2. 8000 SRM 1227 Hydraulic System
Counterweight
Model * mm (* in.)
Weight +50 kg
(110 lb)
0 kg
(0 lb)
J2.00-2.50XM (J40-50Z) 717 mm (28.2 in.) 685 kg (1510 lb)
J2.50-3.00XM (J50-60Z) 861 mm (34.0 in.) 685 kg (1510 lb)
J3.20XM (J65Z) 861 mm (34.0 in.) 750 kg (1650 lb)
*Approximate battery compartment lengths (identifies frame size).
Hydraulic System
Table 1. Manual Control Valve
Item Specification
Relief Pressure, Lift System 20.7 ±0.7 MPa (3000 ±100 psi)
Relief Pressure, Tilt System
With Auxiliary Relief Valve 15.5 ±0.7 MPa (2250 ±100 psi)
Without Auxiliary Relief Valve 21.4 ±0.7 MPa (3100 ±100 psi)
Relief Pressure, Auxiliary 15.5 ±0.7 MPa (2250 ±100 psi)
Relief Pressure, Steering System 8908 ±345 kPa (1292 ±50 psi)
Oil temperature 54 to 66 C (130 to 150 F).
Table 2. E-Hydraulic Control Valve
Item Specification
Relief Pressure, Lift System (Primary Relief Valve) 22.7 ±0.7 MPa (3300 ±100 psi)
Relief Pressure, Tilt System and Auxiliary Functions
(Secondary Relief Valve)
15.5 ±0.7 MPa (2250 ±100 psi)
Relief Pressure, Steering System 8908 ±345 kPa (1292 ±50 psi)
Oil temperature 54 to 66 C (130 to 150 F).
1
3. Steering System 8000 SRM 1227
Steering System
Item Specifications
Oil Temperatures 49 to 60 C (120 to 140 F)
Inside Steering Tire Angle 82
Number of Turns to Lock 4.9
Steering Relief Pressure 8908 ±345 kPa (1292 ±50 psi)
Steering Relief Current (Approximate) 37 amps
Open Center Pressure 50 psi
Open Center Current 5 amps
Steering Time (Unloaded Static) 2.5 seconds
Steering Control Unit Displacement 80
Minimum Turning Radius (Truck With Load) ±2 in. (±50 mm) Acceptable
717 mm Battery Compartment
J2.00XM (J40Z)
J2.50XM (J50Z)
1996 mm (78.58 in.)
861 mm Battery Compartment
J2.50XM (J50Z)
J3.00XM (J60Z)
J3.20XM (J65Z)
2148 mm (84.57 in.)
2
4. 8000 SRM 1227 Battery Specifications
Wheels and Tires
Item Specification
Torque - Drive Wheel Nuts 155 to 175 N•m (114 to 166 lbf ft)
Torque - Steering Wheel Nuts 237 to 305 N•m (175 to 225 lbf ft)
Drive Tires, Size Pneumatic 23 × 10-12 16 Ply
Drive Tires, Size Pneumatic-Shaped Solid 23 × 10-12/8.0
Drive Tires, Size Snap-On Solid Tires 23 × 10-12/8.0
Steering Tires, Size Snap-On Solid Tires 18 × 7 × 8
Steering Tires, Size Pneumatic 18 × 7.00 × 8.00 16 Ply
Steering Tires, Size Pneumatic-Shaped Solid 18 × 7.00-8/4.33
Battery Specifications
Battery Size Minimum/
Maximum
Weight
Model
Min. Com-
partment Size
Width × Length
Length Width Minimum Maximum
J2.00-2.50XM
(J40-50Z)
712 × 1032 mm
(28.0 × 40.6 in.)
1025/1028 mm
(40.4/40.5 in.)
708/711 mm
(27.9 to 28.0 in.)
1470 kg
(3241 lb)
1625 kg
(3582 lb)
J2.50-3.20XM
(J50-60Z)
856 × 1032 mm
(33.7 × 40.6 in.)
1025/1028 mm
(40.4/40.5 in.)
852/855 mm
(33.5 to 33.7 in.)
1780 kg
(3924 lb)
1965 kg
(4332 lb)
The tolerances of the battery compartment are +3 and 0 mm (+0.12 and 0 in.). The battery size column
shows the size range that will permit the battery to still fit into a battery compartment.
The battery compartment length is front to back. Width is side to side. The length dimension of the battery
must fit within the battery compartment side-to-side dimension with a clearance of 0 to 13 mm (0 to 0.5 in.)
maximum. Battery width must fit within the battery compartment front-to-back dimension.
WARNING
The battery must fit the battery compartment so that the battery restraint system will operate
correctly. Use only batteries with the correct length shown in this table. Adjust the spacer plate
and side spacers to prevent the battery from moving more than 13 mm (0.5 in.) either direction.
3
6. 1600 SRM 720 Description
General
This section has the description and repair procedures for the steering housing and the steering control unit.
Additional information on parts of the steering system can be found in the Steering Axle and Hydraulic
System service manual sections for your lift truck.
Description
The steering column assembly uses a steering con-
trol unit with hose connections on the bottom of the
unit. The steering housing has mounts for the steer-
ing column and the steering control unit. The steer-
ing wheel is installed on the steering column. See
Figure 1. The housing is adjustable and is held in po-
sition by a latch. The position of the housing can be
changed for operator comfort. The steering housing
is also the mount for control levers and some instru-
ment clusters.
The steering system is a hydraulic system that does
not have a mechanical connection between the steer-
ing wheel and the steering axle. The control of the
steering is through a hydraulic circuit.
If the hydraulic pump for the steering system does
not operate, steering is still possible. A check valve
permits the steering control unit to control the steer-
ing cylinder. The lift truck is difficult to steer when
the steering pump is not operating, but the steer-
ing control unit can operate the steering cylinder and
make steering possible.
NOTE: INSTRUMENT CLUSTER NOT SHOWN.
H2.00-3.20XM (H40-65XM) SHOWN.
1. STEERING WHEEL
2. STEERING
COLUMN
3. STEERING
CONTROL UNIT
4. COLUMN TILT
LEVER
5. LATCH
6. COVER
7. COWL
8. MOUNT
Figure 1. Steering Housing Assembly
1
7. Operation 1600 SRM 720
Operation
The steering control unit is a rotary valve operated by
the steering wheel. See Figure 2. During the steer-
ing operation, the steering control unit controls the
direction and amount of oil flow to the steering cylin-
der. The steering cylinder in the axle actuates the
steering linkage to move the steer tires. Hydraulic
oil returns from the steering cylinder to the steering
control unit and then to the hydraulic tank.
Turning the steering wheel actuates three main
parts of the steering control unit: the spool for the
control section, the sleeve for the control section, and
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. Dur-
ing this time, oil flows freely through the steering
control unit but none flows 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 necessary force 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 cylinder returns through
the control section of the steering control unit.
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, stopping oil flow to or from the
cylinder. The pressure stays in the steering cylinder
to keep the steer 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 steer wheels
to the straight position, the steering wheel must be
rotated in the opposite direction. The steering con-
trol unit will operate as described, but all parts will
rotate in the opposite direction.
2
8. 1600 SRM 720 Operation
1. SPRING SET
2. SPOOL
3. SLEEVE
4. CENTER PIN
5. GEAR SET
6. CONTROL SECTION
7. METERING SECTION
Figure 2. Steering Control Unit
3
9. Steering Wheel and Column Assembly Repair 1600 SRM 720
Steering Wheel and Column Assembly Repair
The upper end of the steering shaft has splines for the
steering wheel. A large hex nut holds the steering
wheel onto the steering column. The horn button is
the cover for the center of the steering wheel. The
lower end of the steering column has splines or a tang
to engage the steering control unit. See Figure 5 and
Figure 6.
The steering column assembly is adjustable and held
in position by a latch. The position of the steering col-
umn assembly can be changed as needed for different
operator requirements. An access cover on the steer-
ing column gives access to the steering control unit,
key switch, horn switch, and if installed, the direc-
tion switch.
ASSEMBLY COMPONENTS, REMOVE
NOTE: This procedure is for the removal of all com-
ponents of the steering column assembly. All compo-
nents are not often removed for a repair procedure.
Do only those steps of the procedure necessary to re-
move the required component. See Figure 5 and Fig-
ure 6.
WARNING
The hydraulic hoses must be connected to the
correct ports or the steering system will not op-
erate as expected, which can cause damage or
personal injury. Make sure the hoses are iden-
tified and connected correctly.
CAUTION
Disconnect the negative battery cable on inter-
nal combustion trucks. Disconnect the battery
connector on electric trucks. Disconnect the
battery before removing any covers.
1. Attach a tag on the battery connector or negative
cable stating DO NOT CONNECT BATTERY.
Move the steering column to the most FOR-
WARD position. Remove the column tilt lever.
Remove the upper and lower access covers from
the steering column.
2. Remove the key switch and static strap from the
housing of the steering column. Make an identi-
fication of the electric wires and disconnect them
from the key switch.
3. On units with the Direction Control Handle,
Remove the direction switch assembly from the
housing of the steering column. Make an identi-
fication of the electric wires and disconnect them
from the direction switch. See Figure 3.
NOTE: DIRECTION CONTROL HANDLE ASSEMBLY
FOR MODELS J2.00-3.20XM [J40-65Z] (A416/B416),
E1.50-2.00XM [E25-35Z, E40ZS] (E114/F114),
N30XMH, AND N30XMH2 (C210), V30ZMD (D210/
E210), E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS)
(D098/E098), AND E2.00-3.20XM [E45-65Z] (G108)
IS SHOWN. OTHER TRUCK DIRECTION CONTROL
HANDLE ASSEMBLIES ARE SIMILAR.
1. DIRECTION SWITCHES
2. SHIFT LEVER ASSEMBLY
3. SCREW
4. ELECTRICAL CONNECTORS
Figure 3. Direction Control Handle Assembly
4. Remove the plastic rivets that fasten the bracket
for the horn switch to the housing of the steering
column. Move the horn switch and bracket away
from the steering column. See Figure 5 and Fig-
ure 6.
4
10. 1600 SRM 720 Steering Wheel and Column Assembly Repair
CAUTION
If a puller tool is used to remove steering wheel
from steering column, be careful not to damage
the horn wires.
5. Remove the horn button assembly and electrical
wires. Remove the large hex nut and the steer-
ing wheel from the shaft. A puller tool makes
removal of the steering wheel easier, but not all
steering wheels have puller holes.
6. On lift truck models J2.00-3.20XM (J40-
60XM2) (A216), E1.50-1.75XM, E2.00XMS
(E25-40XM2S) (D114), N30XMH, N30XMH2
(C210), and E2.00-3.20XM (E45-65XM2) (F108)
units, remove the optical encoder housing and
optical encoder from the steering column. Make
an identification of the electrical wires and dis-
connect them from the assemblies. See Figure 5.
7. On lift truck models J2.00-3.20XM [J40-
65Z] (A416/B416), E1.50-2.00XM [E25-35Z,
E40ZS] (E114/F114), V30ZMD (D210/E210),
E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS)
(D098/E098), and E2.00-3.20XM [E45-65Z]
(G108), disconnect the connector. Remove the
two capscrews and steering sensor from the
steering column. See Figure 6.
8. Make an identification of the hydraulic hoses
at the steering control unit so they can be con-
nected correctly during assembly. See Figure 4,
Figure 5, Figure 6, and the WARNING in the
beginning of this section. Some hydraulic hoses
have fittings that will permit disconnection at
the steering control unit. Disconnect the other
hydraulic hoses at the base of the cowl, the
control valve, or the steering pump. Remove
all mount clamps so that the hoses will turn
freely and not become twisted. Disconnect the
hydraulic hoses at the bottom of the steering
control unit. Install plugs at all hoses and ports
to prevent dirt from entering the steering hy-
draulic system.
1. HYDRAULIC HOSE ENDS
2. HOSE PORTS
3. STEERING CONTROL UNIT
4. SCREWS
5. HORN SWITCH
Figure 4. Hydraulic Hose Connections
9. If your model of lift truck has an instrument
cluster that wraps around the steering col-
umn, remove the instrument cluster. The
removal procedures for the instrument clus-
ter can be found in the service manual sec-
tions Instrument Cluster 2200 SRM 514 for
models H2.00-3.20XM (H40-65XM) (H177),
S1.50-1.75XM, S2.00XMS (S25-40XM) (D010)
and H1.50-1.75XM, H2.00XMS (H25-35XM,
H40XMS) (E001), or Electrical System,
Replacement, Checks, and Adjustments
Trucks with EV-100/200ZX or SR (SEM)
and SP Motor Controllers 2200 SRM
560 for models E1.50-1.75XM (E25-35XM2)
(D114), E2.00XMS (E40XM2S), E2.00-3.20XM
(E45-65XM2) (F108), and J2.00-3.20XM
(J40-60XM2) (A216).
10. If there is a instrument cluster on the steering
column housing, disconnect all plugs connected
to the display panel.
5
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13. 1600 SRM 720 Steering Wheel and Column Assembly Repair
Legend for Figure 5
NOTE: * NOT INCLUDED ON LIFT TRUCK MODELS H2.00-3.20XM (H40-65XM) (H177), S1.50-1.75XM,
S2.00XMS (S25-40XM) (D010), AND H1.50-1.75XM, H2.00XMS (H25-35XM, H40XMS (E001)
1. ON-DEMAND STEERING COMPONENTS
2. UPPER ACCESS COVER
3. BRACKET
4. PIVOT (STEERING) SHAFT
5. PLATE
6. LOCKWASHER
7. CAPSCREW
8. LOCK NUT
9. SCREW
10. STATIC GROUND PATCH
11. LOWER ACCESS COVER
12. COLUMN TILT LEVER
13. PUSH ROD
14. LATCH
15. SPRING
16. WASHER
17. COTTER PIN
18. PIN
19. STEERING CONTROL UNIT
20. PLUG (WITHOUT TURN SIGNAL)
21. OPTICAL ENCODER HOUSING*
22. GEAR*
23. OPTICAL ENCODER*
24. HORN BUTTON ASSEMBLY
25. STEERING WHEEL
26. STEERING COLUMN
27. RETURN SPRING
28. LARGE HEX NUT
29. INPUT
30. RIGHT TURN
31. LEFT TURN
32. RETURN
33. PLASTIC RIVET
11. Remove the tilt stop screw located at the bottom
left side of the steering column bracket.
12. Remove the capscrews, lockwashers, and lock
plates that fasten the steering column to the
pivots on the lift truck. Remove the steering col-
umn from the lift truck. Make sure the electric
wires and the hydraulic hoses are not damaged
as the steering column is removed.
13. Remove the four capscrews that hold the steer-
ing column to the bracket. Remove the four cap-
screws or nuts that fasten the steering control
unit to the steering column.
STEERING CONTROL UNIT,
DISASSEMBLE
1. Place the steering pump into a soft jaw vise with
the splined shaft facing down.
2. Remove the hydraulic fittings and the special
screws, and rotate the steering pump 90 degrees
sideways in the vise. Discard the O-rings. See
Figure 7.
3. Remove the end cover, spacer, gear housing,
and gear from the steering pump. Discard the
O-rings.
4. Remove the cardan shaft from the spool assem-
bly.
5. Remove the check ball, ball stop, and emergency
steering ball from the pump housing.
6. Remove the spool assembly from the pump hous-
ing.
NOTE: To help with installation of the thrust bearing
assembly, note the positions of the thrust washers
on either side of the thrust bearing while performing
Step 7.
7. Remove the thrust bearing assembly from the
shaft end of the spool assembly.
8. Remove the retaining ring from the spool assem-
bly.
9. Press the cross pin out of the spool assembly.
10. Press the spool from the sleeve and remove the
springs from the spool. Press the spool from the
sleeve and remove the springs from the spool.
11. Remove the shaft seals from the pump housing.
Discard the seals.
7
15. 1600 SRM 720 Steering Wheel and Column Assembly Repair
Legend for Figure 6
1. ON-DEMAND STEERING COMPONENTS
2. UPPER ACCESS COVER
3. BRACKET
4. PIVOT (STEERING) SHAFT
5. PLATE
6. LOCKWASHER
7. CAPSCREW
8. LOCK NUT
9. SCREW
10. STATIC GROUND PATCH
11. LOWER ACCESS COVER
12. COLUMN TILT LEVER
13. PUSH ROD
14. LATCH
15. SPRING
16. WASHER
17. COTTER PIN
18. PIN
19. STEERING CONTROL UNIT
20. PLUG (WITHOUT TURN SIGNAL
21. HORN BUTTON ASSEMBLY
22. STEERING WHEEL
23. STEERING COLUMN
24. RETURN SPRING
25. STEERING SENSOR
26. LARGE HEX NUT
27. INPUT
28. RIGHT TURN
29. LEFT TURN
30. RETURN
31. PLASTIC RIVET
STEERING CONTROL UNIT, CLEAN
WARNING
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.
WARNING
Compressed air can move particles so that they
cause injury to the user or to other personnel.
Make sure that the path of the compressed air
is away from all personnel. Wear protective
goggles or a face shield to prevent injury to the
eyes.
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 sharp
edges.
STEERING CONTROL UNIT, ASSEMBLE
1. Using a seal installer, install the shaft seals in
the pump housing.
2. Install the spool into the sleeve with the key slots
opposite each other.
3. Insert the curved springs between the flat
springs. See Figure 7. Install the spring set into
the spool assembly.
NOTE: The retaining ring must be able to rotate
unimpeded by the springs.
4. Center the springs in the spool assembly, and in-
stall the retaining ring over the sleeve.
5. Install the cross pin into the spool assembly.
6. Install the thrust bearing assembly, as noted dur-
ing removal, on the spool assembly.
7. Place the pump housing in a soft-jawed vise in
the horizontal position. Install the spool assem-
bly into the housing while holding the cross pin
in a horizontal position.
8. Rotate the pump housing to the vertical position,
and rotate the spool so that the pin in the spool
is pointing to the "P" port position. See Figure 5
and Figure 6.
9. Install the emergency steering ball, ball stop,
and check ball in the "P" port. See Figure 5 and
Figure 6.
10. Install a new O-ring on the housing and place the
distributor plate on the housing, with the holes
properly aligned with the pump housing.
11. Install the cardan shaft and rotate it until it is
engaged with the pin in the spool assembly, and
until the teeth of the gear end are aligned as
shown in Figure 7.
12. Install the gear wheel onto the cardan shaft as
shown in Figure 7.
9
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J40Z J50Z J60Z J65Z [B416]](https://image.slidesharecdn.com/hysterb416j65zforkliftservicerepairmanual-201002142345/85/Hyster-b416-j65-z-forklift-service-repair-manual-1-320.jpg)
