembly and shaft seals. Push the cross pin from
the sleeve. Carefully remove the spool from the
sleeve. (Rotate the spool slowly during removal.)
Remove the springs from the spool.

6. Remove the ball and ball stop.

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 precau-
tions and procedures.

1. Clean all the parts in solvent.

2. Dry the parts with compressed air. Do not dry

the parts with a cloth.

3. Make sure all surfaces are free of scratches and

sharp edges.

4

1600 SRM 655

Steering Control Unit Repair

Figure 3. Steering Control Unit

5

System Air Removal

1600 SRM 655

Legend for Figure 3

1. SEAL RING

2. HOUSING

3. BALL

4. STOP

5. SHAFT SEALS

6. BEARING

7. SPOOL

8. PIN

9. SLEEVE

10. SPRING SET

11. SHAFT

12. SPACER

13. O-RING

14. PLATE

15. GEAR SET

16. RELIEF VALVE ASSEMBLY

17. END COVER

18. O-RING

19. SPECIAL SCREW

20. SPECIAL SCREW

21. BALL

ASSEMBLE

1. Carefully assemble the spool and sleeve. Make

sure the spool rotates freely in the sleeve. See
Figure 3.

CAUTION

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

2. Assemble the springs and then push them into

position in the spool. Make sure the flat springs
are installed to the outside of the curved springs.
Install the cross pin.

3. Install the bearing and shaft seal on the spool.

Carefully install the spool and sleeve assembly in
the housing. Install the seal ring in the housing.

4. Install the ball and stop in the housing. Install

the shaft and spacer in the sleeve. Assemble the
O-rings, plate, gear set, and end cover against

the housing. Install the ball and O-rings in the
housing.

5. Install the relief valve assembly.

INSTALL

1. Install the steering column and steering control

unit in the bracket. See Figure 2. Install the
steering wheel and nut. Tighten the nut to 40
to 54 N•m (30 to 40 lbf ft). Connect the wire at
the horn button and install the horn button.

2. Install the mount on the cowl. Install the latch on

the bracket, using the pin and cotter pin. Install
the bracket on the mount with the pivot shaft
and spring. Install the plates and capscrews that
hold the bracket to the shaft. Install the spring
washer and rod for the latch. Install the knob on
the latch. Install the socket head screw and nut.

3. Install the instrument cluster on the front cover

and make the necessary wiring connections. In-
stall the covers on the bracket. Connect the hy-
draulic lines to the steering control unit.

System Air Removal

Air can enter the system when a hydraulic line is dis-
connected. If the operation is rough, start the motor
and rotate the steering wheel from stop to stop sev-
eral times in each direction. The air will be removed

without disconnecting any lines. If the operation is
still rough, check if air is entering the system at a
loose fitting.

6

1600 SRM 655

Troubleshooting

Troubleshooting

PROBLEM

POSSIBLE CAUSE

PROCEDURE OR ACTION

There is no action when the
steering wheel is turned.

The oil level is low or there is no oil
in the tank.

Add oil to correct level.

The steering control unit is dam-
aged.

Repair or replace steering control
unit.

No oil flow from the steering control
unit to the steering cylinder.

Repair or replace steering control
unit. Check hoses for damage and
replace if required.

The sleeve and spool in the control
unit will not move.

Clean and repair the sleeve and
spool.

Hydraulic hoses or connections are
open.

Tighten hose connections.

Slow or difficult steering.

Relief valve for the steering system
needs adjustment.

Adjust to proper specifications.

Low oil pressure from the hydraulic
pump.

Clean, repair, or replace hydraulic
pump. Check hoses for damage and
replace if required.

Seal in the steering cylinder has a
leak.

Replace seal.

Damaged or worn steering control
unit.

Replace steering control unit.

Steering wheel turns the
tires in the wrong direction.

The hydraulic hoses are not con-
nected correctly at the steering
cylinder or at the steering control
unit.

Correctly connect hoses.

Steering function contin-
ues after the steering wheel
stops.

The steering control unit is dam-
aged.

Replace steering control unit.

The steering operation is not
smooth.

The oil level in the tank is low.

Add oil to correct level.

Air was not removed after repair to
the hydraulic system.

Purge air from hydraulic system.

The hydraulic pump has a leak at the
inlet.

Repair leak.

7

NOTES

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8

TECHNICAL PUBLICATIONS

1600 SRM 655

3/02 (8/99)(3/97) Printed in United Kingdom