1600688, OPR, HYSTER, Hyster2, SRM

//-->.pos {position:absolute; z-index: 0; left: 0px; top: 0px;}INTRODUCTIONGENERALThe power steering system is a hydraulic system thatdoes not have a mechanical connection between thesteering wheel and the steer axle. The control of thesteering is through a hydraulic circuit.The hydraulic circuit for the power steering includes acommon hydraulic tank, that is used for both the steer-ing and other hydraulic functions of the lift truck. Thepower steering pump is supplied by its own suction line.The power steering pump directs the hydraulic oil to thesteering control unit located in the steering columnwhen the steering wheel is turned.The steering control unit is a rotary valve operated bythe steering wheel. During the steering operation, thesteering control unit controls the direction of flow andamount of oil that flows to the hydraulic steering cylin-der. The steering cylinder actuates the steering linkageto move the steer wheel. Hydraulic oil returns from thesteering cylinder to the steering control unit and then re-turns to the hydraulic tank. See FIGURE 2 andFIGURE 5.If the steering pump does not operate, a check valve per-mits the steering control unit to control the steering sys-tem. The lift truck is difficult to steer when the steeringpump is not operating, but the steering control unit canoperate the steering cylinder and make steering pos-sible. See the sectionSTEERING HOUSING ANDSTEERING CONTROL UNIT, 1600 SRM 655forinformation concerning the steering control unit.STEERING WHEEL AND COLUMN ASSEMBLYDESCRIPTION(See FIGURE 1, FIGURE 3, and FIGURE 4)The upper end of the steering shaft has splines for thesteering wheel. A large nut holds the steering wheel ontothe steering shaft. The horn button is the cover for thecenter of the steering wheel. The lower end of the steer-ing shaft has splines to engage the steering control unit.The steering column covers on the steering column giveaccess to the steering control unit, horn switch, and di-rection switches.This section does not cover the instrument panel, keyswitch or directional controls which are covered in thesectionELECTRICAL SYSTEM, 2200 SRM 577.RemovalNOTE:This procedure is for the removal of all com-ponents of the steering column assembly. All compo-nents are not often removed for a repair procedure. Doonly those steps of the procedure necessary to removethe required component.1. Disconnect the battery connector. Move the steer-ing column to the most forward position. Remove thesteering column covers from the steering column.11. FRONT COVER2. REAR COVER2FIGURE 1 – STEERING COLUMN COVERS12.Make an identification of the electric wires and dis-move the shift lever assembly. If necessary, disassemblethe shift lever assembly.connect them from the key switch. If necessary, removethe key switch from the steering column cover.3.Make an identification of the electric wires and dis-1connect them from the directional switches. Remove thetwo capscrews and washers retaining the directionalswitch bracket to the steering column. Remove thedirectional switches from the bracket, if necessary.23STEER CYLINDER56L-PORTR-PORT74STEERINGCONTROLUNIT1.2.3.4.5.6.7.8.6STEERING WHEELSTEERING COLUMNSTEERING CONTROL UNITKNOBLATCHCOVERCOWLMOUNTRELIEF1200 psi8STEERINGPUMPFIGURE 3 – STEERING COLUMN5.STRAINERRemove the horn cover, snap ring and base plate.Loosen the screws retaining the horn wire leads to thebase plate. Remove the large hex nut and remove thesteering wheel from the shaft. A puller makes removalof the steering wheel easier.HYDRAULIC TANKWARNINGThe hydraulic hoses MUST be connected to the cor-rect ports and fittings or the steering system will notoperate as expected. This operation that is not ex-pected can cause damage or personal injury. Makesure the hoses are identified and connected correctly.FIGURE 2 – HYDRAULIC SCHEMATIC4.Remove the two capscrews and washers retainingthe shift lever assembly to the steering column and re-218171924252322627291.2.3.4.5.6.7.8.9.10.11.12.13.14.15.16.17.18.19.20.87GROMMETFRONT COVERREAR COVERSCREWKNOB-LATCHSCREWWASHERSPRINGRODCAPSCREWNUTPLATECAPSCREWLOCKWASHERSPRINGSHAFTNUTHORN BUTTONSTEERING WHEELGEAR LATCH2221931515202816121421.22.23.24.25.26.27.28.29.PINCOTTER PINCONTACTORSTEER COLUMNCAPSCREWLOCKWASHERWASHERBRACKETSTEERING CONTROL UNIT13410116FIGURE 4 – STEERING COLUMN COMPONENTS6. Make an identification of the hydraulic hoses at thesteering control unit so that they can be connected cor-rectly during assembly. Remove all mount clamps sothat the hoses will turn freely and not become twisted.Disconnect the hydraulic hoses at the bottom of thesteering control unit. Install plugs at all hose ports toprevent dirt from entering the steering hydraulic system.31.2.3.4.5.6.STEERING CONTROL UNITSTEERING PUMP MOTORSTEERING PUMPSTEERING POWER CYLINDERFEED LINERETURN LINE124365FIGURE 5 – POWER STEERING ARRANGEMENT7. Use a set of locking pliers and position them underthe washer and spring on the rod between the latch andsteering column bracket. Carefully lift the pliers highenough to compress the spring and move the rod out ofthe detent in the latch. Remove the spring, washer and4rod from the steering column. Straighten the cotter pinand remove the cotter pin and clevis pin retaining thelatch. If necessary, remove the latch knob from the latchby removing the two capscrews.POWER STEERING PUMP AND MOTORDESCRIPTION(See FIGURE 6)The power steering pump and motor is located under thefloor plates on the left side of the truck. The power steer-ing pump draws the hydraulic oil from the hydraulictank and directs the oil to the steering control unitmounted in the steering column. The power steeringmotor and pump operate when the key switch is “ON”and the operator is on the seat (seat switch closed). Atimer stops the power steering motor six seconds afterthe operator is off the seat (seat switch open) and the keyswitch is still “ON”.The power steering pump is a single section gear pumpthat is fastened to the power steering motor. The outlet(pressure port) of the pump is connected to the steeringcontrol unit with a hydraulic hose. The inlet (suctionport) of the pump is connected to the hydraulic tank witha hydraulic hose. Bushings at each side of each gear arethe bearings for the gear shafts. A gasket prevents leaksbetween the pump body and stator section.A relief valve in the steering control unit controls the hy-draulic pressure in the steering system to 9.1 MPa (1300psi). The relief valve does not normally need adjust-ment. If the hydraulic pressure cannot be adjusted to thespecification, the steering pump is normally worn ordamaged and must be repaired or replaced.Removal14321.2.3.4.5.5PLATEBRACKETISOLATORMOTORPUMPFIGURE 6 – PUMP AND MOTORMOUNTING1. Disconnect the battery. Remove the battery to gainaccess to the mounting capscrews for the power steeringpump and motor. Follow the instructions inPERIODICMAINTENANCE 8000 SRM 528or theOPERAT-ING MANUALfor battery removal information.2. Remove the floor plate on the operator’s side of thelift truck.3. Mark the electrical wires for identification at as-sembly. Remove the electrical wires.NOTE:If the unit being worked on has brush wearsensing or thermal sensing wires, be certain to removethese wires before attempting to remove the powersteering pump and motor.4. Disconnect the suction line to the power steeringpump. Remove the in-line strainer from the suction line.Disconnect the discharge line from the power steeringpump. Plug both the hydraulic lines and the pump portsto prevent dirt from entering the hydraulic system and toprevent the hydraulic oil from leaking from the system.5WARNINGThe power steering pump and motor is heavy. Besure that all lifting devices (lifts, cables, chains,slings, etc.) are suitable and of adequate capacity tolift the power steering pump and motor. The powersteering pump and motor can weigh approximately30 lbs (13.6 kg). The power steering motor has ce-ramic permanent magnets. If the motor falls, themagnets can be damaged.The power steering pump and motor must be removedas a unit for servicing the pump. The power steeringpump and motor are mounted to the frame with rubberisolator mounts.

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