Hyster E098 (E5.50XL Europe) Forklift Service Repair Manual

General

Thissectionhasthedescriptionandrepairproceduresforthesteeringhousingandthesteeringcontrolunit. Additionalinformationonpartsofthesteeringsystemcanbefoundinthe SteeringAxle and Hydraulic System servicemanualsectionsforyourlifttruck.

Description

Thesteeringcolumnassemblyusesasteeringcontrolunitwithhoseconnectionsonthebottomofthe unit.Thesteeringhousinghasmountsforthesteeringcolumnandthesteeringcontrolunit.Thesteeringwheelisinstalledonthesteeringcolumn.See Figure1.Thehousingisadjustableandisheldinpositionbyalatch.Thepositionofthehousingcanbe changedforoperatorcomfort.Thesteeringhousing isalsothemountforcontrolleversandsomeinstrumentclusters.

Thesteeringsystemisahydraulicsystemthatdoes nothaveamechanicalconnectionbetweenthesteeringwheelandthesteeringaxle.Thecontrolofthe steeringisthroughahydrauliccircuit.

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

NOTE: INSTRUMENTCLUSTERNOTSHOWN. H2.00-3.20XM(H40-65XM)SHOWN.

Figure1.SteeringHousingAssembly

Operation

Thesteeringcontrolunitisarotaryvalveoperatedby thesteeringwheel.SeeFigure2.Duringthesteeringoperation,thesteeringcontrolunitcontrolsthe directionandamountofoilflowtothesteeringcylinder.Thesteeringcylinderintheaxleactuatesthe steeringlinkagetomovethesteertires.Hydraulic oilreturnsfromthesteeringcylindertothesteering controlunitandthentothehydraulictank.

Turningthesteeringwheelactuatesthreemain partsofthesteeringcontrolunit:thespoolforthe controlsection,thesleeveforthecontrolsection,and therotorinthemeteringsection.Whenthesteering wheelisnotmoving,thespoolandsleeveareheld inthe NEUTRAL (center)positionbysprings.Duringthistime,oilflowsfreelythroughthesteering controlunitbutnoneflowstothesteeringcylinder.

Asthesteeringwheelisturned,thespooljustbeginstorotate.Thespringstrytomovethesleeveto keepthe NEUTRAL positionbetweenthespooland sleeve.However,thenecessaryforcetoturntherotorisgreaterthanthepressureofthesprings.The springsbegintobend,lettingthespoolmoveasmall

amountwithinthesleeve.Thespoolstopsmoving whenittouchesthecenterpin.Inthisposition,the holesinthesleeveandthespoolarealigned.Oilcomingintothecontrolunitflowstothemeteringsection.

Morerotationofthesteeringwheelcausesthespool torotatethepin.Thisactioncausestherotationof thesleeveandtherotorinthemeteringsection.The oilthenflowstoonesideofthesteeringcylinder.Oil fromtheothersideofthecylinderreturnsthrough thecontrolsectionofthesteeringcontrolunit.

Whenthesteeringwheelstopsmoving,themeteringactioninthemeteringsectionalsostops.The NEUTRAL positionspringsreturnthesleevetothe NEUTRAL position,stoppingoilflowtoorfromthe cylinder.Thepressurestaysinthesteeringcylinder tokeepthesteertiresinposition.Oilfromthepump flowsthroughthesteeringcontrolunittothetankor otherpartsofthesystem.Toreturnthesteerwheels tothestraightposition,thesteeringwheelmustbe rotatedintheoppositedirection.Thesteeringcontrolunitwilloperateasdescribed,butallpartswill rotateintheoppositedirection.

Figure2.SteeringControlUnit

SteeringWheelandColumnAssemblyRepair

Theupperendofthesteeringshafthassplinesforthe steeringwheel.Alargehexnutholdsthesteering wheelontothesteeringcolumn.Thehornbuttonis thecoverforthecenterofthesteeringwheel.The lowerendofthesteeringcolumnhassplinesoratang toengagethesteeringcontrolunit.SeeFigure5and Figure6.

Thesteeringcolumnassemblyisadjustableandheld inpositionbyalatch.Thepositionofthesteeringcolumnassemblycanbechangedasneededfordifferent operatorrequirements.Anaccesscoveronthesteeringcolumngivesaccesstothesteeringcontrolunit, keyswitch,hornswitch,andifinstalled,thedirectionswitch.

ASSEMBLYCOMPONENTS,REMOVE

NOTE: Thisprocedureisfortheremovalofallcomponentsofthesteeringcolumnassembly.Allcomponentsarenotoftenremovedforarepairprocedure. Doonlythosestepsoftheprocedurenecessarytoremovetherequiredcomponent.SeeFigure5andFigure6.

WARNING

Thehydraulichosesmustbeconnectedtothe correctportsorthesteeringsystemwillnotoperateasexpected,whichcancausedamageor personal injury.Makesurethehosesareidentifiedandconnectedcorrectly.

CAUTION

Disconnectthenegativebatterycableoninternalcombustiontrucks.Disconnectthebattery connectoronelectrictrucks.Disconnectthe batterybeforeremovinganycovers.

1. Attachatagonthebatteryconnectorornegative cablestatingDONOTCONNECTBATTERY. Movethesteeringcolumntothemost FORWARD position.Removethecolumntiltlever. Removetheupperandloweraccesscoversfrom thesteeringcolumn.

2. Removethekeyswitchandstaticstrapfromthe housingofthesteeringcolumn.Makeanidentificationoftheelectricwiresanddisconnectthem fromthekeyswitch.

3. OnunitswiththeDirectionControlHandle, Removethedirectionswitchassemblyfromthe housingofthesteeringcolumn.Makeanidentificationoftheelectricwiresanddisconnectthem fromthedirectionswitch.SeeFigure3.

NOTE: DIRECTIONCONTROLHANDLEASSEMBLY FORMODELSJ2.00-3.20XM[J40-65Z](A416/B416), E1.50-2.00XM[E25-35Z,E40ZS](E114/F114), N30XMH,ANDN30XMH 2 (C210),V30ZMD(D210/ E210),E3.50-5.50XL,E4.50XLS(E70-120Z,E100ZS) (D098/E098),ANDE2.00-3.20XM[E45-65Z](G108) ISSHOWN.OTHERTRUCKDIRECTIONCONTROL HANDLEASSEMBLIESARESIMILAR.

1.DIRECTIONSWITCHES

2.SHIFTLEVERASSEMBLY

3.SCREW

4.ELECTRICALCONNECTORS

Figure3.DirectionControlHandleAssembly

4. Removetheplasticrivetsthatfastenthebracket forthehornswitchtothehousingofthesteering column.Movethehornswitchandbracketaway fromthesteeringcolumn.SeeFigure5andFigure6.

CAUTION

Ifapullertoolisusedtoremovesteeringwheel fromsteeringcolumn,becarefulnottodamage thehornwires.

5. Removethehornbuttonassemblyandelectrical wires.Removethelargehexnutandthesteeringwheelfromtheshaft.Apullertoolmakes removalofthesteeringwheeleasier,butnotall steeringwheelshavepullerholes.

6. OnlifttruckmodelsJ2.00-3.20XM(J4060XM 2)(A216),E1.50-1.75XM,E2.00XMS (E25-40XM 2S)(D114),N30XMH,N30XMH2 (C210),andE2.00-3.20XM(E45-65XM 2)(F108) units,removetheopticalencoderhousingand opticalencoderfromthesteeringcolumn.Make anidentificationoftheelectricalwiresanddisconnectthemfromtheassemblies.SeeFigure5.

7. OnlifttruckmodelsJ2.00-3.20XM[J4065Z](A416/B416),E1.50-2.00XM[E25-35Z, E40ZS](E114/F114),V30ZMD(D210/E210), E3.50-5.50XL,E4.50XLS(E70-120Z,E100ZS) (D098/E098),andE2.00-3.20XM[E45-65Z] (G108),disconnecttheconnector.Removethe twocapscrewsandsteeringsensorfromthe steeringcolumn.SeeFigure6.

8. Makeanidentificationofthehydraulichoses atthesteeringcontrolunitsotheycanbeconnectedcorrectlyduringassembly.SeeFigure4, Figure5,Figure6,andthe WARNING inthe beginningofthissection.Somehydraulichoses havefittingsthatwillpermitdisconnectionat thesteeringcontrolunit.Disconnecttheother hydraulichosesatthebaseofthecowl,the controlvalve,orthesteeringpump.Remove allmountclampssothatthehoseswillturn freelyandnotbecometwisted.Disconnectthe hydraulichosesatthebottomofthesteering controlunit.Installplugsatallhosesandports topreventdirtfromenteringthesteeringhydraulicsystem.

1.HYDRAULICHOSEENDS

2.HOSEPORTS

3.STEERINGCONTROLUNIT

4.SCREWS

5.HORNSWITCH

Figure4.HydraulicHoseConnections

9. Ifyourmodeloflifttruckhasaninstrument clusterthatwrapsaroundthesteeringcolumn,removetheinstrumentcluster.The removalproceduresfortheinstrumentclustercanbefoundintheservicemanualsections InstrumentCluster 2200SRM514for modelsH2.00-3.20XM(H40-65XM)(H177), S1.50-1.75XM,S2.00XMS(S25-40XM)(D010) andH1.50-1.75XM,H2.00XMS(H25-35XM, H40XMS)(E001),or ElectricalSystem, Replacement,Checks,andAdjustments TruckswithEV-100/200ZXorSR(SEM) andSPMotorControllers 2200SRM 560formodelsE1.50-1.75XM(E25-35XM 2) (D114),E2.00XMS(E40XM 2S),E2.00-3.20XM (E45-65XM 2)(F108),andJ2.00-3.20XM (J40-60XM 2)(A216).

10. Ifthereisainstrumentclusteronthesteering columnhousing,disconnectallplugsconnected tothedisplaypanel.

Figure5.SteeringColumnAssembly,ForModelsJ2.00-3.20XM(J40-60XM 2)(A216),E1.50-1.75XM, E2.00XMS(E25-40XM 2S,(D114),N30XMH,N30XMH 2 (C210),andE2.00-3.20XM(E45-65XM 2)(F108)

LegendforFigure5

NOTE: *NOTINCLUDEDONLIFTTRUCKMODELSH2.00-3.20XM(H40-65XM)(H177),S1.50-1.75XM, S2.00XMS(S25-40XM)(D010),ANDH1.50-1.75XM,H2.00XMS(H25-35XM,H40XMS(E001)

11. Removethetiltstopscrewlocatedatthebottom leftsideofthesteeringcolumnbracket.

12. Removethecapscrews,lockwashers,andlock platesthatfastenthesteeringcolumntothe pivotsonthelifttruck.Removethesteeringcolumnfromthelifttruck.Makesuretheelectric wiresandthehydraulichosesarenotdamaged asthesteeringcolumnisremoved.

13. Removethefourcapscrewsthatholdthesteeringcolumntothebracket.Removethefourcapscrewsornutsthatfastenthesteeringcontrol unittothesteeringcolumn.

STEERINGCONTROLUNIT, DISASSEMBLE

1. Placethesteeringpumpintoasoftjawvisewith thesplinedshaftfacingdown.

2. Removethehydraulicfittingsandthespecial screws,androtatethesteeringpump90degrees sidewaysinthevise.DiscardtheO-rings.See Figure7.

3. Removetheendcover,spacer,gearhousing, andgearfromthesteeringpump.Discardthe O-rings.

4. Removethecardanshaftfromthespoolassembly.

5. Removethecheckball,ballstop,andemergency steeringballfromthepumphousing.

6. Removethespoolassemblyfromthepumphousing.

NOTE: Tohelpwithinstallationofthethrustbearing assembly,notethepositionsofthethrustwashers oneithersideofthethrustbearingwhileperforming Step7.

7. Removethethrustbearingassemblyfromthe shaftendofthespoolassembly.

8. Removetheretainingringfromthespoolassembly.

9. Pressthecrosspinoutofthespoolassembly.

10. Pressthespoolfromthesleeveandremovethe springsfromthespool.Pressthespoolfromthe sleeveandremovethespringsfromthespool.

11. Removetheshaftsealsfromthepumphousing. Discardtheseals.

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Figure6.SteeringColumnAssembly,ModelsJ2.00-3.20XM[J40-65Z](A416/B416),E1.50-2.00XM [E25-35Z,E40ZS](E114/F114),V30ZMD(D210/E210),E2.00-3.20XM[E45-65Z](G108),and E3.50-5.50XL,E4.50XLS(E70-120Z,E100ZS)(D098/E098)

STEERINGCONTROL UNIT,CLEAN

WARNING

Cleaningsolventscanbeflammableandtoxic andcancauseskinirritation.Whenusing cleaningsolvents,alwaysfollowthesolvent manufacturer’srecommendedsafetyprecautions.

WARNING

Compressedair canmoveparticlessothatthey causeinjuryto theuserortootherpersonnel. Makesurethatthepathofthecompressedair isawayfromall personnel.Wearprotective gogglesorafaceshieldtopreventinjurytothe eyes.

Cleanallthepartsinsolvent.Drythepartswith compressedair.Donotdrythepartswithacloth. Makesureallsurfacesarefreeofscratchesandsharp edges.

STEERINGCON TROLUNIT,ASSEMBLE

1. Usingasealinstaller,installtheshaftsealsin thepumphousing.

2. Installthespoolintothesleevewiththekeyslots oppositeeachother.

3. Insertthecurvedspringsbetweentheflat springs.SeeFigure7.Installthespringsetinto thespoolassembly.

NOTE: Theretainingringmustbeabletorotate unimpededbythesprings.

4. Centerthespringsinthespoolassembly,andinstalltheretainingringoverthesleeve.

5. Installthecross pinintothespoolassembly.

6. Installthethrustbearingassembly,asnotedduringremoval,onthespoolassembly.

7. Placethepumphousinginasoft-jawedvisein thehorizontalposition.Installthespoolassemblyintothehousingwhileholdingthecrosspin inahorizontal position.

8. Rotatethepump housingtotheverticalposition, androtatethespoolsothatthepininthespool ispointingtothe"P"portposition.SeeFigure5 andFigure6.

9. Installtheemergencysteeringball,ballstop, andcheckball inthe"P"port.SeeFigure5and Figure6.

10. InstallanewO-ringonthehousingandplacethe distributorplateonthehousing,withtheholes properlyalignedwiththepumphousing.

11. Installthecardanshaftandrotateituntilitis engagedwiththepininthespoolassembly,and untiltheteethofthegearendarealignedas showninFigure7.

12. Installthegearwheelontothecardanshaftas showninFigure7.

Figure7.SteeringPump

13. InstallnewO-ringsontothegearhousingandinstallthegearhousingontothedistributorplate, makingsurethattheholesareproperlyaligned.

14. Placethespaceroverthecardanshaft,andinstalltheendcoverwiththe"P"holelinedupwith the"P"portinthehousing.

15. InstallnewO-rings,hydraulicfittings,andspecialscrews.Tightenthefittingsandthespecial screwsto30±3N•m(266±27lbfin)inacross pattern.

ASSEMBLYCOMPONENTS,INSTALL

NOTE: Thisprocedureisfortheinstallationofall componentsofthesteeringcolumnassembly.All componentsarenotofteninstalledforarepairprocedure.Doonlythosestepsoftheprocedurenecessary toinstalltherequiredcomponent.SeeFigure5and Figure6.

WARNING

Thehydraulichosesmustbeconnectedtothe correctportsorthesteeringsystemwillnotoperateasexpected,whichcancausedamageor personalinjury.Makesurethehosesareidentifiedandconnectedcorrectly.

1. Usingfourcapscrews,attachthesteeringcontrol unitassemblytothesteeringcolumn.Installthe steeringcolumnandsteeringcontrolunitassemblyonthebracketInstallthefourcapscrewsthat mountthesteeringcolumntothebracket.See Figure5andFigure6.

2. Ifainstrumentclusterwasremovedfromthe steeringcolumnhousing,installitbyconnecting allplugs.

3. Ifaninstrumentclusterwasremoved,Installtheinstrumentclusteronthefrontcover. fortheinstallationprocedures,seetheservicemanualsections InstrumentCluster 2200SRM514formodelsH2.00-3.20XM(H4065XM),S1.50-1.75XM,S2.00XMS(S25-40XM) andH1.50-1.75XM,H2.00XMS(H25-35XM, H40XMS),or ElectricalSystem, Replacement,Checks,andAdjustmentsTrucks withEV-100/200ZXorSR(SEM)andSP MotorControllers 2200SRM560formodelsE1.50-1.75XM(E25-35XM 2),E2.00XMS (E40XM 2S),E2.00-3.20XM(E45-65XM 2),and J2.00-3.20XM(J40-60XM 2).

WARNING

ThehydraulichosesMUSTbeconnectedto thecorrectportsandfittingsorthesteering systemwillnotoperateasexpected.This unexpectedoperationcancausedamageor personalinjury.Makesurethehosesareidentifiedandconnectedcorrectly.

4. Connectthehydraulichosestothesteeringcontrolunit,thecowl,thecontrolvalve,orthesteeringpumpasremovedduringremoval.Makesure eachhydraulichoseisconnectedtothecorrect

Figure8.InstallSteeringComponents

portsorfittingsasidentifiedduringremoval.See Figure4.

5. OnlifttrucksmodelsJ2.00-3.20XM(J4060XM 2)(A216),E1.50-1.75XM,E2.00XMS (E25-40XM 2S)(D114),N30XMH,N30XMH 2 (C210),andE2.00-3.20XM(E45-65XM 2)(F108) installtheopticalencodercomponentsbyconnectingtheelectricalwirestotheopticalencoder. Installtheopticalencoderandopticalencoder housingtothesteeringcolumn.SeeFigure5.

6. OnlifttruckmodelsJ2.00-3.20XM[J40-65Z] (A416/B416),E1.50-2.00XM[E25-35Z,E40ZS] (E114/F114),V30ZMD(D210/E210),E2.003.20XM[E45-65Z](G108),andE3.50-5.50XL, E4.50XLS(E70-120Z,E100ZS)(D098/E098) models,connecttheconnectorandusingtwo capscrews,installthesteeringsensoronthe steeringcolumn.SeeFigure6.

7. Installthesteeringwheelandlargehexnut. Tightenthelargehexnutto40to54N•m(30to 40lbfft).Connectthewireatthehornbutton andinstallthehornbutton.

8. Ifremoved,installthestaticstrapandwireson thekeyswitchthatwereidentifiedduringremoval.Installthekeyswitch.

9. Ifremoved,installthewiresonthedirection switchthatwereidentifiedduringremoval. Installthedirectionswitchinthehousingand installthetwocapscrews.SeeFigure3.

10. Connectthewireconnectorsatthebottomofthe steeringcolumn.Installtheupperandloweraccesscoversonthesteeringcolumn.SeeFigure9.

11. Installthecolumntiltlever.

WARNING

Aftermakingrepairs,donotextendthehands orarmsthroughthecenterofthesteering

wheel.Ifthecontrolunitwasnotassembled correctlyorthehosesnotconnectedcorrectly, thesteeringwheelcanrotatewithastrong forceandcauseseriousinjury.Ifthisaction occurs,disassemblethecontrolunitandcorrecttheproblem.

12. RemovetheDONOTCONNECTBATTERYtag frombatteryconnectorandconnectthebattery. Operatethesteeringsystemtocheckforcorrect operationandleaks.

1.UPPERACCESS COVER

2.LOWERACCESS COVER

System AirRemoval

Toremoveairfromthesteeringsystem,usethefollowing procedure:

1. Starttheengine.

2. Turnandholdthesteeringwheelfullleftforten seconds.

3. Turnandholdthesteeringwheelfullrightfor tenseconds.

4. Repeat tentimestobleedtheairfromthesteeringsystem.

Figure9.InstallSteeringHousing