STEERING SYSTEM

H16.00-18.00XM/XMS-12
(H400-450HD/HDS) [A236];
H16.00-22.00XM-12EC
(H400-500HD/HDS-EC) [B214]

PART NO. 1638476 1600 SRM 1272

 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 ............................................................................................................................................................... 1
Description ......................................................................................................................................................... 1
Steering Wheel and Column Assembly Repair ................................................................................................ 3
General ........................................................................................................................................................... 3
Steering Wheel and Horn.............................................................................................................................. 3
Remove....................................................................................................................................................... 3
Install ......................................................................................................................................................... 3
Steering Column ................................................................................................................................................ 5
Remove ........................................................................................................................................................... 5
Install ............................................................................................................................................................. 5
Steering Control Unit Repair ............................................................................................................................ 6
General ........................................................................................................................................................... 6
Description ..................................................................................................................................................... 6
Operation ....................................................................................................................................................... 6
Remove ........................................................................................................................................................... 8
Disassemble ................................................................................................................................................... 9
Clean .............................................................................................................................................................. 12
Assemble ........................................................................................................................................................ 12
Install ............................................................................................................................................................. 17
Steering System Air Removal ........................................................................................................................... 17
Troubleshooting.................................................................................................................................................. 18

This section is for the following models:

H16.00-18.00XM/XMS-12 (H400-450HD/HDS) [A236];

H16.00-22.00XM-12EC (H400-500HD/HDS-EC) [B214]

©2006 HYSTER COMPANY i

"THE
QUALITY
KEEPERS"

HYSTER
APPROVED
PARTS
1600 SRM 1272 Description

General
This section has the description and repair proce- unit. Repair information for the parts of the steering
dures for the parts of the steering system. Descrip- axle is in the section Steering Axle 1600 SRM 658.
tion and repair information is given for the steer- Repair information for the steering hydraulic pump
ing wheel, column assembly, and the steering control is in the section Hydraulic System 1900 SRM 1275.

Description
These lift trucks use a hydraulic steering system.
See Figure 1, Diagrams 8000 SRM 1281 for B214
trucks and Diagrams 8000 SRM 1312 for A236
trucks for hydraulic schematic. The hydraulic pump
is driven by the transmission and supplies oil to the
priority valve. The priority valve is operated by the
sense line in such a way that, when the steering
wheel is not being turned, the hydraulic supply goes
to the main valve. When the steering wheel is being
turned, part of the hydraulic flow is modulated to
the steering control unit for steering.
There is a pressure relief valve to protect the steering
system against over pressure. Pressure setting and
check port P1 are shown in the hydraulic schematic.
See Figure 1.
When the engine is not running, a check valve closes
and permits the steering control unit to operate as
a hydraulic motor. The lift truck is difficult to steer
when the steering pump is not operating, but steer-
ing is possible.

1
Description 1600 SRM 1272

1. HYDRAULIC PUMP 5. STEERING PUMP

2. PRIORITY VALVE 6. STEERING CYLINDER
3. COMBINATION PUMP 7. HYDRAULIC TANK
4. CHECKPORT P1

Figure 1. Steering Hydraulic Schematic

2
1600 SRM 1272 Steering Wheel and Column Assembly Repair

Steering Wheel and Column Assembly Repair

GENERAL 1. Disconnect the battery, using the switch.

The steering column, located in the cab, is mounted
to a support bracket and the floor of the cab. See Fig-
ure 2. The steering column is fitted to the steering
control unit through the cab floor. The steering wheel
is held on the splines of the steering column with a
large nut. The steering control unit has splines that
engage with the lower end of the steering column.
The steering control unit is fastened to the under-
side of the cab floor with four bolts. Information on
the gauges in the steering housing are in the section
Instrument Panel Indicators and Senders 2200
SRM 1278.
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.
2. Remove the horn button from the steering wheel.
See Figure 2.
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 2. 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.

Remove

WARNING
To prevent electrical arcs when removing the
cover, disconnect the negative battery cable.

3
Steering Wheel and Column Assembly Repair 1600 SRM 1272

Figure 2. Steering Wheel and Steering Column Assembly

4
1600 SRM 1272 Steering Column

Legend for Figure 2

1. SCREW 10. UPPER STEERING COLUMN 14. RH STEERING COVER
2. WASHER COVER COLUMN
3. SCREW 11. LH STEERING COVER 15. STEERING COLUMN
4. WASHER COLUMN ASSEMBLY
5. SOCKET 12. RH STEERING COVER 16. BOOT
6. HORN BUTTON COLUMN 17. LIGHT
7. SPINNER KNOB 13. LH STEERING COVER 18. STEERING CONTROL UNIT
8. STEERING WHEEL COLUMN (UNDER CAB FLOOR)
9. HARNESS

Steering Column
REMOVE 6. Remove the two hex bolts holding the steering
column to the bracket. See Figure 4.
1. Disconnect the battery, using the switch.
7. Remove steering column. Push the grommet out
2. Disconnect the steering column connector, posi- of the hole and slide the connector through the
tioned under the cab. See Figure 3. hole.

1. STEERING COLUMN TO BRACKET BOLTS

2. STEERING COLUMN TO FLOOR PLATE BOLTS

Figure 4. Steering Column

1. STEERING COLUMN CONNECTOR INSTALL

2. STEERING COLUMN BOLTS
3. STEERING PUMP BOLTS 1. Slide the connector through the hole in the cab
floor and push the grommet into the hole.
Figure 3. Steering Pump
2. Connect the steering column to the bracket with
3. Remove the four hex bolts that fasten the steer- the two hex bolts. See Figure 4.
ing control unit under the cab. Carefully remove
the steering pump. 3. Mount the steering column to the cab floor with
the two cab mounting bolts. See Figure 4.
4. Remove the screws that fasten the left and right
hand steering column covers. See Figure 2. 4. Install the left-hand and right-hand steering col-
umn covers with screws. See Figure 2.
5. Remove the two cab mounting bolts holding the
steering column to the cab floor. See Figure 4.

5
Steering Control Unit Repair 1600 SRM 1272

5. Carefully mount the steering control unit with 6. Connect the steering column connector, posi-
four hex bolts to allow a non-forced coupling be- tioned under the cab. See Figure 3.
tween steering control unit and steering column.
7. Connect the battery, using the switch.

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 5. The
steering control unit is mounted on the underside of
the cab floor. The steering control unit has a shaft as-
sembly, control section, and a metering section. 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 5): (1)
the spool for the control section, (2) the sleeve for
the control section, and (3) the rotor 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 steering cylinder.
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 position, the
holes in the sleeve and the spool are aligned. Oil com-
ing 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 one side of the steering cylinder. Oil
from the other side of the steering cylinder flows back
to 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 steering cylinder to keep the tires in position.
Oil from the pump flows through the steering con-
trol unit to the tank or other parts of the system. To
return the 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 direction.

Legend for Figure 5

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

6
1600 SRM 1272 Steering Control Unit Repair

Figure 5. Steering Control Unit

7
Steering Control Unit Repair
REMOVE
WARNING
To prevent electrical arcs when removing the
cover of the steering column, place the discon-
nect switch to the OFF position.
WARNING
Move all control levers back and forth a mini-
mum of 20 times to remove all hydraulic pres-
sure from pilot system.
1. Close shutoff valves on the bottom of the hy-
draulic tank.
8
1600 SRM 1272
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 3.
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 remove
the steering control unit from the end of the
steering column. See Figure 2.
1600 SRM 1272 Steering Control Unit Repair

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
to ensure that the components will be re-assembled
in the same position. Remove the manifold block.

NOTE: Manifold removed.

1. STEERING CONTROL UNIT
2. VISE

STEP 2.
Remove the cover on the bottom of the steering con-
trol unit.

1. O-RING
2. COVER
3. CAPSCREW

9
Steering Control Unit Repair 1600 SRM 1272

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. Re-
move the center shaft.

1. O-RING
2. CENTER SHAFT
3. PORT PLATE
4. STATOR
5. ROTOR
6. SPACER

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

1. SCREW

10
1600 SRM 1272 Steering Control Unit Repair

STEP 5.
Remove the spool and sleeve assembly. Remove the thrust bearing assembly from the spool. Push the center
pin from the sleeve. Carefully remove the spool from the sleeve. (Rotate the spool slowly during removal.)
Remove the ring from the sleeve. Remove the neutral position springs from the spool.

1. SPOOL AND SLEEVE ASSEMBLY 5. NEUTRAL POSITION SPRINGS

2. RING 6. CENTER PIN
3. SPOOL 7. THRUST BEARING
4. SLEEVE 8. THRUST WASHER

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

11
Steering Control Unit Repair 1600 SRM 1272

CLEAN Clean all the parts in solvent. Dry the parts with
compressed air. Do not dry the parts with a cloth.
WARNING Make sure all surfaces are free of scratches and sharp
edges.
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.

ASSEMBLE
Use new seals, O-rings, and neutral position springs during assembly. Lubricate all parts with clean hydraulic
oil. Assemble the components in the same position by using the identification mark.

STEP 1.
Install dust seal in housing. Install relief valve as-
sembly.

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

12
1600 SRM 1272 Steering Control Unit Repair

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.

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 hous-
ing 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 remove the washer,
tube, and spool from the housing.

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

13
Steering Control Unit Repair 1600 SRM 1272

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. Carefully 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

STEP 6.
Install the check ball and sleeve. Make sure the
sleeve is even with or below the surface of the hous-
ing. 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

14
1600 SRM 1272 Steering Control Unit Repair

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.

1. CENTER SHAFT 4. STATOR

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

15
Steering Control Unit Repair 1600 SRM 1272

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.

1. CHECK BALL 4. O-RING

2. THREADED BUSHING 5. COVER
3. CAPSCREW 6. SPACER

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

16
1600 SRM 1272 Steering System Air Removal

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

STEP 10.
See Figure 2. Install steering column and steering control unit on brackets. Connect hydraulic lines at manifold
block. Start engine and operate steering 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 column.
WARNING
Do not try to locate hydraulic leaks by putting
hands on pressurized hydraulic components.
Hydraulic oil can be injected into the body by
pressure.
CAUTION
Never start the engine with closed shutoff
valves. Open the shutoff valves before starting
the engine to prevent damage to hydraulic
components.

2. Remove caps and connect the hydraulic lines to
the steering control unit according to the tags
made during removal.
3. Connect the steering column connector, posi-
tioned under the cab. See Figure 3.
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.

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.

17
Troubleshooting 1600 SRM 1272

Troubleshooting

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

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

Lines are loose at control unit or Tighten fittings.

manifold block.

Sleeve and spool in control unit will Repair steering control unit.
not move.

Steering cylinder leaks. Repair steering cylinder.

Priority valve sticks. Clean priority valve.

Spacer for center pin is not installed. Assemble steering control unit cor-
rectly.

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

Lines to control unit are damaged. Repair oil lines.

Sleeve and spool in control unit are Repair steering control unit.
worn.

Parts of metering section are worn. Repair steering control unit.

Check valve in control unit does not Clean or repair steering control unit.
open.

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

ifold block is damaged or is not ad-
justed correctly.

Priority valve is not operating cor- Clean or repair priority valve.

rectly.

Steering relief pressure is too low. Adjust relief pressure.

Engine idle speed is too low. Adjust idle speed to specifications.

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

18
1600 SRM 1272 Troubleshooting

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

Tires continue to turn after Neutral position springs are broken. Repair steering control unit.
steering wheel stops.

Sleeve or spool has damage. Repair steering control unit.

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

19
 NOTES

____________________________________________________________

____________________________________________________________

____________________________________________________________

____________________________________________________________

____________________________________________________________

____________________________________________________________

____________________________________________________________

____________________________________________________________

____________________________________________________________

____________________________________________________________

____________________________________________________________

____________________________________________________________

____________________________________________________________

____________________________________________________________

____________________________________________________________

____________________________________________________________

____________________________________________________________

____________________________________________________________

____________________________________________________________

____________________________________________________________

20
 TECHNICAL PUBLICATIONS

1600 SRM 1272 12/06 (5/06) Printed in United Kingdom