STEERING SYSTEM

H40.00-48.00XM-12 (H800-1050HD/HDS) [A917];

RS45-27CH, RS45-31CH, RS46-36CH, RS46-40CH, RS46-41S CH,
RS46-41L CH, RS46-41LS CH, RS45-24IH, RS45-28IH, RS46-33IH,
RS46-37IH, RS46-38S IH, RS46-38L IH, RS46-38LS IH (HR45-27,
HR45-31, HR45-36, HR45-40, HR45-41S, HR45-41L, HR45-41LS)
[B222];
H40.00-52.00XM-16CH (H1050HD-CH, 1150HD-CH) [E117, F117];
RS45-27CH, RS45-31CH, RS46-36CH, RS46-41L CH, RS46-41S CH,
RS46-41LS CH, RS45-24IH, RS45-28IH, RS46-33IH, RS46-38L IH,
RS46-38S IH, RS46-38LS IH (RS45-27, RS45-31, RS46-36, RS46-41L,
RS46-41S, RS46-41LS) [C222];
H36XMS-12, H40XM-12, H44XM-12, H48XM-12
(H800HD, H1050HD) [B917];
H40XM-16CH, H44XM-16CH, H48-16CH, H50-16CH, H52XM-16CH
(H1050HD, H1150HD) [G117];
H40.00-52.00XM-16CH (H1050HD-16CH, H1150HD-16CH) [H117];
RS45-27CH, RS45-31CH, RS46-36CH, RS46-41L CH, RS46-41S CH,
RS46-41LS CH, RS46-33IH, RS46-38L IH, RS46-38S IH, RS46-38LS IH
(RS45-27CH, RS45-31CH, RS46-36CH, RS46-41L CH, RS46-41S CH,
RS46-41LS CH) [D222];
H40XM-12, H44XM-12, H48XM-12, H36XMS-12, H40XMS-12,
H44XMS-12, H48XMS-12 (H800HDS, H900HDS, H970HDS,
H1050HDS) [C917]

PART NO. 1565182 1600 SRM 1109

 SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• The Service Manuals are updated on a regular basis, but may not reflect recent design changes to the
product. Updated technical service information may be available from your local authorized Hyster®
dealer. Service Manuals provide general guidelines for maintenance and service and are intended for
use by trained and experienced technicians. Failure to properly maintain equipment or to follow in-
structions contained in the Service Manual could result in damage to the products, personal injury,
property damage or death.
• 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 Maintenance 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 ex-
ceed 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 flamma-
ble. 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 hazardous situation which, if not avoided, could result in death
or serious injury.

CAUTION
Indicates a hazardous situation which, if not avoided, could result in minor
or moderate injury and property damage.

On the lift truck, the WARNING symbol and word are on orange back-
ground. The CAUTION symbol and word are on yellow background.
 Table of Contents

TABLE OF CONTENTS

General .....................................................................................................................................................................1
Description ...............................................................................................................................................................2
Steering Wheel and Column Assembly Repair ......................................................................................................5
General ................................................................................................................................................................ 5
Steering Wheel and Horn ................................................................................................................................... 8
Remove ............................................................................................................................................................ 8
Install .............................................................................................................................................................. 8
Steering Column ......................................................................................................................................................8
Remove ................................................................................................................................................................ 8
Install ...................................................................................................................................................................9
Steering Control Unit Repair ............................................................................................................................... 10
General .............................................................................................................................................................. 10
Description ........................................................................................................................................................ 10
Operation ...........................................................................................................................................................10
Remove .............................................................................................................................................................. 11
Disassemble .......................................................................................................................................................14
Clean ..................................................................................................................................................................17
Assemble ............................................................................................................................................................17
Install .................................................................................................................................................................23
Steering System Air Removal ...............................................................................................................................24
Steering Relief Pressure Check and Adjustments ...............................................................................................24
Flow Amplifier Repair ...........................................................................................................................................26
General .............................................................................................................................................................. 26
Description ........................................................................................................................................................ 26
Operation ...........................................................................................................................................................28
Neutral Position ............................................................................................................................................28
During Steering Function ............................................................................................................................ 28
Manual Steering Function ........................................................................................................................... 28
Disassemble .......................................................................................................................................................28
Pressure Relief Valve ................................................................................................................................... 28
End Cover at PP Port ................................................................................................................................... 29
End Cover at LS Port ................................................................................................................................... 29
Spools .............................................................................................................................................................30
Directional Valve Spool ................................................................................................................................ 30
Priority Valve Spool ......................................................................................................................................30
Pressure Control/Amplifier Valve Spool ......................................................................................................30
Check Valve .................................................................................................................................................. 32
Cushion/Suction Valves ................................................................................................................................32
Clean ..................................................................................................................................................................32
Assemble ............................................................................................................................................................33
Troubleshooting .....................................................................................................................................................33

©2014 HYSTER COMPANY i

Table of Contents

This section is for the following models:

H40.00-48.00XM-12 (H800-1050HD/HDS) [A917];

RS45-27CH, RS45-31CH, RS46-36CH, RS46-40CH, RS46-41S CH, RS46-41L CH,
RS46-41LS CH, RS45-24IH, RS45-28IH, RS46-33IH, RS46-37IH, RS46-38S IH,
RS46-38L IH, RS46-38LS IH (HR45-27, HR45-31, HR45-36, HR45-40, HR45-41S,
HR45-41L, HR45-41LS) [B222];
H40.00-52.00XM-16CH (H1050HD-CH, 1150HD-CH) [E117, F117];
RS45-27CH, RS45-31CH, RS46-36CH, RS46-41L CH, RS46-41S CH, RS46-41LS
CH, RS45-24IH, RS45-28IH, RS46-33IH, RS46-38L IH, RS46-38S IH, RS46-38LS
IH (RS45-27, RS45-31, RS46-36, RS46-41L, RS46-41S, RS46-41LS) [C222];
H36XMS-12, H40XM-12, H44XM-12, H48XM-12 (H800HD, H1050HD) [B917];
H40XM-16CH, H44XM-16CH, H48-16CH, H50-16CH, H52XM-16CH (H1050HD,
H1150HD) [G117];
H40.00-52.00XM-16CH (H1050HD-16CH, H1150HD-16CH) [H117];
RS45-27CH, RS45-31CH, RS46-36CH, RS46-41L CH, RS46-41S CH, RS46-41LS
CH, RS46-33IH, RS46-38L IH, RS46-38S IH, RS46-38LS IH (RS45-27CH,
RS45-31CH, RS46-36CH, RS46-41L CH, RS46-41S CH, RS46-41LS CH) [D222];
H40XM-12, H44XM-12, H48XM-12, H36XMS-12, H40XMS-12, H44XMS-12,
H48XMS-12 (H800HDS, H900HDS, H970HDS, H1050HDS) [C917]

ii
1600 SRM 1109 General

General
This section has the description and repair information for the steering hydraulic pump is in
procedures for the parts of the steering system. the section Hydraulic System 1900SRM1257 for
Description and repair information is given for the B222 trucks, Hydraulic System 1900 SRM 1476
steering wheel and column assembly, the steering for C222 trucks, Hydraulic System
control unit, and the flow amplifier. Repair 1900SRM1102 for E117 trucks and Hydraulic
information for the parts of the steering axle is in System 1900SRM1239 for A917 and F117 trucks.
the section Steering Axle 1600SRM1114. Repair

1
Description
Description
These lift trucks use a hydraulic steering system.
See Figure 1 and Figure 2. The steering pump is
driven by the engine and supplies hydraulic oil to
the flow amplifier and the steering control unit.
When the operator turns the steering wheel, the
steering control unit activates the flow amplifier to
send oil to the steering cylinder. When the steering
wheel is not being turned, the flow amplifier sends
the flow from the pump to the control valve for the
lift and tilt circuit.
When the engine is not running, a check valve
closes and permits the steering control unit to oper-
ate as a hydraulic motor. The lift truck is difficult
to steer when the steering pump is not operating,
but steering is possible.
2
1600 SRM 1109
When the steering wheel is turned, a pilot line (LS)
from the steering control unit activates the priority
valve in the flow amplifier. The priority valve
moves to send the necessary oil (1/5) from the steer-
ing pump to the steering control unit. This oil is di-
rected to the left or right part of the flow amplifier,
depending on which way it is turned. The flow am-
plifier adds oil flow (4/5 part) and directs all oil flow
(5/5 part) to the left or right port of the steering cyl-
inder. The tank flow operates the opposite way. Re-
turn flow from the steering system is sent to the
tank through the line connected to port HT on the
flow amplifier.
1600 SRM 1109 Description

A. PRESSURE LINE C. PILOT LINE

B. RETURN LINE
1. HYDRAULIC TANK 5. STEERING CONTROL UNIT AT CAB
2. STEERING PUMP 6. TO LIFT/TILT CONTROL VALVE
3. FLOW AMPLIFIER 7. RETURN MANIFOLD
4. STEERING CYLINDER
Figure 1. Steering System Diagram

3
Description 1600 SRM 1109

Figure 2. Steering System Schematic Diagram

4
1600 SRM 1109 Steering Wheel and Column Assembly Repair

Legend for Figure 2

1. STEERING CONTROL UNIT 3. STEERING CYLINDER

2. FLOW AMPLIFIER 4. FROM HYDRAULIC PUMP
A. PRESSURE VALVE 5. TO CONTROL VALVE
B. RELIEF VALVE 6. TO HYDRAULIC TANK
C. PRIORITY VALVE
D. PRESSURE CONTROL/AMPLIFIER VALVE
E. DIRECTIONAL VALVE
F. CUSHION/SUCTION VALVE

Steering Wheel and Column Assembly Repair

GENERAL
The steering column, located in the cab, is mounted
to a support bracket and the floor of the cab. See
Figure 3. The steering column is fitted to the steer-
ing control unit through the cab floor. See Figure 6.
The steering wheel is held on the splines of the
steering column with a large nut. The steering con-
trol unit has splines that engage with the lower end
of the steering column. The steering control unit is
fastened to the underside of the cab floor with four
bolts. Information on the gauges in the steering
housing are in the section Instrument Panel In-
dicators and Senders 2200SRM1110 for E117 lift
trucks and Instrument Panel Indicators and
Senders 2200SRM1234 for A917, B222, C222, and
F117 lift trucks.

5
Steering Wheel and Column Assembly Repair 1600 SRM 1109

Figure 3. Steering Wheel and Steering Column Assembly

6
1600 SRM 1109 Steering Wheel and Column Assembly Repair

Legend for Figure 3

1. SCREW 11. LH STEERING COVER COLUMN

2. WASHER 12. RH STEERING COVER COLUMN
3. SCREW 13. LH STEERING COVER COLUMN
4. WASHER 14. RH STEERING COVER COLUMN
5. SOCKET 15. STEERING COLUMN ASSEMBLY
6. HORN BUTTON 16. BOOT
7. SPINNER KNOB 17. LIGHT
8. STEERING WHEEL 18. STEERING CONTROL UNIT (UNDER CAB
9. HARNESS FLOOR)
10. UPPER STEERING COLUMN COVER

7
Steering Column
STEERING WHEEL AND HORN
This procedure describes the replacement of the
steering wheel and horn actuator assembly. Disas-
semble the parts as required to make repairs.
Remove
WARNING
To prevent electrical arcs when removing the
cover, disconnect the negative battery cable.
1. Disconnect the battery, using the switch.
2. Remove the horn button from the steering
wheel. See Figure 3.
Steering Column
REMOVE
1. Disconnect the battery, using the switch.
2. Disconnect the steering column connector, posi-
tioned under the cab. See Figure 4.
3. Remove the four hex bolts that fasten the steer-
ing control unit under the cab. Carefully re-
move the steering pump.
4. Remove the screws that fasten the left and
right hand steering column covers. See Fig-
ure 3.
8
1600 SRM 1109
3. Remove the electrical wire to the horn button.
Remove the large nut and pull the steering
wheel from the steering shaft.
Install
1. Install the steering wheel and the large nut
onto the steering shaft. See Figure 3. Tighten
the nut to 35 to 45 N•m (26 to 33 lbf ft).
2. Attach the electrical wire from the horn switch
to the horn button.
3. Install the horn button onto the steering wheel.
4. Connect the battery, using the switch.
5. Remove the two cab mounting bolts holding the
steering column to the cab floor. See Figure 5.
6. Remove the two hex bolts holding the steering
column to the bracket. See Figure 5.
7. Remove steering column. Push the grommet
out of the hole and slide the connector through
the hole.
1600 SRM 1109 Steering Column

INSTALL
1. Slide the connector through the hole in the cab
floor and push the grommet into the hole.

2. Connect the steering column to the bracket

with the two hex bolts. See Figure 5.

3. Mount the steering column to the cab floor with

the two cab mounting bolts. See Figure 5.

4. Install the left-hand and right-hand steering

column covers with screws. See Figure 3.

5. Carefully mount the steering control unit with

four hex bolts to allow a non-forced coupling be-
tween steering control unit and steering col-
umn.

6. Connect the steering column connector, posi-

tioned under the cab. See Figure 4.
1. STEERING COLUMN CONNECTOR
2. STEERING COLUMN BOLTS 7. Connect the battery, using the switch.
3. STEERING PUMP BOLTS
Figure 4. Steering Pump

1. STEERING COLUMN TO BRACKET BOLTS

2. STEERING COLUMN TO FLOOR PLATE BOLTS
Figure 5. Steering Column

9
Steering Control Unit Repair
Steering Control Unit Repair
GENERAL
This section has the description, operation, and re-
pair procedures for the steering control unit.
DESCRIPTION
The steering control unit is a hydrostatic unit that
is controlled by the steering wheel. See Figure 6.
The steering control unit is mounted on the under-
side of the cab floor. The steering control unit has a
shaft assembly, control section, and a metering sec-
tion. The hydraulic hoses for the steering system
are fastened to a manifold block.
OPERATION
Turning the steering wheel actuates three main
parts of the steering control unit (see Figure 6): (1)
the spool for the control section, (2) the sleeve for
the control section, and (3) the rotor in the meter-
ing 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.
10
1600 SRM 1109
As the steering wheel is turned, the spool just be-
gins 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 ro-
tor 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 posi-
tion, 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 rotor in the metering section.
The oil then flows to the flow amplifier and then to
one side of the steering cylinder. Oil from the other
side of the steering cylinder flows back through the
flow amplifier and the control section of the steer-
ing control unit.
1600 SRM 1109 Steering Control Unit Repair

When the steering wheel stops moving, the meter-
ing action in the metering section also stops. The
neutral position springs return the sleeve to the
neutral position. When this action occurs, the pres-
sure stays in the steering cylinder to keep the tires
in position. Oil from the pump flows through the
steering control unit to the tank or other parts of
the system. To return the tires to the straight posi-
tion, the steering wheel must be rotated in the op-
posite direction. The steering control unit will oper-
ate as described, but all parts will rotate in the op-
posite direction.
REMOVE
WARNING
To prevent electrical arcs when removing the
cover of the steering column, disconnect the neg-
ative cable form the battery.
1. Close shutoff valves on the bottom of the hy-
draulic tank.
2. Remove the cover on the frame, located on the
front underside of the cab.
3. Disconnect the steering column connector, posi-
tioned under the cab. See Figure 4.
4. Place tags on the hydraulic lines at the steering
control unit.
5. Disconnect the hydraulic lines and place caps
on the openings.
6. Remove four hex bolts that fasten the steering
control unit under the cab, and carefully re-
move the steering control unit from the end of
the steering column. See Figure 3.

WARNING
Move all control levers back and forth a minimum
of 20 times to remove all hydraulic pressure from
pilot system.

11
Steering Control Unit Repair 1600 SRM 1109

Figure 6. Steering Control Unit

12
1600 SRM 1109 Steering Control Unit Repair

Legend for Figure 6

A. SHAFT INSTALLED SO THAT PIN IS ALIGNED WITH GROOVE IN ROTOR

1. SPOOL 9. METERING SECTION
2. SLEEVE 10. CHECK VALVE CHANGES CONTROL UNIT TO
3. SHAFT HAND OPERATED UNIT WHEN ENGINE IS OFF
4. STATOR 11. HORN CONTACT ARRANGEMENT
5. ROTOR 12. SHAFT AND COLUMN ASSEMBLY
6. PIN 13. HORN CONTACT ARRANGEMENT
7. SPRINGS 14. CENTERING SPRINGS RETURN VALVE TO
8. CONTROL SECTION NEUTRAL
15. SPOOL AND SLEEVE ASSEMBLY

13
Steering Control Unit Repair 1600 SRM 1109

DISASSEMBLE
Disassemble the unit as follows:

STEP 1.
Put the control unit in a vise with soft jaws. Make
an identification mark on the length of the control
unit. Remove the manifold block.

NOTE: MANIFOLD REMOVED.

1. STEERING CONTROL UNIT

2. VISE
STEP 2.
Remove the cover on the bottom of the steering
control unit.

1. CAPSCREW 3. O-RING
2. COVER

14
1600 SRM 1109 Steering Control Unit Repair

STEP 3.
Remove the spacer, stator, rotor, and port plate.
Put a mark on the stator so that the same side is
toward the body of the control unit. Remove the O-
rings. Remove the center shaft.

1. SPACER 4. PORT PLATE

2. STATOR 5. O-RING
3. ROTOR 6. CENTER SHAFT

STEP 4.
Remove the screw for the check ball. Remove the
check ball.

1. SCREW

STEP 5.
Remove the spool and sleeve assembly. Remove the thrust bearing assembly from the spool. Push the cen-
ter pin from the sleeve. Carefully remove the spool from the sleeve. (Rotate the spool slowly during re-
moval.) Remove the ring from the sleeve. Remove the neutral position springs from the spool.

15
Steering Control Unit Repair 1600 SRM 1109

1. SPOOL AND SLEEVE ASSEMBLY 5. SLEEVE

2. THRUST WASHER 6. SPOOL
3. THRUST BEARING 7. RING
4. CENTER PIN 8. NEUTRAL POSITION SPRINGS

STEP 6.
Remove relief valve assembly and dust seal from
housing. Do not disassemble relief valve cartridge.

1. DUST SEAL
2. RELIEF VALVE ASSEMBLY
3. HOUSING

16
1600 SRM 1109 Steering Control Unit Repair

CLEAN 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
WARNING sharp edges.
Cleaning solvents can be flammable and toxic and
can cause skin irritation. When using cleaning
solvents, always follow the solvent manufactur-
er's recommended safety precautions.

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

STEP 1.
Install dust seal in housing. When used, install re-
lief valve assembly.

1. DUST SEAL
2. RELIEF VALVE ASSEMBLY

STEP 2.
Carefully assemble the spool and sleeve. Make
sure the spool rotates freely in the sleeve.

1. SPOOL 2. SLEEVE
STEP 3.
Assemble the neutral position springs, then push them into position in the spool. Make sure the flat
springs are installed to the outside of the curved springs. Install the center pin. Install the ring on the
sleeve (over the neutral position springs). The ring must turn freely on the sleeve.

17
Steering Control Unit Repair 1600 SRM 1109

1. NEUTRAL POSITION SPRINGS (FLAT) 4. SPOOL

2. NEUTRAL POSITION SPRINGS (CURVED) 5. RING
3. CENTER PIN

STEP 4.
Put the spool on the workbench, then put the
housing onto the spool as shown. Install the guide
ring with the O-ring on the end of the spool. Put a
large thrust washer (see STEP 5) on top of the
guide ring and O-ring assembly. Use a deep socket
or tube to push on the washer and install the O-
ring and guide ring in the housing. Carefully re-
move the washer, tube, and spool from the hous-
ing.

1. O-RING 4. WASHER
2. GUIDE RING 5. TUBE
3. SPOOL 6. HOUSING

18
1600 SRM 1109 Steering Control Unit Repair

STEP 5.
Install the thrust washers and thrust bearing on
the spool. Make sure the chamfer on the inner
thrust washer is toward the sleeve. Install the
spool and sleeve assembly in the housing. Care-
fully rotate the spool and sleeve assembly during
installation to make sure the spool fits correctly in
the seal installed in STEP 4. Make sure the center
pin in the spool and sleeve assembly is horizontal
(parallel to the port surface).

1. HOUSING
2. SPOOL AND SLEEVE ASSEMBLY
3. THRUST WASHER
4. THRUST BEARING
5. SPOOL
6. SLEEVE

19
Steering Control Unit Repair 1600 SRM 1109

STEP 6.
Install the check ball and sleeve. Make sure the
sleeve is even with or below the surface of the
housing. Lubricate the O-ring and install the O-
ring and port plate. Align the holes in the port
plate with the holes in the housing.

1. CHECK BALL SLEEVE

2. HOUSING
3. O-RING
4. PORT PLATE

STEP 7.
Install the center shaft so that it engages with the center pin in the spool and sleeve assembly. Make sure
the center pin is still parallel to the port surface. Install the rotor on the center shaft. Make sure that a
valley in the rotor aligns with the slot (center pin) in the center shaft. See insert. Install the O-ring and
stator. Make sure to align the marks made during disassembly.

20
1600 SRM 1109 Steering Control Unit Repair

1. CENTER SHAFT 4. STATOR

2. CENTER PIN 5. O-RING
3. ROTOR

STEP 8.
Install the spacer. Install the O-ring and the cover. Tighten the capscrews for the cover, in the sequence
shown, to 17 N•m (150 lbf in). Then tighten them to 30 N•m (265 lbf in). Make sure the capscrew with the
pin fits in the hole for the check ball.

21
Steering Control Unit Repair 1600 SRM 1109

1. SPACER 4. CAPSCREW
2. O-RING 5. CHECK BALL
3. COVER
STEP 9.
Install the manifold block and O-rings on the
steering control unit. Tighten the capscrews for
the manifold block to 40 N•m (30 lbf ft).

1. O-RING
2. MANIFOLD BLOCK
3. STEERING CONTROL UNIT

22
1600 SRM 1109 Steering Control Unit Repair

WARNING
After making repairs, do not extend hands or arms
through steering wheel. If control unit was not as-
sembled correctly or lines not connected cor-
rectly, steering wheel can rotate with a strong
force and cause injury. If this action occurs, dis-
assemble control unit or check lines to correct
problem.

STEP 10.
See Figure 3. Install steering column and steering
control unit on brackets. Connect hydraulic lines
at manifold block. Start engine and operate steer-
ing wheel. Check for correct operation.

INSTALL 4. Connect the battery, using the switch.

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
hoses are not connected correctly it can rotate
with a strong force and cause injury. If this action
occurs, disassemble the control unit and correct
the problem.
1. Carefully mount the steering control unit with
four hex bolts to allow a non-forced coupling be-
tween steering control unit and steering col-
umn.
2. Remove caps and connect the hydraulic lines to
the steering control unit according to the tags
made during removal.
WARNING
Do not try to locate hydraulic leaks by putting
hands on pressurized hydraulic components. Hy-
draulic oil can be injected into the body by pres-
sure.
CAUTION
Never start the engine with closed shutoff valves.
Open the shutoff valves before starting the engine
to prevent damage to hydraulic components.
5. Operate hydraulic system and check for leaks
and correct operation.
6. Install the cover on the frame, located on the
front underside of the cab.

3. Connect the steering column connector, posi-

tioned under the cab. See Figure 4.

23
Steering System Air Removal 1600 SRM 1109

Steering System Air Removal

Air can enter the system when a hydraulic line is in each direction. Air will be removed without dis-
disconnected. If the operation is rough, start engine connecting any lines. If the operation is still rough,
and rotate steering wheel stop-to-stop several times air can be entering the system at a loose fitting.

Steering Relief Pressure Check and Adjustments

NOTE: The relief valve is in the flow amplifier. The
relief pressure is set at the factory.
1. Connect 0 to 28 MPa (0 to 4000 psi) gauge to
check port M1, see Figure 7 and Figure 8 for
A917, E117, and F117 lift trucks. For B222 lift
trucks, go to Step 2. See Figure 9 for B222 lift
trucks.
7. If you cannot correctly adjust relief pressure,
replace parts of relief valve (cartridge). See Fig-
ure 10.
8. When checks are complete, remove gauge and
install cap on fitting.

2. Connect 0 to 28 MPa (0 to 4000 psi) gauge to

check port MLS2. See Figure 9.

3. Start engine. Operate hydraulic system until

temperature of hydraulic oil is 55 to 65°C (130
to 150°F). Run engine at full throttle when
checking the pressure.

4. Turn steering wheel until steering wheel spin-

dle is against the stop on the axle. Correct relief
pressure is 16.7 to 18.2 MPa (2425 to 2640 psi)
for E117 and F117 lift trucks. For A917 and
B222 lift trucks, the correct relief pressure is
21.0 to 22.5 MPa (3046 to 3263 psi).

WARNING
The adjustment screw compresses a spring. Use
caution and wear eye protection when adjusting
relief valve.

5. If relief pressure is not correct, remove plug 1. CHECK PORT M1

and adjust pressure by turning screw.
Figure 7. Flow Amplifier (E117 and F117)
6. When correct pressure is achieved, lock the
plug. Do final pressure check after locking the
plug, because the settings can shift when lock-
ing the plug by force.

24
1600 SRM 1109 Steering Relief Pressure Check and Adjustments

1. CHECK PORT MLS2

Figure 9. Flow Amplifier (B222)

1. CHECK PORT M1

Figure 8. Flow Amplifier (A917)

25
Flow Amplifier Repair
Flow Amplifier Repair
GENERAL
The flow amplifier regulates and directs the flow of
oil to the steering cylinder. The flow amplifier in-
creases the output oil flow five times more than the
pilot input flow from the steering control unit. The
rate of oil flow to the steering cylinder is directly
proportional to the rate of the pilot flow from the
steering control unit.
DESCRIPTION
The following valves are part of the flow amplifier.
See Figure 10.
PRIORITY VALVE. This valve selects and directs
the oil flow for steering. The priority is determined
in response to pressure in the load sensing line
from the steering control unit. In the neutral posi-
tion (no steering demand), the priority valve allows
oil to flow from the pump to the main control valve.
DIRECTIONAL VALVE. This valve opens the cor-
rect cylinder supply and return passages when it
senses the load sensing pressure from the steering
26
1600 SRM 1109
control unit. The directional valve checks steering
overrun by directing return flow from the cylinder
to verify there is control under all conditions.
AMPLIFIER VALVE. This valve is moved by pilot
pressure and opens to pump flow directly from the
priority valve. This oil flow is then combined with
the pilot flow.
CUSHION AND SUCTION VALVES. The "cush-
ion" function of these valves makes a hydraulic
cushion to reduce sharp increases of pressure in the
steering cylinder. The "suction" function of these
valves uses the cylinder return flow to prevent cavi-
tation of oil inside the cylinder if steering "overrun"
forces are sensed.
RELIEF VALVE. This valve senses high pressure
from the load sensing line from the steering control
unit. The relief valve opens and directs the oil flow
to the hydraulic tank.
1600 SRM 1109 Flow Amplifier Repair

1. O-RING 14. PRIORITY VALVE SPOOL

2. SEAL 15. PRESSURE CONTROL/AMPLIFIER VALVE AS-
3. HOUSING, FLOW AMPLIFIER SEMBLY
4. SCREW 16. AMPLIFIER VALVE SPOOL
5. CAPSCREW 17. RELIEF VALVE
6. SPRING WASHER 18. PLUG
7. COVER, PP END 19. ORIFICE
8. PLATE 20. THROTTLE CHECK VALVE
9. COVER, LS END 21. SPRING
10. CUSHION/SUCTION VALVE ASSEMBLY 22. SPRING CONTROL
11. DIRECTIONAL VALVE ASSEMBLY 23. STOP
12. DIRECTIONAL VALVE SPOOL 24. PIN
13. PRIORITY VALVE 25. INNER SPOOL
Figure 10. Flow Amplifier Assembly

27
Flow Amplifier Repair
OPERATION
Neutral Position
In the neutral position, the oil flows from the steer-
ing pump to the priority valve and discharges
through the EF port. The EF port is connected to
the working pressure of the hydraulic system at the
main control valve.
During Steering Function
When the steering wheel is turned, pilot pressure
causes oil to flow from the steering control unit to
the priority valve. The priority valve is shifted. Oil
flows from the steering control unit to the flow am-
plifier.
The directional valve is shifted by pressure across
the bore of the spool.
The pilot pressure moves the spool and causes oil to
flow through the pressure control/amplifier valve to
the directional valve.
The main oil flow passes from the priority valve to
the pressure control/amplifier valve where the
spool is in the "left turn" position. Oil now flows
through holes in the valve to a chamber in one end
of the spool.
The spool shifts to a position so the pressure is the
same at both ends of the spool. Oil now flows
through the valve to the directional valve.
The main flow and pilot flow of oil combine, in-
creasing the flow through the directional valve to
the steering cylinder. The return oil flows from the
cylinder, through the directional valve to the hy-
draulic tank.
28
1600 SRM 1109
The flow amplifier has cushion valves to prevent
pressure peaks in the steering cylinder. Suction
valves are installed to prevent cavitation in the
steering cylinder.
Manual Steering Function
If the steering pump fails, or the engine looses
power, the lift truck can be steered manually. The
steering effort, however, will be increased.
The steering control unit has the characteristics of
a hand pump when the steering wheel is turned
(when there is no pressure input). The pressure de-
veloped by the steering control unit (when the
steering wheel is turned) operates all the valves in
the flow amplifier as if operating conditions were
normal. There is no amplification because only the
oil from the steering control unit flows to the steer-
ing cylinder.
DISASSEMBLE
Pressure Relief Valve
1. Remove the plug and washer. Use an 8 mm Al-
len wrench. See Figure 10.
2. Use a 10 mm Allen wrench to remove the relief
valve assembly.
3. Remove the washer with a magnetic rod.
4. Hold the relief valve cartridge with pliers and
remove the adjustment screw with a 5 mm Al-
len head wrench. See Figure 11.
1600 SRM 1109 Flow Amplifier Repair

1. CARTRIDGE BODY
2. PISTON
3. SPRING
4. ADJUSTMENT SCREW
1. STOP 4. O-RING
Figure 11. Pressure Relief Valve 2. SPRING 5. SPRING GUIDE
3. PLATE

Figure 12. End Cover at PP Port

End Cover at PP Port
1. Remove the capscrews, spring washers, and
end cover. See Figure 12.
2. Remove the stop and two springs.
3. Remove the single spring.
4. Remove the plate and six O-rings (4 large, 2
small). Remove the spring guide.
End Cover at LS Port
1. Remove the capscrews, spring washers, and
end cover. See Figure 13.
2. Remove the stop and two springs.
3. Remove the stop and single spring.
4. Remove the plate and four O-rings. Remove the
spring guide.

29
Flow Amplifier Repair 1600 SRM 1109

Priority Valve Spool

1. Remove the plug or throttle check valve (which-
ever is installed) from the priority valve spool.
Hold the end of the spool on the small diameter
with pliers. See Figure 15.

1. SPRINGS 2. PLATE
Figure 13. End Cover at LS Port
1. THROTTLE CHECK VALVE

Figure 15. Priority Valve Spool

Spools

Remove the three spools (directional valve, pres-

sure control/amplifier valve, and priority valve)
from the housing. These spools will slide easily
from the housing.
Directional Valve Spool
Remove the orifice from the directional valve spool
with a 4 mm Allen wrench. See Figure 14. Hold the
spool through a hole with a mandrel.
2. Remove the two spring rings from the grooves
with a small screwdriver and carefully guide
the rings back on the spool. Do not damage the
spring rings.
Pressure Control/Amplifier Valve Spool
1. Use a finger and press out the first pin. Remove
the plug and spring. See Figure 16.
2. Remove the second pin, then remove the inner
spool. Make a note of how the inner spool is in-
stalled. The square end on the inner spool must
be installed in the same direction. If the inner
spool is rotated 180° and then installed, the
flow amplifier will not operate correctly.

3. Remove the inner spool (check valve) from the

other end of the spool. Use a hexagon socket for
a 17 mm external hexagon and a mandrel
through a pin hole on the surface that is not
machined. Do not damage the spool surface.

4. Remove the orifice from the plug with a 4 mm

1. SPOOL 2. ORIFICE Allen head wrench and a mandrel.

Figure 14. Directional Valve Spool

30
1600 SRM 1109 Flow Amplifier Repair

Legend for Figure 16

A. STEP 1 C. STEP 3
B. STEP 2 D. STEP 4
1. ORIFICE 5. INNER SPOOL
2. PLUG 6. SECOND PIN
3. FIRST PIN 7. SPOOL
4. SPRING

Figure 16. Pressure Control/Amplifier Valve Spool

31
Flow Amplifier Repair 1600 SRM 1109

Check Valve

Put the check valve in a 17 mm socket wrench. See

Figure 17. Use an Allen head wrench and remove
the plug from the check valve. Remove the spring
and ball.

1. PLUG 3. BALL
2. SPRING 4. O-RING

Figure 17. Check Valve

Cushion/Suction Valves

Remove the cushion/suction valves with a flat tip 1. LOCK NUT

2. PILOT VALVE
screwdriver. See Figure 18. Put an Allen head 3. PILOT VALVE CARTRIDGE
wrench under the screwdriver so it is a fulcrum for 4. DISC
removal. 5. SPOOL
6. SPRING
1. Remove the lock nut from inside the valve 7. VALVE HOUSING
8. PISTON
housing. Use a socket for a 13 mm external 9. ADJUSTMENT SCREW
hexagon and a mandrel through a hole in the 10. O-RING
pilot valve cartridge.
Figure 18. Cushion/Suction Valve
NOTE: When assembling the cushion/suction
valve, hold the valve with a 13 mm ring spanner.
CLEAN
2. Remove the disc and spring from the valve
housing. Remove the housing from the pilot
valve. WARNING
Cleaning solvents can be flammable and toxic and
3. Loosen the pilot valve from the cartridge with a can cause skin irritation. When using cleaning
19 mm socket wrench. Use a mandrel to hold solvents, always follow the solvent manufactur-
the cartridge. Remove the pilot valve, spring, er's recommended safety precautions.
and spool from the cartridge.

4. Remove the adjustment screw, spring, and pis- Clean all the parts in solvent. Dry the parts with
ton from the pilot valve. compressed air. Do not dry the parts with a cloth.
Verify all surfaces are free of scratches and sharp
edges.

32
1600 SRM 1109 Troubleshooting

ASSEMBLE 2. Assemble the flow amplifier assembly using the

reverse of the procedure as described in Disas-
1. Use new seals, O-rings, and neutral position semble. See Figure 10, Figure 11, Figure 12,
springs during assembly. Lubricate all parts Figure 13, Figure 14, Figure 15, Figure 16, Fig-
with clean hydraulic oil. ure 17, and Figure 18.

Troubleshooting

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

No action when steering wheel is No oil or not enough oil in hy- Fill tank to correct level.
turned. draulic tank.

Lines are loose at control unit or Tighten fittings.

manifold block.

Sleeve and spool in control unit Repair steering control unit.

will not move.

Steering cylinder leaks. Repair steering cylinder.

Priority valve sticks. Clean priority valve.

Spacer for center pin is not in- Assemble steering control unit
stalled. correctly.

Lift truck steers slowly. Steering Oil level is low. There is no oil in Fill tank to correct level.
wheel is hard to turn. tank.

Lines to control unit are dam- Repair oil lines.

aged.

Sleeve and spool in control unit Repair steering control unit.

are worn.

Parts of metering section are Repair steering control unit.

worn.

Check valve in control unit does Clean or repair steering control

not open. unit.

Check valve or relief valve in Clean or replace manifold block.

manifold block is damaged or is
not adjusted correctly.

Priority valve is not operating Clean or repair priority valve.

correctly.

Steering relief pressure is too Adjust relief pressure.

low.

33
Troubleshooting 1600 SRM 1109

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

Engine idle speed is too low. Adjust idle speed to specifica-

tions.

Steering wheel turns tires in Lines at control unit are not cor- Connect lines correctly.
wrong direction. rectly connected.

Tires continue to turn after steer- Neutral position springs are bro- Repair steering control unit.
ing wheel stops. ken.

Sleeve or spool has damage. Repair steering control unit.

Steering wheel kicks back in both Center shaft is not correctly Assemble steering control unit
directions. aligned with metering section. correctly.

34
 TECHNICAL PUBLICATIONS

1600 SRM 1109 7/14 (1/12)(7/11)(7/07)(1/07)(7/06)