Hyster D004 (S100XL) Forklift Service Repair Manual

General

Thissectionhasthedescriptionandrepairproceduresforthesteeringhousingandthesteering controlunit.Additionalinformationonpartsofthe steeringsystemareinthefollowingsections: SteeringAxle 1600SRM451(B024,C024),1600SRM 326(D004,D019,E007,F006,G006),1600SRM10

(A177,B177,C177),and1600SRM71(E008)and HydraulicSystem 1900SRM453(B024,C024), 1900SRM333(D004),1900SRM443(D019,E007), 1900SRM328(F006,G006),and1900SRM130 (A177,B177,C177).

Description

Thissectionhasadescriptionandtherepairproceduresformorethanonebrandofsteeringcontrol unit.SeeFigure1.Theunitsaresimilarinconstructionandoperation,withhoseconnectionsontheside atamanifoldorvalveblockassembly.SeeFigure2 orFigure4.Somemanifoldsalsohaveareliefvalve.

Thesteeringcontrolunitisahydrostaticunitthat iscontrolledbythesteeringwheel.Thecontrolunit isinstalledinahousingoronabracketatthecowl andisoperatedbythecolumnassemblyandsteering wheel.Thesteeringcontrolunithasacontrolsection andameteringsection.

Thesteeringsystemisahydraulicsystemthatdoes nothaveamechanicalconnectionbetweenthesteeringwheelandthesteeringaxle.Thecontrolofthe steeringisthroughahydrauliccircuit.

Ifthehydraulicpumpforthesteeringsystemdoes notoperate,steeringisstillpossible.Acheckvalve permitsthesteeringcontrolunittocontrolthesteeringcylinder.Thelifttruckisdifficulttosteerwhen thesteeringpumpisnotoperating,butthesteeringcontrolunitcanoperatethesteeringcylinderand makesteeringpossible.

Operation

Thesteeringcontrolunitisarotaryvalveoperatedby thesteeringwheel.SeeFigure1.Duringthesteeringoperation,thesteeringcontrolunitcontrolsthe directionofflowandamountofoilthatflowstothe steeringcylinder.Thesteeringcylinderintheaxle actuatesthesteeringlinkagetomovethesteertires. Hydraulicoilreturnsfromthesteeringcylinderto thesteeringcontrolunitandthenreturnstothehydraulictank.

Turningthesteeringwheelactuatesthreemain partsofthesteeringcontrolunit:(1)Thespoolfor thecontrolsection,(2)thesleeveforthecontrol section,and(3)therotorinthemeteringsection. Whenthesteeringwheelisnotmoving,thespool andsleeveareheldintheneutral(center)position bysprings.Duringthistime,oilflowsfreelythrough thesteeringcontrolunit.Theoildoesnotflowtothe steeringcylinder.

Asthesteeringwheelisturned,thespooljustbeginstorotate.Thespringstrytomovethesleeve tokeeptheneutralpositionbetweenthespooland sleeve.However,theforcenecessarytoturntherotorisgreaterthanthepressureofthesprings.The springsbegintobend,lettingthespoolmoveasmall

amountwithinthesleeve.Thespoolstopsmoving whenittouchesthecenterpin.Inthisposition,the holesinthesleeveandthespoolarealigned.Oilcomingintothecontrolunitflowstothemeteringsection. Morerotationofthesteeringwheelcausesthespool torotatethepin.Thisactioncausestherotationof thesleeveandtherotorinthemeteringsection.The oilthenflowstoonesideofthesteeringcylinder.Hydraulicoilfromtheothersideofthesteeringcylinderreturnsthroughthecontrolsectionofthesteeringcontrolunit.

Whenthesteeringwheelstopsmoving,themeteringactioninthemeteringsectionalsostops.The neutralpositionspringsreturnthesleevetotheneutralposition,stoppingoilflowtoorfromthecylinder. Thepressurestaysinthesteeringcylindertokeep thesteertiresinposition.Oilfromthepumpflows throughthesteeringcontrolunittothetankorother partsofthesystem.Toreturnthesteerwheelstothe straightposition,thesteeringwheelmustberotated intheoppositedirection.Thesteeringcontrolunit willoperateasdescribed,butallpartswillrotatein theoppositedirection.

Theupperendofthesteeringshafthassplinesforthe steeringwheel.Alargenutholdsthesteeringwheel ontothesteeringshaft.Thehornbuttonisthecover forthecenterofthesteeringwheel.Thelowerendof thesteeringshafthassplinesoratangtoengagethe steeringcontrolunit.Contactsatthehornbutton (seeFigure2),awireinthecolumn,andslipring contactsinthecolumnassembly(seeFigure1)allow forhornoperationbytheoperator.

Therearetwotypesofsteeringcolumnassemblies discussedhere;TypeAandTypeB.TypeAhasacolumnhousingthatisasupportforthemountbracket

TYPEASTEERINGCOLUMNASSEMBLY RemoveandDisassemble

CAUTION

Disconnectthenegativebatterycableoninternalcombustiontrucks.Disconnectthebattery connectoronelectrictrucks.Disconnectthe batterybeforeremovingthecovers.

1. Attachatagonthebatteryconnectorornegative cablestatingDONOTCONNECTBATTERY. Movethesteeringcolumntothemost-forward position.Removetheaccesscoverfromthe steeringcolumn.SeeFigure2andFigure3.

2. Puttagsforidentificationonthehydraulichoses atthesteeringcontrolunitsotheycanbeconnectedcorrectlyduringassembly.Disconnectthe hydraulichosesatthebottomofthemanifoldor valveblock.Installplugsatallhosesandportsto preventdirtfromenteringthesteeringhydraulic system.

ofthesteeringcontrolunitasshowninFigure3. TypeBhasamountbracketofthesteeringcontrol unitthatisthesupportforthecolumnhousingas showninFigure4.

Thesteeringcolumnassemblyisadjustableandheld inpositionbyalatch.Theassemblypositioncanbe changedasneededforoperatorcomfort.Anaccess coveronthesteeringcolumngivesaccesstothesteeringcontrolunithoseconnections.

3. Carefullyliftthehornswitchatthecenterofthe steeringwheelandpulltheswitchwireoutofthe steeringshaft.SeeFigure1.Pulltheswitchassemblyoutofthesteeringwheelanddisconnect it.Removethenut.Ifpossible,useapullerto removethesteeringwheel.

4. Puttagsforidentificationonthemetersand gaugewiresatthesteeringcolumnhousingso theycanbeconnectedcorrectlyduringassembly. Also,putatagonthehornwire.SeeFigure1. Disconnectallwires.

5. Removethecapscrewsthatfastenthemount platetothecowlandremovethesteeringcolumn assemblyfromthelifttruck.

6. Removethetwospringsforthelatch.Remove thetwocapscrews,nuts,washers,andspacersat thepivotpointsofthecolumnhousing.Remove themountplate.

Figure2.SteeringWheelandSteeringColumnAssembly

LegendforFigure2

NOTE: H20.00-32.00F/FS(H440-700F/FS)SHOWN,OTHERSSIMILAR.

7. Removethefourcapscrews,washers,grommets, andspacersthatfastenthebracketforthesteeringcontrolunittothecolumnhousing.Carefullyremovethesteeringcontrolunit,bracket, andcolumnfromthecolumnhousing.Ifnecessary,removethelatchassemblyfromthecolumn housing.

8. Removethefourscrewsthatfastenthebracket andsteeringcolumntothesteeringcontrolunit. Donotlosethespacersorwashers.Removethe twoscrewsthatfastenthemanifoldorvalve blocktotheportsideofthesteeringcontrolunit. Ifnecessary,disassemblethesteeringcontrol unitasshowninSteeringControlUnit,Disassemble.

AssembleandInstall

1. Ifnecessary,assemblethesteeringcontrolunit asshowninSteeringControlUnit,Assemble.Installthemanifoldorvalveblockonthesteering controlunitusingnewO-rings.Ifremoved,installthelatchassemblyinthecolumnhousing. SeeFigure2andFigure3.

2. Installthesteeringcolumnandbracketonthe steeringcontrolunitasremovedduringdisassembly.Installthisassemblyinthecolumnhousing.Donotdamagethehornwirecontactorcolumngrommet(seeFigure1).Makesuretoinstallthegrommets,washers,andspacersasa soundisolatorforthesteeringcontrolunit.

3. Installthetwocapscrews,nuts,washers,and spacersatthepivotpointsofthecolumnhousingandmountplate.Installthetwospringsfor thelatch.Installthemountplateandcolumnassemblyonthecowlofthelifttruck.

WARNING

ThehydraulichosesMUSTbeconnectedtothe correctportsandfittingsorthesteeringsystemwillnotoperateasexpected.Thisoperationthatisnotexpectedcancausedamageor personalinjury.Makesurethehosesareidentifiedandconnectedcorrectly.

4. Installallwiresandhosesasremovedduring disassembly.Installthesteeringwheelandnut. Pushthehornswitchwireintothesteeringshaft andinstalltheswitchinthesteeringwheel.Installtheaccessplate,removethebatterytag,and connectthebatteryconnectororcable.

WARNING

Aftermaking repairs,donotextendthehands orarmsthroughthecenterofthesteering wheel.Ifth econtrolunitwasnotassembled correctlyorthehosesnotconnectedcorrectly, itcanrotatewithastrongforceandcauseseriousinjury.Ifthisactionoccurs,disassemble thecontrolunitandcorrecttheproblem.

5. Operatethesteeringsystemtocheckforcorrect operation andleaks.

Figure3.SteeringWheelandSteeringColumnAssembly

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LegendforFigure3

NOTE: H8.00-12.00XL(H165-280XL)ANDH13.00-16.00XL(H300-360,H330-360XL-EC)SHOWN,OTHERSSIMILAR.

TYPEBSTEERINGCOLUMNASSEMBLY

RemoveandDisassemble

CAUTION

Disconnectthenegativebatterycableoninternalcombustiontrucks.Disconnectthebattery connectoronelectrictrucks.Disconnectthe batterybeforeremovinganycovers.

1. Attachatagonthebatteryconnectorornegative cablestatingDONOTCONNECTBATTERY. Movethesteeringcolumntothemost-forward position.SeeFigure4.

2. Puttagsforidentificationonthehydraulichoses atthesteeringcontrolunitsotheycanbeconnectedcorrectlyduringassembly.Disconnectthe hydraulichosesatthebottomofthemanifoldor valveblock.Installplugsatallhosesandportsto preventdirtfromenteringthesteeringhydraulic system.

3. Carefullyliftthehornswitchatthecenterofthe steeringwheelandpulltheswitchwireoutofthe steeringshaft.SeeFigure1.Pulltheswitchassemblyoutofthesteeringwheelanddisconnect it.Removethenut.Ifpossibletoinstall,usea pullertoremovethesteeringwheel.

4. Puttagsforidentificationonthemetersand gaugewiresatthesteeringcolumnhousingso theycanbeconnectedcorrectlyduringassembly. Alsoputatagonthehornwire.SeeFigure1. Disconnectallwires.

5. Removethescrewsthatfastenthecolumnhousingtothebracketforthesteeringcontrolunit. Carefullyliftthecolumnhousingandbushingoff thesteeringcolumnassembly.

6. Removethefourscrews,washers,isolator,and spacersthatfastenthesteeringcolumnandthe steeringcontrolunittothebracket.Removethe steeringcolumnfromthesteeringcontrolunit. Removethetwoscrewsthatfastenthemanifold orvalveblocktotheportsideofthesteeringcontrolunit.Ifnecessary,disassemblethesteering controlunitasshowninSteeringControlUnit, Disassemble.

7. Ifnecessary,removeallpartsofthelatchfrom thebracket.Ifnecessary,removeallpartsof thespringmechanismandpivottoremovethe bracketfromthecowlofthelifttruck.

AssembleandInstall

1. Ifnecessary,assemblethesteeringcontrolunit asshowninSteeringControlUnit,Assemble.Installthemanifoldorvalveblockonthesteering controlunitusingnewO-rings.Ifremoved,installthebracketandspringmechanismonthe cowlofthelifttruck.Ifremoved,installthelatch assemblyandspringmechanismonthesteering controlbracket.

2. Installthesteeringcolumnonthesteeringcontrolunit.Installthefourscrews,washers,isolator,andspacersthatfastenthesteeringcolumnandthesteeringcontrolunittothebracket. MakesuretoinstalltheclampinthecorrectpositionasshowninFigure4.

3. Carefullyinstallthecolumnhousingandbushingoverthesteeringcolumn.Installthescrews thatfastenthehousingtothebracket.

Figure4.SteeringWheelandSteeringColumnAssembly

LegendforFigure4

NOTE: H2.00-3.00XL(H40-60XL),S6.00-7.00XL(S135-155XL),ANDS3.50-5.50XL(S70-120XL)SHOWN,OTHERSSIMILAR.

WARNING

ThehydraulichosesMUSTbeconnectedtothe correctportsandfittingsorthesteeringsystemwillnotoperateasexpected.Thisoperationthatisnotexpectedcancausedamageor personalinjury.Makesurethehosesareidentifiedandconnectedcorrectly.

4. Installallwiresandhosesasremovedduring disassembly.Installthesteeringwheelandnut. Pushthehornswitchwireintothesteeringshaft andinstalltheswitchinthesteeringwheel.Removethebatterytagandconnectthebatteryconnectororcable.

WARNING

Aftermakingrepairs,donotextendthehands orarmsthroughthecenterofthesteering wheel.Ifthecontrolunitwasnotassembled correctlyorthehosesnotconnectedcorrectly, itcanrotatewithastrongforceandcauseseriousinjury.Ifthisactionoccurs,disassemble thecontrolunitandcorrecttheproblem.

5. Operatethesteeringsystemtocheckforcorrect operationandleaks.

SteeringControlUnit

Disassemble

Disassemblethesteeringcontrolunitasfollows:

STEP1. Putthecontrolunitinavisewithsoftjaws.Makean identificationmarkonthelengthofthecontrolunit. Wheninstalled,removethemanifoldblock.

STEP2. Removethecoveronthebottomofthesteeringcontrolunit.

1.STEERINGCONTROLUNIT 2.VISE

1.CAPSCREW 2.COVER 3.O-RING 4.CHECKBALL

STEP3.

Removethespacer(ifused),thestator,rotor,andport plate.Putamarkonthestatorsothatthesameside willbetowardthebodyofthecontrolunitatassembly.RemovetheO-rings.Removethecentershaft.

STEP4.

Removethescrewforthecheckvalveassembly.Removethepartsforthecheckvalve.Forsomeunits, thecheckballisintheoppositeendofthecontrol unit.

1.SCREW 2.CHECKVALVEASSEMBLY

STEP5.

Removethespoolandsleeveassembly.Removethethrustbearingassemblyfromthespool.Pushthecenterpin fromthesleeve.Carefullyremovethespoolfromthesleeve.Rotatethespoolslowlyduringremoval.Remove theringfromthesleeve.Removetheneutralpositionspringsfromthespool.

STEP6.

Wheninstalled,removethesnapring,bushing,O-ring,andsealring.Removetheoilsealfromthebushingor housing.

WARNING

Cleaningsolventscanbeflammableandtoxicandcancauseskinirritation.Whenusingcleaning solvents,alwaysfollowthesolventmanufacturer’srecommendedsafetyprecautions.

WARNING

Compressedaircanmoveparticlessotheycauseinjurytotheuserortootherpersonnel.Make surethepathofthecompressedairisawayfromallpersonnel.Wearprotectivegogglesoraface shieldtopreventinjurytotheeyes.

Cleanallthepartsinsolvent.Drythepartswithcompressedair.Donotdrythepartswithacloth.Makesure allsurfacesarefreeofscratchesandsharpedges.