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1 INTRODUCTION GENERAL The A1.00–1.50XL (A20–30XL) series of lift trucks have a power steering system. This section describes the disassembly and assembly of the power steering system for repairs. There is a description for each part of the steering system at the beginning of each repair section. The steering system rotates the master drive unit (MDU) to steer the lift truck. Additional information for the components of the steer- ing system is found in the following sections: MASTER DRIVE UNIT, 630 SRM 363. THE STEERING CONTROL UNIT, 1600 SRM 54. NOTE: A modification has been made in the manifold assembly of the steering control unit used in this lift truck that is different than the unit described in 1600 SRM 54. The four hydraulic ports are in the bottom of the steering control unit. These ports connect to the four hydraulic hoses for the steering system. The four hy- draulic ports on the side of the steering control unit are not used. DESCRIPTION (See FIGURE 1.) The power steering system is a hydraulic system that does not have a mechanical link between the steering wheel and the hydraulic motor. The control of the steer- ing is through a hydraulic circuit. An electric motor for the steering pump is energized when the key switch is in the “ON” position and the seat switch is closed. When the electric motor operates the steering pump, hydraulic oil flows through the power steering system. The hy- draulic oil flows from the gear pump through the steer- ing control unit and returns to the hydraulic tank when the steering wheel is not being rotated. The steering control unit is a rotary valve operated by the steering wheel. When the steering wheel is not moved, this rotary valve has a minimum restriction to oil flow. During the steering operation, the steering con- trol unit sends and controls the oil flow to the hydraulic motor. The motion and metering function of the steering control unit controls the rotation of the hydraulic motor. The hydraulic motor with a sprocket on the output shaft, rotates the MDU by a steering chain. Hydraulic oil re- turns from the hydraulic motor to the steering control unit and then returns to the hydraulic tank. If the steering pump does not operate, a check valve closes and permits the steering control unit to continue control of the steer- ing system. The lift truck is difficult to steer when the steering pump is not operating, but the steering control unit can operate the hydraulic motor and make steering possible. FIGURE 1. POWER STEERING COMPONENTS 1. STEERING WHEEL 2. STEERING CONTROL UNIT 3. POWER STEERING MOTOR 4. POWER STEERING PUMP 5. HYDRAULIC TANK 6. FILTER 7. HYDRAULIC CONTROL VALVE 8. HYDRAULIC STEERING MOTOR 9. STEERING CHAIN 10. MASTER DRIVE UNIT 1 2 3 4 5 6 7 8 9 10 11960

INTRODUCTION A203 (A1...INTRODUCTION GENERAL The A1.00–1.50XL (A20–30XL) series of lift trucks have a power steering system. This section describes the disassembly and assembly

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Page 1: INTRODUCTION A203 (A1...INTRODUCTION GENERAL The A1.00–1.50XL (A20–30XL) series of lift trucks have a power steering system. This section describes the disassembly and assembly

INTRODUCTION

GENERAL

The A1.00–1.50XL (A20–30XL) series of lift truckshave a power steering system. This section describes thedisassembly and assembly of the power steering systemfor repairs. There is a description for each part of thesteering system at the beginning of each repair section.The steering system rotates the master drive unit(MDU) to steer the lift truck.

Additional information for the components of the steer-ing system is found in the following sections:

MASTER DRIVE UNIT, 630 SRM 363.

THE STEERING CONTROL UNIT, 1600 SRM 54.

NOTE: A modification has been made in the manifoldassembly of the steering control unit used in this lifttruck that is different than the unit described in 1600SRM 54. The four hydraulic ports are in the bottom ofthe steering control unit. These ports connect to the fourhydraulic hoses for the steering system. The four hy-draulic ports on the side of the steering control unit arenot used.

DESCRIPTION (See FIGURE 1.)

The power steering system is a hydraulic system thatdoes not have a mechanical link between the steering

wheel and the hydraulic motor. The control of the steer-ing is through a hydraulic circuit. An electric motor forthe steering pump is energized when the key switch isin the “ON” position and the seat switch is closed. Whenthe electric motor operates the steering pump, hydraulicoil flows through the power steering system. The hy-draulic oil flows from the gear pump through the steer-ing control unit and returns to the hydraulic tank whenthe steering wheel is not being rotated.

The steering control unit is a rotary valve operated bythe steering wheel. When the steering wheel is notmoved, this rotary valve has a minimum restriction tooil flow. During the steering operation, the steering con-trol unit sends and controls the oil flow to the hydraulicmotor. The motion and metering function of the steeringcontrol unit controls the rotation of the hydraulic motor.The hydraulic motor with a sprocket on the output shaft,rotates the MDU by a steering chain. Hydraulic oil re-turns from the hydraulic motor to the steering controlunit and then returns to the hydraulic tank. If the steeringpump does not operate, a check valve closes and permitsthe steering control unit to continue control of the steer-ing system. The lift truck is difficult to steer when thesteering pump is not operating, but the steering controlunit can operate the hydraulic motor and make steeringpossible.

FIGURE 1. POWER STEERING COMPONENTS

1. STEERING WHEEL2. STEERING CONTROL UNIT3. POWER STEERING MOTOR4. POWER STEERING PUMP5. HYDRAULIC TANK

6. FILTER7. HYDRAULIC CONTROL VALVE8. HYDRAULIC STEERING MOTOR9. STEERING CHAIN

10. MASTER DRIVE UNIT

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Page 2: INTRODUCTION A203 (A1...INTRODUCTION GENERAL The A1.00–1.50XL (A20–30XL) series of lift trucks have a power steering system. This section describes the disassembly and assembly

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STEERING WHEEL AND COLUMNASSEMBLY (See FIGURE 3.)

The steering wheel attaches to the steering shaft withsplines. A large nut holds the steering wheel onto thesteering shaft. The horn button is the cover for the centerof the steering wheel. The lower end of the steering shaft

has splines that engage the steering control unit. A pushrod joins the horn button and the horn switch.

The steering column can be raised to the “UP” positionso that additional clearance is available for removing thebattery. The steering column can also be adjusted for theoperator. A latch holds the steering column in position.A cover on the steering column gives access to the steer-ing control unit, the key switch, and the horn switch.

FIGURE 2. STEERING SYSTEM, HYDRAULIC SCHEMATIC

1. HYDRAULIC STEERING MOTOR2. STEERING CONTROL UNIT3. STEERING WHEEL4. POWER STEERING PUMP5. HYDRAULIC TANK6. FILTER7. HYDRAULIC CONTROL VALVE

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Page 3: INTRODUCTION A203 (A1...INTRODUCTION GENERAL The A1.00–1.50XL (A20–30XL) series of lift trucks have a power steering system. This section describes the disassembly and assembly

FIGURE 3. STEERING WHEEL AND STEERING COLUMN ASSEMBLY (1 OF 2)

10. PLASTIC WASHER11. SPRING12. LATCH13. LOCK RING14. ADJUSTER SPOOL NUT15. STEERING WHEEL NUT16 EXTERNAL SNAP RING17. INTERNAL SNAP RING18. PUSH ROD

11959

19. PIN20. HORN SWITCH21. BRACKET22. PIN23. COTTER PIN24. KEY SWITCH25. CLAMP26. BRACKET27. SNAP RING28. WIRE HARNESS29. SCREW

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1. STEERING COLUMN2. STEERING CONTROL

UNIT3. BRACKET4. STEERING WHEEL5. STEERING SHAFT6. HORN COVER7. BASE PLATE8. BEARING9. PLASTIC TUBE

TRW

INPUT

OUTPUT

RIGHT TURN

LEFT TURN

DANFOSS

INPUTOUTPUT

RIGHT TURN

LEFT TURN

Page 4: INTRODUCTION A203 (A1...INTRODUCTION GENERAL The A1.00–1.50XL (A20–30XL) series of lift trucks have a power steering system. This section describes the disassembly and assembly

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Page 5: INTRODUCTION A203 (A1...INTRODUCTION GENERAL The A1.00–1.50XL (A20–30XL) series of lift trucks have a power steering system. This section describes the disassembly and assembly

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10. PLASTIC WASHER11. SPRING12. LATCH13. LOCK RING14. ADJUSTER SPOOL NUT15. STEERING WHEEL NUT16 EXTERNAL SNAP RING17. INTERNAL SNAP RING18. PUSH ROD

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19. PIN20. HORN SWITCH21. BRACKET22. PIN23. COTTER PIN24. KEY SWITCH25. CLAMP26. BRACKET27. SNAP RING28. WIRE HARNESS29. SCREW

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1011

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1. STEERING COLUMN2. STEERING CONTROL

UNIT3. BRACKET4. STEERING WHEEL5. STEERING SHAFT6. HORN COVER7. BASE PLATE8. BEARING9. PLASTIC TUBE

PETRI STEERING WHEEL

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9

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1514629

FGURE 3. STEERING WHEEL AND STEERING COLUMN ASSEMBLY (2 OF 2)

Page 6: INTRODUCTION A203 (A1...INTRODUCTION GENERAL The A1.00–1.50XL (A20–30XL) series of lift trucks have a power steering system. This section describes the disassembly and assembly

REPAIR

REMOVAL, STEERING CONTROL UNIT(See FIGURE 3.)

1. Disconnect the battery. Raise the steering column tothe ”UP” position. Remove the access cover from thesteering column.

2. Remove the key switch from the housing of the steer-ing column. Make an identification of the electricalwires and disconnect them from the key switch. Preventdamage to the wire harness.

3. Remove the capscrew which fastens the bracket forthe horn switch to the housing of the steering column.Move the horn switch and bracket away from the steer-ing column.

4. Remove the horn cover, snap ring and base plate. Liftthe push rod and adjuster spool out of the top of thesteering shaft. Remove the large hex nut and pull thesteering wheel from the shaft.

5. Make an identification of the hydraulic hoses at thesteering control unit so that the hydraulic hoses can becorrectly connected during assembly. The hydraulichoses can not be disconnected at the steering controlunit unless they are first disconnected at their oppositeends. The only disconnect fittings on the hydraulichoses are at the hydraulic motor, steering pump, andmain control valve. Disconnect the hydraulic hoses atthe hydraulic motor (2), steering pump (1), and the maincontrol valve assembly (1). Remove all mountingclamps so that the hoses will turn freely and not becometwisted. Disconnect the hydraulic hoses at the bottom ofthe steering control unit.

6. Remove the capscrews, lock washers, and lock platesthat fasten the steering column to the pivots on the lifttruck. Remove the steering column from the lift truck.

7. Use the following procedure to remove the steeringshaft from the steering column:

a. Move the plastic tube and washer toward thesteering control unit and compress the spring forthe horn switch. Then remove the pin from thesteering shaft.

b. Remove the outer snap ring that holds the bearingin the steering column. Pull the steering shaft andbearing from the steering column. Use a smallprybar at the bottom of the steering shaft near the

steering control unit. The return spring, the wash-er and tube are removed as the steering shaft is re-moved through the top of the steering housing.

c. Remove the two capscrews that hold the steeringcontrol unit and the bracket to the steering col-umn. Remove the four capscrews that fasten thesteering control unit to the bracket.

INSTALLATION, STEERING CONTROLUNIT (See FIGURE 3.)

1. Fasten the two halves of the mount bracket to thesteering control unit. Install the steering control unit andthe bracket into the steering column and fasten with twocapscrews through the bracket. Fasten the horn switchand the switch bracket to the steering control unit withone of the two capscrews.

2. Install the bearing on the steering shaft. The seal ofthe bearing must be toward the steering wheel. Installthe snap ring onto the steering shaft.

3. Put the steering shaft through the opening for thebearing in the steering housing. Install the pin that holdsthe plastic tube and flange for the horn switch. Install theplastic tube, the plastic flange and the spring onto thesteering shaft. Push the steering shaft into the splines ofthe steering control unit. Install the snap ring that holdsthe bearing in the steering housing.

4. Install the steering column on the cowl mounts. Lu-bricate the pivots with multi–purpose grease and installthe capscrews into the housing.

5. Install the steering wheel with one spoke towards themast. Install the large hex nut onto the steering shaft.Install the push rod and adjuster spool into the steeringshaft. Install the base plate, the lock ring and the horncover.

6. Install the key switch and connect the electrical wires.

7. Connect the hydraulic hoses to the steering controlunit. Make sure each hydraulic hose is connected to thecorrect port on the steering control unit.

8. Install the hydraulic hoses through the frame and con-nect them to the correct connections on the hydraulicsteering motor, the steering pump and the the main con-trol valve.

9. Connect the wires at the bottom of the steering col-umn. Attach the access cover onto the steering column.

Page 7: INTRODUCTION A203 (A1...INTRODUCTION GENERAL The A1.00–1.50XL (A20–30XL) series of lift trucks have a power steering system. This section describes the disassembly and assembly

6

POWER STEERING MOTOR AND PUMP

DESCRIPTION (See FIGURE 4. )

The power steering motor and pump are under the floorplate. Two straps hold the power steering motor andpump to mounts on the frame. The power steering motorand pump operate when the key switch is “ON” and theoperator is on the seat (seat switch closed).

REMOVAL AND DISASSEMBLY(See FIGURE 4. and FIGURE 5.)

NOTE: The power steering motor must be removedfrom the mounts on the frame when the brushes must bereplaced.

1. Disconnect the battery. Remove the floor plate. Makean identification of the power cables and disconnectthem from the power steering motor.

2. Disconnect the hydraulic hoses from the power steer-ing pump. Put plastic caps on the ends of the hoses tokeep dirt from entering the hose connectors.

3. Loosen the straps that hold the power steering motorto the mounts on the frame and remove the power steer-ing motor and pump.

�������

The power steering motor and pump assembly has aweight of approximately 11 kg (24.2 lbs). The powersteering motor has ceramic permanent magnets. Ifthe motor falls, the magnets can be damaged.

4. Check the brushes. See the sections, PERIODICMAINTENANCE, 8000 SRM 370 and DC MOTORREPAIR, 620 SRM 294 for additional information forinspection of the brushes and commutator.

5. If the motor must be disassembled for cleaning or re-pairs, remove the pump so that a new oil seal can beinstalled. Make match marks for alignment on the endplates and the motor housing. These marks are neces-sary to correctly assemble the motor.

FIGURE 4. POWER STEERING MOTORAND PUMP

1. POWER STEERING MOTOR2. FROM HYDRAULIC TANK3. POWER STEERING PUMP4. TO STEERING CONTROL UNIT

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ASSEMBLY AND INSTALLATION(See FIGURE 4. and FIGURE 5.)

1. When the end plate with the brush holder is installed,push the brushes into their holders so that the springpushes against the side of the brush. This arrangementwill permit easier installation of the brushes on the com-mutator.

2. Install the end plates to the motor housing and alignthe marks for assembly.

3. Install the brushes into their holders. Make sure thatthe brushes move freely in their holders. Make sure thespring pushes evenly on the brush.

4. Install a new seal ring onto the motor shaft. Install anew O–ring between the motor and the pump. The shaftseal ring and the O–ring must be in good condition orthe oil which lubricates the coupling can leak.

Page 8: INTRODUCTION A203 (A1...INTRODUCTION GENERAL The A1.00–1.50XL (A20–30XL) series of lift trucks have a power steering system. This section describes the disassembly and assembly

5. Install the drive coupling onto the motor shaft. Makesure that the drive coupling is correctly engaged with themotor shaft.

6. Install the pump onto the motor. Make sure the pumpshaft correctly engages the drive coupling.

7. Put the power steering motor and pump into positionon the frame mount before the strap is tightened. Tight-en the strap and install the power cables.

8. Connect the hydraulic hoses to the hydraulic pump.

FIGURE 5. POWER STEERING MOTOR, EARLY MODELS (1 OF 2)

18. END PLATE, COMMUTATOR19. HOUSING SCREWS, (4)20. FAN21. FAN COVER22. SCREWS, (4)23. SCREW, FAN COVER

1. COUPLING2. END PLATE, DRIVE3. SEAL RING4. RETAINING RING5. BEARING6. SCREW, HOUSING7. RETAINING RING8. MOTOR HOUSING9. ARMATURE

10. POWER TERMINAL

11. BRUSH12. BRUSH HOLDER13. PLATE NUT14. BRUSH PLATE15. COVER, COMMUTATOR16. BEARING17. DISK

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22. FAN23. COVER, FAN24. CAPSCREW25. WASHER26. NUT27. BAND28. HOUSING29. SNAP RING30. DRIVE END PLATE31. SEAL RING

1. SNAP RING2. BEARING3. SCREW/WASHER4. ARMATURE5. WASHER6. STUD7. NUT8. PLATE9. SCREW/WASHER

10. TERMINAL11. NUT

12. SCREW/WASHER13. NUT14. WASHER15. SCREW16. BRUSH17. HOLDER, BRUSH18. SPRING, BRUSH19. SPACER20. BEARING21. DISK

FIGURE 5. POWER STEERING MOTOR, LATE MODELS (2 OF 2)

Repairs, Power Steering Pump(See FIGURE 6.)

Seals that are worn or damaged are the most commoncause of pump repair. The pump bearings, gears andshafts also wear. Most service persons do not repair aworn pump. The cost of repairs can be greater than thecost of a new pump. The seals can be replaced in the hy-draulic pump. Replace a hydraulic pump that is worn ordamaged.

The power steering pump is a single section gear pumpthat is fastened to the power steering motor. The outlet(pressure port) of the pump is connected to the steering

control unit with a hydraulic hose. The inlet (suctionport) of the pump is connected to the hydraulic tank witha hydraulic hose. Bushings at each side of each gear arethe bearings for the gear shafts. The bushings also havepassages for the oil flow to the pump outlet and for lu-brication. Seals prevent leaks between sections of thepump housing. A coupling is connected between themotor shaft and the pump shaft. A relief valve in the out-let of the pump controls the pressure in the steering sys-tem.

When the pump is installed onto the motor, use a newO–ring between the pump and the motor housings.

Page 10: INTRODUCTION A203 (A1...INTRODUCTION GENERAL The A1.00–1.50XL (A20–30XL) series of lift trucks have a power steering system. This section describes the disassembly and assembly

FIGURE 6. POWER STEERING PUMP

1. DRIVE COUPLING2. O–RING3. END COVER, FLANGE4. DOWEL PIN5. SEALING RING, (2)6. O–RING, SPECIAL (2)7. BACK–UP RING8. BEARING BLOCK9. DRIVE GEARS

10. DRIVEN GEAR11. PUMP BODY12. END COVER13. RELIEF VALVE14. CAPSCREW, SHORT (2)15. THROUGH BOLT (2)

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SEAL REPLACEMENT (See FIGURE 6.)

NOTE: If the pump is held in a vise for disassembly, donot cause distortion of the pump body. Use a vise withsoft jaws or blocks of soft wood between the pump bodyand the jaws of the vise.

Make an identification of the location of the parts andseals during disassembly. Similar parts can cause errorsduring assembly. Identification of the parts can be diffi-cult if the parts are mixed.

1. Remove the four capscrews that hold the pump to-gether. Two of the capscrews are through bolts and fas-ten to the end plate of the motor.

2. Carefully remove the end covers and remove the sealsand O–rings.

3. Carefully press the gear bearings and gear assembliesfrom the pump body.

4. Inspect the gear assemblies, the gear bearings and thepump body for wear or damage.

NOTE: Some pump bodies will show marks caused bygears, as the gears rotate against the pump body. Thesmall clearances between the parts cause the gears toleave the marks. These marks do not always indicatethat the pump is worn or damaged. If the pump will notsupply the volume and pressure shown in the specifica-tions, then the pump must be repaired or replaced.

5. Clean the internal parts of the pump. Use hydraulicoil to lubricate the parts as they are installed into thepump. Install new seals into the bushings.

6. Install the gears and bushings into the pump body.

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7. Install new O–rings, seal rings and dowel pin into theend cover of the pump with the relief valve. For the ar-rangement of the components, See FIGURE 6.

8. Install new O–rings, seal rings and dowel pin into theother end cover with the flange. Install this end coveronto the pump.

9. Check that all of the parts are in the correct position,and install the four capscrews. Tighten the capscrews to34 to 40 N.m (25 to 30 lbf ft.).

10. Install a new O–ring onto the flange which will sealagainst the end plate of the motor.

HYDRAULIC STEERING MOTOR

DESCRIPTION (See FIGURE 7.)

The hydraulic steering motor controls the steering func-tion of the master drive unit (MDU) using a steeringchain. The hydraulic motor rotates the MDU for steer-ing the lift truck.

The hydraulic steering motor uses a gear wheel set in-side of the motor to change hydraulic energy into me-chanical energy. The gear wheel set has a fixed gear rimand a gear wheel. The center of the gear wheel movesaround the center of the gear rim and at the same timethe gear wheel rotates. The directions of these two mo-tions are opposite. See FIGURE 7. The center of thegear wheel moves around the center of the gear rim sixtimes per revolution of the gear wheel.

The part of the output shaft which is in the motor hous-ing has two purposes: an output shaft and a distributorvalve. The distributor valve rotates with the gear wheel.This distributor valve sends oil to the pressure chambersof the gear wheel set and away from the return cham-bers.

REPAIRS, HYDRAULIC STEERINGMOTOR

Removal

NOTE: Most service personnel remove the counter-weight from the lift truck for this procedure. The hy-draulic steering motor can be removed without remov-ing the counterweight. Removal of the counterweightgives better access to the hydraulic steering motor,steering chain, and the MDU. See the section, THEFRAME, 100 SRM 362 for the procedure to removethe counterweight.

1. Use the hex nut adjustment to loosen the steeringchain on the MDU.

2. Identify the two hydraulic hoses to the hydraulic mo-tor and disconnect them. Put caps over the ends of thehydraulic hose connectors.

3. Remove the two capscrews that fasten the hydraulicmotor to the lift truck frame.

FIGURE 7. HYDRAULIC STEERING MOTOR, OPERATION

1. OUTPUT SHAFT2. DISTRIBUTOR VALVE (PART OF OUTPUT SHAFT3. MOTOR HOUSING4. CENTER SHAFT5. GEAR WHEEL SET6. FIXED GEAR RIM7. GEAR WHEEL

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Page 12: INTRODUCTION A203 (A1...INTRODUCTION GENERAL The A1.00–1.50XL (A20–30XL) series of lift trucks have a power steering system. This section describes the disassembly and assembly

��

Disassembly (See FIGURE 8.)

1. Put the motor in a vise or other holding tool. If a viseis used, do not cause distortion of the motor housing.Use a vise with soft jaws.

2. Remove the capscrews from the end cover. Slide theend cover from the motor.

3. Lift the gear set and remove the O–rings. Remove thedistributor plate.

4. Remove the center shaft. Remove the output shaftfrom the housing.

5. From the other end of the housing, remove the screwsfrom the flange cover. Remove the flange cover. Re-move the O–ring and bearing race from the flange cover.

6. Use a screwdriver to loosen and remove the shaft sealfrom the flange cover. Remove the dust seal from theflange cover.

7. Remove the needle bearings.

Cleaning And Inspection

Clean all parts with a mineral oil cleaning solvent.

Check all parts and replace the parts that are worn ordamaged.

Lubricate all parts with hydraulic oil during assembly.

Assembly (See FIGURE 8.)

1. Put the shaft seal in the flange cover. Use a plastichammer and carefully install the shaft seal.

2. Put the dust seal ring in the outer face of the flangecover. Put a steel block over the dust seal ring to helpinstallation. Use a hammer against the steel block.

3. Put the O–ring and bearing race into the flange cover.Use a thin coat of grease on the O–ring to hold it in posi-tion.

4. Install the flange cover on the motor housing. Put thespring washers onto the six screws and fasten the flangecover onto the motor housing. Tighten the screws to 5to 8 N.m (45 to 70 lbf in).

5. Turn the motor over and install the output shaft intothe motor housing.

6. Put the motor in a horizontal position and install thewoodruff key into the end of the output shaft. Put tapeover the woodruff key and shaft to hold the woodruffkey in position until installation.

7. Install the cap into the bore of the output shaft. Put thehollow side of the cap toward the bottom of the bore.

8. Install the thrust bearing in the motor housing. Installthe O–ring and distributor plate so that the screw holesalign with the holes in the motor housing. Use a thin lay-er of grease on the O–ring.

NOTE: Install the thrust bearing so that the dowel in thethrust bearing is toward the distributor plate.

9. Slide the center shaft into the motor housing and holdthe end of the shaft. Make a tool of thin metal to fit underthe splines of the center shaft and hold the shaft in posi-tion. See FIGURE 9.

10. Install the gear wheel set over the end of the centershaft. Use a thin coat of grease to hold the O–ring inposition. Align the screw holes with the holes in thehousing and distributor plate. Adjust the gear wheel (ro-tor) so that a line between the tops of two opposite teethis parallel with the holes in the mounting flange of themotor (correct direction of rotation). See FIGURE 9.

11. Install the end cover over the gear wheel set andinstall the six capscrews with new washers. Remove theholding tool from the center shaft. Tighten the caps-crews in the end cover to 30 to 36 N.m (22 to 25 lbf ft).

12. Insert plastic plugs into the inlet and outlet ports toprevent dirt from entering the motor before installation.

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FIGURE 8. HYDRAULIC STEERING MOTOR

1. CAPSCREW2. SPRING WASHER3. DUST SEAL RING4. FLANGE COVER5. SHAFT SEAL6. O–RING7. BEARING RACE8. NEEDLE BEARING9. WOODRUFF KEY

10. OUTPUT SHAFT AND MOTOR HOUSING ( MATCHED SET)11. THRUST BEARING12. CAP13. CENTER SHAFT14. SPACER15. O–RING16. DISTRIBUTOR PLATE17. GEAR WHEEL SET18. END COVER19. WASHER20. CAPSCREW

21. NAMEPLATE22. SCREW23. CHECK VALVE24. O–RING25. WASHER26. DRAIN PLUG27. CASTLE NUT28. WASHER29. PLASTIC PLUGS

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��

FIGURE 9. ASSEMBLY OF GEAR WHEEL SET

1 HOLDING TOOL2. ROTOR3. GEAR WHEEL SET4. CENTER SHAFT5. DISTRIBUTOR PLATE6. HOLE IN MOUNTING FLANGE OF MOTOR

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Installation, Hydraulic Steering Motor

1. Put the hydraulic motor into position in the lift truckframe and install the two capscrews.

2. Connect the two hydraulic hoses to their correct portson the hydraulic motor.

3. Install the steering chain. See the Checks And Adjust-ments for making adjustments to the steering chain.

4. Install the counterweight.

CHECKS AND ADJUSTMENTS

POWER STEERING ADJUSTMENTS

Air In The Steering System

If there is air in the hydraulic lines of the steering sys-tem, the operation will not be constant. Rotate the steer-ing wheel from stop to stop several times to remove theair from the steering system. If the air can not be re-moved from the steering system, check for leaks at thepower steering pump. Check for a loose fitting or a leakin the intake manifold. If the O–ring or the oil seal be-tween the power steering motor and pump has a defect,air will enter the hydraulic system.

Steering Pressure (See FIGURE 10.)

1. Temporarily install a Tee fitting in the outlet of thepower steering pump. See FIGURE 10. Connect a 20MPa (2000 psi) gauge onto the Tee fitting.

FIGURE 10. PRESSURE CHECK, STEERINGSYSTEM

1 POWER STEERING PUMP2. SUCTION PORT3. PRESSURE PORT4. RELIEF VALVE

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Page 15: INTRODUCTION A203 (A1...INTRODUCTION GENERAL The A1.00–1.50XL (A20–30XL) series of lift trucks have a power steering system. This section describes the disassembly and assembly

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2. Operate the power steering pump and steering for acomplete turn. Check that the maximum pressure is10.7 to 11.0 MPa (155 0 to 1,600 psi).

3. If the pressure is greater than 11.0 MPa (1,600 psi),replace the relief valve. If the pressure is less than 10.7MPa (1,550 psi), check that the power steering pump isnot worn or damaged.

4. When the pressure checks are complete, return thesteering system to normal operation.

Check the Operation and Alignment ofthe Steering System (See FIGURE 11.)

Raise the lift truck to remove the weight of the lift truckfrom the MDU. Loosen or tighten the hex nut that holdsone end of the steering chain on the master drive unit.Push on the chain between the sprocket and the end ofthe chain. The tension is correct when the chain moves7.35 to 11.00 mm (0.29 to 0.43 in).

FIGURE 11. ADJUSTMENT OF THESTEERING CHAIN

1 CHECK CHAIN ADJUSTMENT HERE2. MAKE ADJUSTMENT HERE

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TROUBLESHOOTINGPROBLEM POSSIBLE CAUSE

Steering is slow or more difficult than normal.The power steering pump is worn. Check the hydraulic pres-sure.

The spring for the relief valve is weak or damaged.

The steering control unit has a defect. See the section THESTEERING CONTROL UNIT, 1600 SRM 54.

The MDU does not turn when the steeringh l i t d

Air in the steering hydraulic system.gwheel is turned. Steering pump does not send oil to the steering system.

The relief valve for the steering system is open (damaged).

See the section, THE STEERING CONTROL UNIT, 1600SRM 54.

The master drive unit rotates in the wrongdi ti f th di ti f th t i

The hydraulic lines are wrong at the hydraulic steering motor.gdirection from the direction of the steeringwheel.

The hydraulic lines are wrong at the steering control unit.wheel.

If the steering control unit was disassembled, check the rotorfor correct alignment.

The master drive unit continues to turn afterth t i h l h t d t i

A centering spring is broken in the steering control unit.the steering wheel has stopped turning. There is damage to the sleeve or the spool of the steering con-

trol unit.

Check for dirt in the hydraulic system and the steering controlunit.

The power steering motor makes noise that isnot normal.

There is air entering the power steering pump. Check for airentering the pump through the inlet port or the seals betweenthe pump and the motor.