STEERING SYSTEM

J1.60XMT, J1.80XMT,

J2.00XMT [E160, G160];

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

J2.00XMT-Plus [G160]

PART NO. 1453608

1600 SRM 687

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 ...............................................................................................................................................................

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

Steering Wheel and Column Assembly.............................................................................................................

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

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

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

Power Steering Pump and Motor......................................................................................................................

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

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

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

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

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

Steering Axle Components ................................................................................................................................

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

Wheel and Tire Assembly..............................................................................................................................

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

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

Wheel Hub Assembly.....................................................................................................................................

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

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

Steering Axle Assembly.................................................................................................................................

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

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

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

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

Operation Check ................................................................................................................................................

Steering Pressure Check ...................................................................................................................................

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

This section is for the following models:

J1.60XMT, J1.80XMT,

J2.00XMT [E160, G160];

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

J2.00XMT-Plus [G160]

"THE

QUALITY

KEEPERS"

HYSTER

APPROVED

PARTS

1600 SRM 687

Operation

General

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

The hydraulic circuit for the power steering includes
a common hydraulic tank that is used for both the
steering and other hydraulic functions of the lift
truck. The power steering pump is supplied by its
own suction line. The power steering pump directs
the hydraulic oil to the steering control unit, located
in the steering column, when the steering wheel is
turned.

The steering control unit is a rotary valve operated
by the steering wheel. During the steering operation,
the steering control unit controls the direction of flow
and amount of oil that flows to the rotary actuator
located in the rear compartment. The rotary actu-
ator turns the steering axle and moves the steering
wheels. Hydraulic oil returns from the rotary actu-
ator to the steering control unit and then returns to
the hydraulic tank. See Figure 4 and Figure 7.

An optional on-demand steering module is available.
When the on-demand steering module is furnished,

the steering pump motor does not operate unless the
steering wheel is rotated. There is a delay between
the last rotation of the steering wheel and the sys-
tem shutting down. This delay keeps the system op-
erating when the operator is not turning the steering
wheel.

A gear on the shaft of the steering wheel drives a
gear on the optical encoder when the steering wheel
is turned. The optical encoder sends a signal to the
power steering control unit. The power steering
control unit is a transistorized motor control that
controls the power steering pump motor. Refer to
the section Electrical System 2200 SRM 698 (G160
only) or 2200 SRM 585 (E160 only).

If the steering pump does not operate, a check valve
permits the steering control unit to control the steer-
ing system. The lift truck is difficult to steer when
the steering pump is not operating, but the steer-
ing control unit can operate the rotary actuator and
make steering possible. See the section Steering
Housing and Steering Control Unit 1600 SRM
655 for information concerning the steering control
unit.

Operation

The steering control unit is a rotary valve operated
by the steering wheel. During the steering opera-
tion, the steering control unit controls the direction
of flow and amount of oil that flows to the rotary
actuator. The rotary actuator actuates the steering
tires. Hydraulic oil returns from the rotary actuator
to the steering control unit and then returns to the
hydraulic tank.

Turning the steering wheel actuates three main
parts of the steering control unit:
• Spool for the control section
• Sleeve for the control section
• 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
rotary actuator.

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 sec-
tion. The oil then flows to one side of the rotary actu-
ator. Hydraulic oil from the other side of the rotary
actuator 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 neu-
tral position springs return the sleeve to the neutral
position. When this action occurs, the pressure stays
in the rotary actuator to keep the steering tires in po-
sition. Oil from the pump flows through the steering

Steering Wheel and Column Assembly

1600 SRM 687

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 Wheel and Column Assembly

DESCRIPTION

The upper end of the steering shaft has splines for
the steering wheel. A large nut holds the steering
wheel onto the steering shaft. The horn button is the
cover for the center of the steering wheel. The lower
end of the steering shaft has splines to engage the
steering control unit. See Figure 1.

The steering column covers allow access to the opti-
cal encoder, steering control unit, key switch, horn
switch, and direction switches.

The steering housing has mounts for the steering
column and the steering control unit. The steering
wheel is installed on the steering column. The hous-
ing is adjustable and is held in position by a latch.
The position of the housing can be changed for dif-
ferent operator requirements. The steering housing
is also the mount for the control levers.

This section does not cover the instrument panel, key
switch, or directional controls. Refer to the section
Electrical System 2200 SRM 698.

REMOVE

NOTE:

This procedure is for the removal of all com-

ponents of the steering column assembly. It is not al-
ways necessary to remove all components for a repair
procedure. Perform only those steps of the procedure
necessary to remove the required component.

1. Disconnect battery connector. Move steering col-

umn to the most forward position. Remove steer-
ing column covers from steering column. See Fig-
ure 2.

2. Make an identification of the electric wires and

disconnect them from key switch. If necessary,
remove key switch from steering column cover.

WARNING

The spring (23, Figure 2) used to retain the op-
tical encoder has tension and can release with
enough force to cause injury.

3. Remove optical encoder by releasing spring re-

taining encoder to steering column. Move unit
and ribbon wire away from steering column.

1. STEERING WHEEL

2. STEERING

COLUMN

3. STEERING

CONTROL UNIT

4. KNOB

5. LATCH

6. COVER

7. COWL

8. MOUNT

Figure 1. Steering Column

1600 SRM 687

Steering Wheel and Column Assembly

Figure 2. Steering Column Components

Steering Wheel and Column Assembly

1600 SRM 687

Legend for Figure 2

1. GROMMET

2. UPPER COVER

3. LOWER COVER

4. SCREW

5. KNOB-LATCH

6. SCREW

7. WASHER

8. SPRING

9. ROD

10. SOCKET HEAD BOLT

11. NUT

12. PLATE

13. HEX HEAD BOLT

14. LOCKWASHER

15. SPRING

16. SHAFT

17. NUT

18. HORN BUTTON

19. STEERING WHEEL

20. GEAR LATCH

21. PIN

22. COTTER PIN

23. SPRING

24. GEAR

25. ENCODER

26. HOUSING

27. STEERING COLUMN

28. HEX HEAD BOLT

29. LOCKWASHER

30. WASHER

31. BRACKET

32. STEERING CONTROL UNIT

33. HORN CONTACT

4. When a directional switch is used on the steering

column instead of a MONOTROL

pedal, make

an identification of electric wires and disconnect
them from directional switches. See Figure 3.
Remove two shoulder bolts, spring washers,
and nuts retaining directional switch bracket to
steering column. Remove directional switches
from bracket if necessary.

1. SHIFT LEVER

2. SCREW

3. NUT

4. PLUNGER

5. CRANK

6. CRANK

7. LINK

8. SHOULDER BOLT

9. NUT

10. SPRING WASHER

11. BASE

12. HEX HEAD BOLT

13. LOCKWASHER

14. WASHER

15. NUT

16. SWITCH

17. HEX HEAD BOLT

18. LOCKWASHER

19. WASHER

20. PLATE

21. WIRE HARNESS

Figure 3. Optional Directional Switch

WARNING

Be careful when removing or installing snap
rings. These snap rings can come loose during
removal or installation with enough force to
cause eye injury. Always use the correct snap
ring pliers and wear eye and face protection
during removal and installation.

5. Remove horn cover, snap ring, and base plate.

Loosen screws retaining horn wire leads to base
plate. Remove large hex nut and remove steer-
ing wheel from shaft. A puller makes removal of
steering wheel easier.

6. Remove two hex head bolts and washers retain-

ing shift lever assembly to steering column and
remove shift lever assembly. If necessary, disas-
semble shift lever assembly.

WARNING

The hydraulic hoses MUST be connected to
the correct ports and fittings, or the steering
system will not operate as expected.

This

unexpected operation can cause damage or
personal injury. Make sure the hoses are iden-
tified and connected correctly.

7. Make an identification of the hydraulic hoses at

the steering control unit so they can be connected
correctly during assembly. Remove all mount
clamps so the hoses will turn freely and not be-
come twisted. Disconnect hydraulic hoses at the
bottom of the steering control unit. Install plugs
at all hose ports to prevent dirt from entering
steering hydraulic system.

1600 SRM 687

Steering Wheel and Column Assembly

WARNING

The spring (8, Figure 2) used to operate the
latch for locking the steering column has ten-
sion and can release with enough force to cause
injury.

8. Use a set of locking pliers and position them un-

der washer and spring on rod between latch and
steering column bracket. Carefully lift pliers
high enough to compress spring and move rod
out of the detent in the latch. Remove spring,
washer, and rod from steering column. Remove
cotter pin and clevis pin retaining latch. If neces-
sary, remove latch knob from latch by removing
two screws.

9. Remove four hex head bolts retaining steering

control unit to steering column bracket. Remove
steering column from steering control unit and
steering column bracket. Remove steering con-
trol unit. See the section Steering Housing
and Steering Control Unit 1600 SRM 655 for
information concerning repairs to the steering
control unit.

WARNING

The spring (15, Figure 2) used between the
steering column and the cowl mount has ten-
sion and can release with enough force to
cause injury.

10. Loosen four hex head bolts retaining shaft,

spring, plate, and steering column to cowl.
Remove socket head bolt and nut that guides
steering column through tilting positions from
cowl bracket.

Remove four hex head bolts,

spring, and pin from cowl.

INSTALL

WARNING

The spring (15, Figure 2) used between the
steering column and the cowl mount has ten-
sion and can release with enough force to
cause injury.

1. Align steering column with cowl mounting. See

Figure 2. Install spring on shaft and plate. Align
one end of spring in bracket on cowl and other
end in steering column bracket. Install four hex
head bolts and washers to retain steering col-
umn bracket, spring, and plate to cowl. Install

socket head bolt through slot in steering column
bracket. Apply Loctite No. 242 or equivalent on
nut and install nut on inside of cowl. Tighten hex
head bolts and nut to 25 N•m (18 lbf ft).

2. Install splined end of steering column in steering

control unit. Install unit and column in steering
control bracket. Install four hex head bolts and
washers to retain unit and column to steering
column bracket.

WARNING

The spring (8, Figure 2) used to operate the
latch for locking the steering column has ten-
sion and can release with enough force to cause
injury.

3. Install latch on steering column bracket using

clevis pin and new cotter pin. Install washer
and spring on rod in steering column bracket.
Then, using locking pliers on rod below spring
and washer, raise rod and compress spring to
seat rod in latch. Install latch knob using screws.

4. Remove plugs from steering control unit ports

and install hydraulic steering hoses to steer-
ing control unit. Tighten hose fittings to 25 to
29 N•m (18 to 21 lbf ft).

5. If the optional directional switch is used, install

directional switch assembly to steering column
bracket using two shoulder head bolts, spring
washers, and nuts.

6. Identify and install electrical connections to di-

rectional switches.

WARNING

7. Install steering wheel on steering column shaft.

Install steering wheel hex nut and tighten nut to
40 to 54 N•m (30 to 40 lbf ft). Install electrical
leads for horn to base plate and retain leads us-
ing hex head bolts. Install base plate, retaining
ring, and horn cover in steering wheel.

Power Steering Pump and Motor

1600 SRM 687

WARNING

The spring (23, Figure 2) used on the optical en-
coder has tension and can release with enough
force to cause injury.

8. Install optical encoder on steering column using

spring to retain unit.

9. Install key switch in bottom steering pod cover.

Install electrical connections to key switch.

10. Align and install steering pod covers on steering

column using six screws removed at disassembly.
Connect battery connector.

WARNING

After making repairs, do not extend the hands
or arms through the steering wheel. If the con-
trol unit was not assembled correctly or the hy-
draulic hose not connected correctly, it can ro-
tate with a strong force and cause serious in-
jury. If this action occurs, disassemble the con-
trol unit and correct the existing problem.

11. Test steering of truck by slowly driving truck in

an open area. Rotate steering wheel from lock to
lock.

Power Steering Pump and Motor

DESCRIPTION

The power steering pump and motor are located un-
der the floor plates on the left side of the truck. The
power steering pump is a single-section gear pump
which draws the hydraulic oil from the hydraulic
tank and directs the oil to the steering control unit
mounted in the steering column. The power steering
motor and pump operate when the key switch is ON
and the operator is on the seat (seat switch closed).
A timer stops the power steering motor 6 seconds
after the operator is off the seat (seat switch open)
and the key switch is still ON.

REMOVE

The power steering pump and motor must be re-
moved as a unit for servicing the pump. See Figure 4.
The power steering pump and motor are mounted to
the frame with rubber isolator mounts. See Figure 5.

1. Disconnect battery. Remove battery to gain ac-

cess to hex head bolts for mounting power steer-
ing pump and motor. Follow the instructions in
Periodic Maintenance 8000 SRM 699 or the
Operating Manual for battery removal infor-
mation.

2. Remove floor plate on operator’s side of lift truck.

3. Mark electrical wires for identification at assem-

bly. Remove electrical wires.

NOTE:

If the unit being worked on has brush wear

sensing or thermal sensing wires, be certain to re-
move these wires before attempting to remove the
power steering pump and motor.

4. Disconnect suction line to power steering pump.

Remove in-line strainer from suction line. Dis-
connect discharge line from power steering
pump. Plug both hydraulic lines and pump ports
to prevent dirt from entering hydraulic system
and to prevent hydraulic oil from leaking from
system.

WARNING

The power steering pump and motor are
heavy. Be sure that all lifting devices (lifts,
cables, chains, slings, etc.) are suitable and of
adequate capacity to lift the power steering
pump and motor. The power steering pump
and motor can weigh approximately 13.6 kg
(30 lb). The power steering motor has ceramic
permanent magnets. If the motor falls, the
magnets can be damaged.

5. Remove three capscrews, washers, and brackets

retaining power steering pump and motor to lift
truck frame.

6. Carefully lift power steering pump and motor out

of lift truck.

7. If the motor must be serviced, follow the instruc-

tions found in the section DC Motor Mainte-
nance 620 SRM 294.

1600 SRM 687

Power Steering Pump and Motor

Figure 4. Power Steering Arrangement

Power Steering Pump and Motor

1600 SRM 687

Legend for Figure 4

1. STEERING CONTROL UNIT

2. STEERING PUMP MOTOR

3. STEERING PUMP

4. ROTARY ACTUATOR

5. FEED LINE

6. RETURN LINE

7. BLEED POINT

1. PLATE

2. BRACKET

3. ISOLATOR

4. MOTOR

5. PUMP

6. STRAINER

Figure 5. Pump and Motor Mount

INSTALL

WARNING

1. Carefully locate power steering pump and motor

in lift truck.

2. Align power steering pump and motor and

brackets with mount holes in frame. Install

capscrews, washers, and nuts to retain pump
and motor to lift truck frame. Tighten nuts to
25 N•m (18 lbf ft).

3. Remove plugs from discharge port and dis-

charge line. Install discharge line into pump
port. Clean and inspect in-line strainer. Re-
place in-line strainer if necessary. Install in-line
strainer in suction line. Install suction line on
suction side of pump.

4. Install all electrical wires disconnected at time of

removal.

5. Install floor plates.

6. Install battery. Follow the instructions in the Pe-

riodic Maintenance 8000 SRM 699 or the Op-
erating Manual for battery installation infor-
mation. Connect battery.

DISASSEMBLE

1. Mark pump and motor to ensure proper align-

ment at assembly. Remove two capscrews and
washers retaining pump to motor.

Separate

pump from motor. See Figure 6.

2. Remove eight capscrews and washers retaining

housing and cover together. Carefully separate
cover from housing.

3. Remove gears, drive shaft, keys, spacer, and idler

shaft and gear.

WARNING

Be careful when removing or installing snap
rings. These snap rings can come loose dur-
ing removal or installation with enough force
to cause an injury. Always use the correct snap
ring pliers and wear eye and face protection
during removal and installation.

4. Remove snap rings and needle bearings.

5. Clean and inspect needle bearings for damage.

Inspect gears, idler shaft and gear, and drive
shaft for erosion or damage. Replace all defec-
tive parts. Replace oil seal and joints.

1600 SRM 687

Power Steering Pump and Motor

1. HOUSING

2. SCREW

3. PLUG

4. NEEDLE BEARING

5. KEY

6. SNAP RING

7. GEAR

8. SPACER

9. COVER

10. OIL SEAL

11. DRIVE SHAFT

12. GUIDE PIN

13. GASKET

14. IDLER SHAFT AND GEAR

Figure 6. Power Steering Pump

ASSEMBLE

Lubricate all components with clean hydraulic oil be-
fore assembly.

WARNING

1. Install needle bearings in pump halves. Install

snap rings to retain bearings.

2. Install spacer on shafts. Install remaining two

gears on shafts.

3. Install oil seal in upper half of pump. Carefully

install drive shaft through oil seal and needle
bearing. Install keys on drive shaft.

4. Install idler shaft and gear in needle bearing of

upper half of pump. Align and install gear on
drive shaft and key so it mates with idler gear.

5. Ensure housing and cover are properly aligned

and install gasket. Install eight capscrews and
washers retaining housing and cover together.

Steering Axle Components

1600 SRM 687

Steering Axle Components

GENERAL

The steering axle assembly has a horizontal shaft
and gear assembly that extends through the gear
housing, which is mounted in the rear of the truck
frame. The shaft and gear assembly is rotated by
the horizontal movement of a gear rack. The power
steering pump feeds hydraulic oil to the steering con-
trol unit, which directs the oil to two pistons in the
gear housing. These two pistons control the move-
ment of the gear rack. See Figure 7.

WHEEL AND TIRE ASSEMBLY

Remove

WARNING

Before attempting to remove the wheel from
the steering axle, put blocks under each side
of the frame. The blocks must prevent the lift
truck from falling and causing injury or dam-
age. Do not place jacking equipment under the
counterweight.

WARNING

Deflate tire completely before removing the
wheel from the lift truck. Air pressure in the
tires can cause the tire and rim parts to ex-
plode causing serious injury or death. Never
loosen the nuts that hold the inner and outer
wheel halves together when there is air pres-
sure in the tire.

NOTE:

The instructions are for one wheel and tire

assembly. If necessary, perform the same operation
for the opposite side.

1. Turn steering wheel so wheel and tire assembly

that is to be removed is accessible. Move key to
OFF position. Disconnect battery.

2. Chock drive wheels and apply parking brakes.

3. Loosen lug nuts retaining wheel assembly.

WARNING

Lifting and carrying of tires is not recom-
mended because their weight could be in
excess of 45 kg (100 lb). Where applicable, use
a wheel or tire dolly to assist in the removal

and installation of the wheel. Follow the in-
structions in Periodic Maintenance 8000 SRM
699 or the Operating Manual.

4. Using a suitable hoist or jacking equipment,

raise rear of truck until wheels and tires are free
to rotate. Put lift trucks on blocks, see How to
Put Lift Truck on Blocks, in either the Oper-
ating Manual or the Periodic Maintenance
8000 SRM 699.

Figure 7. Hydraulic Schematic

1600 SRM 687

Steering Axle Components

5. Remove lug nuts and remove wheel assembly

from steering axle.

Install

WARNING

Lifting and carrying of tires is not recom-
mended because their weight could be in
excess of 45 kg (100 lb). Where applicable, use
a wheel or tire dolly to assist in the removal
and installation of the wheel. Follow the in-
structions in Periodic Maintenance 8000 SRM
699 or the Operating Manual.

1. Align wheel and tire assembly with studs and

install wheel and tire assembly on wheel hub.

2. Install lug nuts on studs to retain wheel assem-

bly. Tighten nuts hand tight.

3. Lower lift truck to floor. Tighten lug nuts to

170 N•m (125 lbf ft).

4. Remove chocks from wheels. Connect battery.

5. After 2 to 5 hours of operation, check all wheel

nuts. Tighten lug nuts in a cross pattern to
170 N•m (125 lbf ft). When nuts stay tight after
an 8-hour check, the interval for checking the
torque can be extended to 350 hours.

WHEEL HUB ASSEMBLY

Remove

NOTE:

The instructions are for one wheel hub assem-

bly. If necessary, perform the same operation for the
opposite side.

1. Remove wheel and tire assembly. See Wheel and

Tire Assembly, Remove.

2. Remove hub cap. Straighten, remove, and dis-

card cotter pin. Remove nut, washer, spacer, and
hub assembly.

WARNING

3. Remove and discard nilos sealing rings from hub.

Use a soft, metal drift to remove bearings. Re-
move snap rings.

4. Inspect bearings for damage. Inspect axle shaft

for damage or corrosion. Inspect wheel studs for
damage. Replace all damaged components.

Install

1. Prior to installation, pack bearings and new nilos

sealing rings with grease. See the section Peri-
odic Maintenance 8000 SRM 699 or the Oper-
ating Manual for the recommended grease.

WARNING

2. Install snap rings in hub to retain bearings.

Make certain snap rings are seated in wheel
hub. Install both inner and outer wheel bearings
in hub. Install inner nilos sealing ring.

3. Carefully install hub on axle so seal is not dam-

aged. Install outer nilos sealing ring.

4. Install spacer and washer on axle. Install slotted

nut. Tighten nut to 47 N•m (35 lbf ft). Rotate
wheel while tightening nut. If necessary, back
off on the nut to align nut and hole in axle shaft.

5. Install new cotter pin. Install hub cap.

6. Install wheel assembly. See Wheel and Tire As-

sembly, Install.

7. Remove chocks from drive wheels. Connect bat-

tery.

STEERING AXLE ASSEMBLY

Remove

NOTE:

The removal instructions listed are done with

the counterweight, wheels, and tires installed.

1. Disconnect battery connector. Block drive tires.

Position blocks between steer tires and steering
axle weldment to prevent tires and wheels from
rotating. Remove wheel assembly.

Steering Axle Components

1600 SRM 687

2. Remove two capscrews that retain rear cover to

counterweight. Remove rear cover.

WARNING

The capacitors in the traction controllers can
hold an electrical charge after the battery is
disconnected. To prevent electrical shock and
injury, discharge the capacitors after discon-
necting the battery connector and before re-
pairing or replacing any component in the rear
compartment. Wear safety glasses. Make cer-
tain the battery has been disconnected. Dis-
charge the capacitors in the controllers by con-
necting a 200-ohm, 2-watt resistor across the
controller’s POS and NEG terminals (outer two
power cable terminals). DO NOT short across
the motor controller terminals with a screw-
driver or jumper wire. Remove the 200-ohm,
2-watt resistor before reconnecting the battery.
See Figure 8.

3. Discharge controller capacitors.

1. POSITIVE POWER CABLE CONNECTION

2. NEGATIVE POWER CABLE CONNECTION

3. INSULATED JUMPER WIRES

4. 200-OHM, 2-WATT RESISTOR

Figure 8. Discharging Capacitors

4. Unscrew cylinder from gear housing. Remove

O-ring from gear housing. See Figure 9.

5. Remove piston from inside cylinder.

NOTE:

Two screwdrivers with well-rounded and

slightly bent tips (approximately 10 degrees) will aid
in the removal and installation of the seals.

6. Remove two piston guideways and compact seal

from piston.

7. Remove four capscrews that fasten yoke assem-

bly and gear housing shaft assembly. Separate
shaft assembly from yoke assembly.

8. Remove protection cover from end of yoke shaft.

Remove cotter pin, nut, and U-disc.

9. Remove assembled wheel hub from yoke shaft.

Remove bearings and wheel bolts if necessary.

10. Remove nilos ring from yoke shaft.

11. Remove nut, washer, shims, nilos ring, and bear-

ings from flange shaft.

12. Remove flange shaft from gear housing.

13. Remove bearing and nilos ring from flange shaft.

14. Slide gear rack out of gear housing. Remove lin-

ers from each end of gear housing.

15. Remove safety ring, shaft seals, and bearing

raceway from top and bottom opening of gear
housing if 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.

1. Clean all parts in solvent.

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

with a cloth.

3. Make sure all surfaces are free of scratches and

sharp edges.

1600 SRM 687

Steering Axle Components

1. NUT

2. WASHER

3. SHIM

4. NILOS RING

5. BEARING

6. SHIM

7. SAFETY RING

8. SHAFT SEAL

9. PISTON GUIDEWAY

10. COMPACT SEAL

11. CYLINDER

12. PISTON

13. O-RING

14. LINER

15. GEAR RACK

16. HOUSING

17. SHAFT SEAL

18. RACEWAY

19. PROTECTION COVER

20. NUT

21. COTTER PIN

22. U-DISC

23. BEARING

24. WHEEL HUB

25. BEARING

26. NILOS RING

27. WHEEL BOLT

28. CAPSCREW

29. FLANGE SHAFT

30. NILOS RING

31. BEARING

32. PLUG SCREW

Figure 9. Steering Axle Assembly

Steering System Air Removal

1600 SRM 687

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 the hoses not connected correctly,
it can rotate with a strong force and cause
serious injury. If this action occurs, disassem-
ble the control unit and correct the existing
problem.

NOTE:

Use new seals and O-rings during assembly.

Lubricate all parts with clean hydraulic oil.

1. Install shaft seal and bearing raceway into bot-

tom of gear housing. See Figure 9.

2. Install safety ring in groove at top of gear hous-

ing. Install shaft seal into top of gear housing.

3. Install liners into each end of gear housing. In-

stall gear rack through both liners in gear hous-
ing, making sure middle groove of gear rack is
located in middle of gear housing.

4. Fill nilos ring with grease and position ring over

flange shaft. Press bearing on flange shaft.

5. Install flange shaft through gear housing. In-

stall selected shims, bearing, nilos ring, addi-
tional shims, washer, and nut over end of flange
shaft.

6. Install five wheel bolts into each wheel hub.

Press bearings into each end of wheel hubs. Fill
nilos ring with grease and place it over yoke
shaft. Install assembled wheel hub over yoke
shaft. Fill inside area of wheel hub with grease.

7. Install U-disc and nut over end of yoke shaft.

Tighten nut firmly and secure assembly in place
with cotter pin. Install protection cover over end
of yoke shaft.

8. Assemble yoke assembly to gear housing with

shaft assembly. A pressed pin in yoke will help
to properly align the two assemblies. Fasten the
two assemblies together with four capscrews.

9. Install two piston guideways and a compact seal

over piston. Install piston into cylinder and push
piston to end of cylinder.

10. Fill cylinder with 125 cm

of grease.

11. Apply a light film of hydraulic oil on cylinder and

O-ring. Install O-ring into gear housing on top of
liners. Screw cylinder into end of gear housing.

12. Operate unit several times. Install plug screw

into gear housing.

13. Connect battery connector. Remove blocks from

between tires and steer axle.

14. Install rear compartment cover. Lower lift truck

to floor and remove blocks from drive wheels.
Test operate lift truck before returning lift truck
to service.

Steering System Air Removal

If there is air in the hydraulic lines of the steering
system, the operation will not be smooth. The steer-
ing system must be purged of all air at assembly in
order to operate properly. This is normally done by
simply turning the steering wheel from lock to lock
about six times. No further bleeding should be re-
quired. If that doesn’t remove the air, then follow
the steps below:

1. Bleed air from one steering cylinder at a time.

2. Disconnect hydraulic hose from one of the steer-

ing cylinders and attach a tee fitting to steering

cylinder. Connect hydraulic hose and a short ex-
tension hose to tee. Be careful to catch all oil in
a drip pan. Place free end of extension hose into
drip pan.

3. Slowly turn steering wheel fully counterclock-

wise to lock, or until oil comes from hose.

4. Slowly turn steering wheel continuously clock-

wise to lock, or until oil comes from hose.

5. Disconnect tee fitting and reconnect hydraulic

hose fittings at steering cylinders and repeat
Step 1 through Step 5 on the other side.

1600 SRM 687

Troubleshooting

Operation Check

The purpose of this check is to make sure the steer-
ing trunnion turns the correct degrees of its rotation
(approximately 180 degrees). Put lift truck on blocks
so weight of lift truck is removed from steering trun-
nion.

Operate power steering system. Rotate trunnion
to its stop in one direction, then rotate trunnion to
its stop in the other direction. Check that steering

wheel turns trunnion smoothly. The face of the wheel
should be approximately parallel to the frame plate
at the back of the battery compartment when the
steering trunnion is rotated fully in each direction
to its stops.

To check the operation of the printed circuit card that
controls the steering, see the section Electrical Sys-
tem 2200 SRM 585.

Steering Pressure Check

NOTE:

The correct relief valve pressure is 7.7

±0.34 MPa (1100 ±50 psi).

1. Install a pressure gauge in power steering pump

discharge line (between pump and steering con-
trol unit).

2. Operate steering pump and rotate steering wheel

so relief valve (in steering control unit) operates.
Check that maximum pressure is 7.7 ±0.34 MPa
(1100 ±50 psi).

3. If pressure is greater than 8.05 MPa (1150 psi),

or less than 7.35 MPa (1050 psi), replace steering
control unit.

4. When pressure checks are complete, remove

pressure gauge.

5. Operate power steering system. Rotate trunnion

to its stop in one direction, then rotate trunnion
to its stop in the other direction. Check that
steering turns trunnion smoothly. The face of
the wheel should be approximately parallel to the
frame plate at the back of the battery compart-
ment when steering trunnion is rotated fully in
each direction to its stops.

Troubleshooting

PROBLEM

POSSIBLE CAUSE

PROCEDURE OR ACTION

No action when the steering
wheel is turned.

Check the steering pump fuse.

Replace fuse as required.

No oil or not enough oil in hydraulic
tank.

Fill tank to correct level.

No oil flow from the steering control
unit to the rotary actuator.

Repair steering control unit.

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

Repair steering control unit.

Electric motor for the steering pump
does not activate steering pump.

Repair electric motor.

Troubleshooting

1600 SRM 687

PROBLEM

POSSIBLE CAUSE

PROCEDURE OR ACTION

The axle does not turn when
the steering wheel is turned.

Air in the steering hydraulic system.

Purge air from the steering hydraulic
system.

Steering pump does not send oil to
the steering system.

Repair steering pump.

The axle rotates in the wrong
direction from the direction
of the steering wheel.

The hydraulic lines are connected in-
correctly at the rotary actuator or the
steering control unit.

Connect the hydraulic lines correctly.

The steering control unit has been
disassembled.

Check the rotor for correct alignment
and repair as required.

The power steering pump
makes noise that is not nor-
mal.

Air is entering the power steering
pump.

Tighten connection at the inlet port
or replace seals between the pump
and motor.

Bearings in the electric motor or the
power steering pump are worn.

Replace bearings.

Dirty inlet strainer.

Clean

inlet strainer using

oil-based solvent.

Lift truck steers slowly.
Steering wheel is hard to
turn.

No oil or not enough oil in hydraulic
tank.

Fill tank to correct level.

No oil flow from the steering control
unit to the rotary actuator.

Repair steering control unit.

Steering gearbox seals leaking.

Replace seals.

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

Repair steering control unit.

Low hydraulic oil pressure.

Repair steering pump.

Steering control unit not working
properly.

Repair steering control unit.

On-demand module is defective.

Replace on-demand module.

Power steering pump pressure is too
high or too low.

Adjust relief pressure or clean and
inspect for contamination.

Relief valve cannot be adjusted.

Replace the steering control unit.

1600 SRM 687

Troubleshooting

PROBLEM

POSSIBLE CAUSE

PROCEDURE OR ACTION

Power steering pump and
motor is overheating.

Hydraulic pressure and current
draw at idle is above:
36V Trucks - 0.42 to 0.56 MPa (60 to
80 psi) and 4 to 6 amps.
48V Trucks - 0.42 to 0.69 MPa (60 to
100 psi) and 4 to 6 amps.

Repair pump and motor.

Hydraulic pressure and current
draw at medium steering and re-
lief is above:
5.60 to 5.95 MPa (800 to 850 psi) and
20 to 25 amps.

Repair pump and motor.

Hydraulic pressure and current
draw at relief is above:
7.7 MPa (1100 psi) and 30 to 35
amps.

Repair pump and motor.

Momentary motor current draw at
relief is 45 amps or above.

Replace pump.

Motor current draw at idle is 10
amps or higher and relief pressure
is normal.

Clean or replace all filters and strain-
ers, back flush system, and fill with
clean hydraulic oil.

High idle current draw.

Check for kinked hoses.

Replace