Hyster C108 Operating instructions

Hyster C108 (E40XL, E50XL, E55XL, E60XL) Electric Forklift

STEERING SYSTEM
FOR ELECTRICLIFT
TRUCKS
A1.00-1.50XL (A20-30XL) [A203]; J2.00-3.00XL (J40-60XL) [B168];
E1.25-1.75XL (E25-35XL) [C114]; E2.00-3.00XL (E40-60XL) [C108];
E3.50-5.50XL (E70-120XL, E70-120XL3) [C098];
E1.50-2.00XMS (E25-40XMS, E25-40XM2S) [D114];
E2.00-3.20XM (E45-65XM, E45-65XM2) [F108];
J2.00-3.20XM (J40-60XM, J40-60XM2) [A216];
N30XMH, N30XM2H [A210, C210]
PART NO. 897450 1600 SRM 485

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 for Electric Lift Trucks Table of Contents
TABLE OF CONTENTS
General ............................................................................................................................................................... 1
Description ......................................................................................................................................................... 3
Steering Wheel and Column Assembly Repair ................................................................................................ 4
Assembly Components, Remove ................................................................................................................... 4
Assembly Components, Install ..................................................................................................................... 9
Power Steering Motor and Pump...................................................................................................................... 12
Description ..................................................................................................................................................... 12
Remove and Disassemble, Models E1.25-3.00XL (E25-60XL), J2.00-3.00XL (J40-60XL),
E2.00-3.20XM (E45-65XM, E45-65XM2), N30XMH, and N30XM2H, ....................................................... 14
Remove and Disassemble, Models E3.50-5.50XL (E70-120XL, E70-120XL3)............................................ 17
Remove and Disassemble, Models J2.00-3.20XM (J40-60XM, J40-60XM2)............................................... 18
Remove and Disassemble, Models A1.00-1.50XL (A20-30XL) .................................................................... 19
Remove and Disassemble, Models E1.50-2.00XMS (E25-40XMS, E25-40XM2S) ...................................... 19
Assemble and Install - All models with a vertical mount except J2.00-3.20XM (J40-60XM,
J40-60XM2) .................................................................................................................................................... 20
Assemble and Install, Models J2.00-3.20XM (J40-60XM, J40-60XM2)...................................................... 20
Assemble and Install, Models E1.50-2.00XMS (E25-40XMS, E25-40XM2) ............................................... 21
Power Steering Pump, Repair....................................................................................................................... 21
Seal, Replace.............................................................................................................................................. 23
Hydraulic Steering Motor.................................................................................................................................. 23
Description ..................................................................................................................................................... 23
Hydraulic Steering Motor Repairs................................................................................................................ 24
Remove....................................................................................................................................................... 24
Disassemble............................................................................................................................................... 24
Clean and Inspect...................................................................................................................................... 26
Assemble.................................................................................................................................................... 26
Install......................................................................................................................................................... 27
Steering System Air Removal ........................................................................................................................... 27
Steering Pressure Check ................................................................................................................................... 27
Steering Chain Tension Check (Unit With MDU Only)................................................................................... 28
Optical Encoder and Activator Circuits Check ................................................................................................ 29
Troubleshooting.................................................................................................................................................. 31
This section is for the following models:
A1.00-1.50XL (A20-30XL) [A203];
J2.00-3.00XL (J40-60XL) [B168];
E1.25-1.75XL (E25-35XL) [C114];
E2.00-3.00XL (E40-60XL) [C108];
E3.50-5.50XL (E70-120XL, E70-120XL3) [C098];
E1.50-2.00XMS (E25-40XMS, E25-40XM2S) [D114];
E2.00-3.20XM (E45-65XM, E45-65XM2) [F108];
J2.00-3.20XM (J40-60XM, J40-60XM2) [A216];
N30XMH, N30XM2H [A210, C210]
©2003 HYSTER COMPANY i

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"THE
QUALITY
KEEPERS"
HYSTER
APPROVED
PARTS

1600 SRM 485 General
General
There are two different steering systems available:
Power Steering and Power Steering with On-De-
mand. The difference in the components for each
system can be found in Figure 1 and Figure 2. This
section covers the description, disassembly, assem-
bly, checks, adjustments, and the troubleshooting
of the steering system. There is a description for
each part of the steering system at the beginning
of each repair section. On units with three wheels,
the steering system turns the Master Drive Unit
(MDU) to steer the lift truck. On units that have
four wheels and a steering axle, the steering system
operates the steering cylinder to steer the lift truck.
Additional information for the components of the
steering system is found in the Master Drive Unit
630 SRM 363 which contains the description and
repair of the MDU for the A1.00-1.5.XL (A20-30XL),
the Steering Axle for your unit, and the Steering
Control Unit for your lift truck model.
A modification has been made in the manifold as-
sembly of the steering control unit used in the A1.00-
1.50XL (A20-30XL) trucks that is different than the
unit described in the Steering Control Unit 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 hydraulic ports on the side of the steering con-
trol unit are not used.
A. THREE WHEEL UNITS B. MANY FOUR WHEEL UNITS
1. STEERING WHEEL
2. OPTICAL ENCODER
3. ACTIVATOR
4. STEERING CONTROL UNIT
5. STEERING PUMP MOTOR
6. STEERING PUMP
7. PRESSURE SWITCH [EXCEPT A1.00-1.50XL
(A20-30XL)]
8. HYDRAULIC STEERING MOTOR
9. STEERING CHAIN
10. MASTER DRIVE UNIT
11. STEERING CYLINDER
12. STEERING AXLE
13. FROM TANK
14. TO TANK
*E3.50-5.50XL (E70-120XL, E70-120XL3)ONLY.
#POWER STEERING WITH ON-DEMAND ONLY.
Figure 1. Power Steering Components
1

General 1600 SRM 485
Figure 2. Power Steering Components E1.50-2.00XMS (E25-40XMS, E25-40XM2S)
2

1600 SRM 485 Description
Legend for Figure 2
1. STEERING CYLINDER
2. TO STEERING CONTROL UNIT
3. PRESSURE CHECK FITTING
4. PUMP MOTOR
5. STEERING PUMP
6. PRESSURE SWITCH (ON-DEMAND STEERING
ONLY)
7. RETURN TO HYDRAULIC TANK
8. FROM HYDRAULIC TANK
9. MOUNT FOR STEERING MOTOR
Description
The steering system used on these lift trucks is a
hydraulic system that does not have a mechani-
cal connection between the steering wheel and the
MDU or steering axle. The control of the steering
is through a hydraulic circuit. See Figure 1 and
Figure 3. An electric motor drives a hydraulic pump.
To energize the motor, the key switch must be ON
and the seat switch must be closed. When the key
switch is first moved to the ON position, forward or
reverse direction must also be selected for the steer-
ing system to operate. After the starting sequence is
completed, the electric motor on the Power Steering
pump will run continuously. The pump motor with
the On-Demand system will operate only when the
steering wheel is turned. When the electric motor
operates the pump, hydraulic oil flows through the
power steering system.
When the steering wheel is rotated to steer the lift
truck, the hydraulic oil is routed to the steering mo-
tor at the MDU or to the steering cylinder on units
with a steering axle. There is a delay between the
last rotation of the steering wheel and the system
deenergizing in the Power Steering with On-Demand
system. This delay keeps the system operating when
the operator is not turning the steering wheel during
straight travel. The delay is approximately 1 second
on some truck models to between 4 and 5 seconds on
other models.
1. MOTOR
2. STEERING PUMP
3. PRESSURE TEST PORT
4. STEERING CONTROL UNIT
5. STEERING WHEEL
6. STEERING CYLINDER OR MOTOR
7. PRESSURE TEST PORT*
8. HYDRAULIC TANK
9. FILTER
*PRESSURE SWITCH FOR ON-DEMAND STEERING OPTION ONLY. REPLACES CHECK PORT.
Figure 3. Steering System Hydraulic Schematic
3

Steering Wheel and Column Assembly Repair 1600 SRM 485
A gear on the shaft of the steering wheel drives the
gear of the optical encoder as the steering wheel is
moved to steer the lift truck. The optical encoder
sends a signal to the activator. The activator com-
pletes the battery negative circuit for the steering
contactor to energize the steering pump motor. See
Figure 4 and Figure 19 for the electrical connections
for Power Steering with the On-Demand system.
Also see Diagrams section for your unit. The steer-
ing control unit is also operated by the steering
wheel to direct oil to the steering cylinder or hy-
draulic motor.
NOTE: On units with a steering axle, there is a
pressure switch in the hydraulic circuit. Any time
the system is operational and the system pressure
is above 2.07 kPa (0.3 psi), the switch energizes the
contactor for the steering pump motor. This pressure
switch allows the system to continue to operate even
if the steering wheel is not moving.
Units that have On-Demand steering have an opti-
cal encoder circuit. A gear on the shaft of the steering
wheel moves the gear of the optical encoder when the
steering wheel is moved. See Figure 4, Figure 6 and
Figure 7. The optical encoder sends a signal to the ac-
tivator assembly. The activator assembly completes
the battery negative circuit for the steering contactor
to energize the steering pump motor. The steering
wheel also operates the steering control unit. When
the steering wheel is rotated to steer the lift truck,
the hydraulic oil is sent to the steering cylinder on
the steering axle.
The steering control unit is a rotary valve operated
by the steering wheel. During the steering operation,
the steering control unit controls the direction of flow
and volume of oil to control the direction and degree
of turn. On units with an MDU, the hydraulic motor
has a sprocket on the output shaft that rotates the
MDU by a steering chain. On units that have a steer
axle, the steering cylinder moves the steering link-
agetomovethesteerwheels. Hydraulicoilreturns
fromthehydraulicmotororcylindertothesteering
control unit and then returns to the hydraulic tank.
If for any reason the steering pump does not operate,
a check valve permits the steering control unit to still
control the steering system. The lift truck is difficult
to steer when the steering pump is not operating, but
the steering control unit can operate the hydraulic
motororsteeringcylinderandmakessteeringpossi-
ble.
Steering Wheel and Column Assembly Repair
The upper end of the steering shaft has splines for
the steering wheel. A large nut holds the steering
wheel onto the steering shaft. The horn button is the
cover for the center of the steering wheel. The lower
end of the steering shaft has splines or a tang to en-
gage the steering control unit. A push rod allows the
horn button to actuate the horn switch. See Figure 4,
Figure 5, Figure 6 and Figure 7.
The steering column is adjustable and is held in posi-
tion by a latch. The steering column position can be
changed for different operators. The steering column
must be raised to the UP position to provide clear-
ance for the seat when removing or installing the
battery. There is a cover on the steering column for
access to the steering control unit, key switch, horn
switch, direction switch (if installed), optical encoder,
and on some units, the activator. The activator on
many of the XM units is under the instrument panel
to the left of steering column.
ASSEMBLY COMPONENTS, REMOVE
NOTE: See the section, Steering Control Unit for
your unit for the correct repair procedures for the
steering control unit.
NOTE: This procedure is for the removal of all com-
ponents of the steering column assembly. Usually it
is not necessary to remove all of the components. Do
only those steps of the procedure necessary to remove
the component you need to remove.
1. Disconnect the battery and attach a tag on the
truck battery connector, stating DO NOT CON-
NECT BATTERY. Raise the steering column to
the UP position. Remove the access cover from
the steering column.
2. Remove the housing of the steering column. Re-
move key switch. Make an identification of the
electrical wires and disconnect them from the key
switch.
4

1600 SRM 485 Steering Wheel and Column Assembly Repair
Figure 4. Steering Wheel and Steering Column Assembly (Early XL Units)
5

Steering Wheel and Column Assembly Repair 1600 SRM 485
Legend for Figure 4
NOTE: FOR CORRECT CONNECTION, SEE THE DIAGRAMS SRM FOR YOUR LIFT TRUCK.
A. DANFOSS B. TRW
1. TRUCK WIRE HARNESS
2. SNAP RING
3. PLASTIC TUBE
4. PIN
5. STEERING SHAFT
6. SOCKET HEAD SCREW
7. KEY SWITCH
8. CLAMP
9. BRACKET
10. STEERING CONTROL UNIT
11. LATCH
12. BRACKET
13. OPTICAL ENCODER AND BRACKET
14. DRIVE GEAR AND SETSCREW
15. ENCODER/ACTIVATOR WIRE HARNESS
16. ACTIVATOR
17. INPUT
18. OUTPUT
19. LEFT TURN
20. RIGHT TURN
3. Remove the instrument display panel or instru-
ment display meters and gauges. Early model
lift trucks can have either an instrument dis-
play cluster that wraps around the steering col-
umn, near the steering wheel, or instrument dis-
play meters and gauges that are located on both
sides of and near the bottom of the steering col-
umn. See the service manual sections Instru-
ment Cluster,Instrument Panel Indicators
and Senders or Electrical System foryourlift
truck model for the removal procedures.
4. For later model lift trucks, the display panel is
located on the cowl, or steering column housing,
to the right of the steering column assembly. Dis-
connect all plugs connected to the display panel.
5. If installed, remove the handle, boot, and large
nut that fasten the direction switch. Remove the
direction switch from the housing of the steer-
ing column. Make an identification of the electri-
cal wires and disconnect them from the direction
switch.
6. Remove the capscrew that fastens the bracket for
the horn switch to the housing of the steering
column. Move the horn switch and bracket away
from the steering column.
7. Remove the horn cover, snap ring, and base plate
(not part of Petri steering wheel). Lift the push
rod and adjuster spool out the top of the steering
shaft. Remove the large hex nut and remove the
steering wheel from the shaft. A puller makes
removal of the steering wheel easier, but not all
steering wheels have puller holes.
8. If the lift truck has On-Demand steering, remove
the optical encoder and activator and the brack-
ets. SeeFigure4,Figure6,andFigure7. Itis
not necessary to remove the activator if it is not
in the steering column. See Make an identifica-
tion of the electrical wires and disconnect them
from the assemblies.
9. Make an identification of the hydraulic hoses
at the steering control unit so they can be con-
nected correctly during assembly. Some hoses
have swivel fittings to permit disconnecting at
the steering control unit. Disconnect the other
hoses at the base of the cowl, the control valve, or
the steering pump. Remove all mounting 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 hose ports and hoses to prevent dirt from
entering the system.
10. 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 electrical
wires and the hydraulic hoses are not damaged
as the steering column is removed.
6

1600 SRM 485 Steering Wheel and Column Assembly Repair
NOTE: PETRI STEERING WHEEL SHOWN.
1. LATCH PIVOT PIN
2. COTTER PIN
3. BRACKET
4. HORN SWITCH
5. PIN
6. PUSH ROD
7. INTERNAL SNAP RING
8. STEERING WHEEL NUT
9. LOCK RING
10. SOCKET HEAD SCREW
11. ADJUSTER SPOOL NUT
12. HORN COVER
13. BASE PLATE
14. STEERING WHEEL
15. EXTERNAL SNAP RING
16. BEARING
17. STEERING SHAFT
18. PLASTIC TUBE
19. PLASTIC WASHER
20. SPRING
21. BRACKET
22. STEERING CONTROL UNIT
23. STEERING COLUMN
24. LATCH
25. SOCKET HEAD SCREW
Figure 5. Steering Wheel and Steering Column Assembly (Later XL Units)
7

Steering Wheel and Column Assembly Repair 1600 SRM 485
Figure 6. Steering Wheel and Steering Column Assembly (Early Model XM Units)
8

1600 SRM 485 Steering Wheel and Column Assembly Repair
Legend for Figure 6
NOTE: FOR CORRECT CONNECTION, SEE THE DIAGRAMS SRM FOR YOUR LIFT TRUCK.
1. STEERING WHEEL, SHAFT, AND ON-DEMAND
STEERING PARTS
2. STEERING CONTROL UNIT
3. SPRING
4. WASHER
5. COTTER PIN
6. PIN
7. PUSH ROD
8. COLUMN TILT LEVER
9. SCREW
10. REAR COVER
11. MOUNT
12. CAPSCREW
13. PLATE
14. ALLEN HEAD CAPSCREW
15. PIVOT SHAFT
16. RETURN SPRING
17. FRONT COVER
18. BRACKET
19. OPTICAL ENCODER AND BRACKET
20. DRIVE GEAR AND SETSCREW
21. ENCODER/ACTIVATOR WIRE HARNESS
22. ACTIVATOR (UNDER INSTRUMENT PANEL TO
LEFT OF STEERING COLUMN)
23. TRUCK WIRE HARNESS
24. LATCH
11. Remove the steering shaft as follows:
a. Move the plastic tube and washer toward the
steering control unit and compress the spring
for the horn switch. Then remove the pin
that goes through the steering shaft and en-
gages the plastic tube.
b. Remove the external snap ring that holds the
bearing in the steering column. On units
that have On-Demand steering, loosen the
setscrew in thegearontheshaft. There-
turn spring, washer, and tube are removed at
thesametimea
s the steering shaft and bear-
ing are removed. Use a small pry bar at the
bottom of the steering shaft near the steer-
ing control unit to remove the steering shaft
and bearing (also, return spring, washer, and
tube) from the steering column.
12. Remove the two capscrews that hold the steer-
ing control unit and the bracket to the steering
column. Remove the four capscrews or nuts that
fasten the steering control unit to the bracket.
ASSEMBLY COMPONENTS, INSTALL
NOTE: This procedure is for the installation of all
components of the steering column assembly. Usu-
ally it is not necessary to install all of the compo-
nents. Do only those steps of the procedure neces-
sary to install the component you need to install.
1. Install the steering column on the cowl mounts.
Lubricate the pivots with multipurpose grease
and install the capscrews into the housing.
2. Fasten the two halves of the mount bracket to
the steering control unit. Make sure to install
bracket for activator if the activator is in the
steering column. Install the steering control unit
assembly into the steering column. Make sure to
install the horn switch and the switch bracket as
well as the two wire clamps on the same mount
capscrews.
3. For early model lift trucks, if the instrument
display panel or instrument display meters and
gauges were removed, install them. See the
service manual sections Instrument Cluster,
Instrument Panel Indicators and Senders
or Electrical System foryourlifttruckmodel
for the installation procedures.
4. For later model lift trucks, if the display panel
was removed, install it and connect all plugs to
the display panel.
5. If removed, install the wires on the key switch as
identified during removal. Install the key switch.
6. If removed, install the wires on the direction
switch as identified during removal. Install the
direction switch in the housing and install the
large nut, boot, and handle.
9

Steering Wheel and Column Assembly Repair 1600 SRM 485
Figure 7. Steering Wheel and Steering Column Assembly (Later Model XM Units)
10

1600 SRM 485 Steering Wheel and Column Assembly Repair
Legend for Figure 7
1. ON-DEMAND STEERING COMPONENTS
2. FRONT COVER
3. BRACKET
4. PIVOT (STEERING) SHAFT
5. PLATE
6. LOCKWASHER
7. CAPSCREW
8. LOCK NUT
9. SCREW
10. STATIC GROUND PATCH
11. REAR 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 AND BRACKET
22. DRIVE GEAR AND SETSCREW
23. OPTICAL ENCODER
24. HORN SYSTEM
25. STEERING WHEEL
26. STEERING COLUMN
27. RETURN SPRING
28. LARGE HEX NUT
29. INPUT
30. RIGHT TURN
31. LEFT TURN
32. RETURN
7. Install the bearing on the steering shaft. The
seal of the bearing must be toward the steering
wheel. Install the snap ring in the groove on the
steering shaft.
8. Put the steering shaft through the opening for
the bearing in the steering housing. Install the
gear for On-Demand steering onto the steering
shaft. Install the pin that holds the plastic tube
and flange for the horn switch. Install the plastic
tube, the plastic flange, and the spring onto the
steering shaft. Push the steering shaft into the
splines or align the tang of the steering control
unit. Install the snap ring that holds the bearing
in the steeringhousing.
9. If removed, installtheopticalencoderand
bracket assembly on the column housing. Make
sure the pinion gear of the optical encoder and
the drive gear on the steering shaft are correctly
aligned. Tighten the setscrew for the drive gear.
Install the wires on the activator as identified
during removal. The correct connections are
also shown in Figure 4, and Figure 6. Install the
activator on the bracket fastened to the steering
control unit.
10. Install the steering wheel. Install the large hex
nut onto the steering shaft. Install the push rod
and adjuster spool into the steering shaft. Install
thebaseplate(n
ot part of Petri steering wheel),
the lock ring, and the horn cover.
WARNING
The hydraulic hoses MUST be connected to the
correct ports and fittings, or the steering sys-
tem will not operate as expected. This opera-
tion that is not expected can cause damage or
personal injury. Connect the hoses as identi-
fied during removal.
11. Connect the hydraulic hoses to the steering con-
trol unit, the cowl, the control valve, or the steer-
ing pump as removed during removal. Make sure
each hydraulic hose is connected to the correct
ports or fittings as identified during removal.
12. Connect the wire connectors at the bottom of the
steering column. Install the access cover on the
steering column.
11

Power Steering Motor and Pump 1600 SRM 485
Power Steering Motor and Pump
DESCRIPTION
NOTE: See the section Hydraulic System for your
lift truck model for additional information on the
power steering pump.
The power steering motor and pump assem-
bly is under the floor plate on all units ex-
cept the J2.00-3.20XM (J40-60XM, J40-60XM2),
E1.50-2.00XMS (E25-40XMS, E25-40XM2S), and
E3.50-5.50XL (E70-120XL, E70-120XL3) units. The
E1.50-2.00XMS (E25-40XMS, E25-40XM2S) and
the E3.50-5.50XL (E70-120XL, E70-120XL3) units
have the motor and pump assembly under the bat-
tery compartment. The J2.00-3.20XM (J40-60XM,
J40-60XM2) units have the motor and pump assem-
bly mounted behind the battery compartment. The
power steering motor and pump operate as described
in Description in front part of this manual. See Fig-
ure 8, Figure 9, and Figure 10.
A. E1.25-3.00XL (E25-60XL), J2.00-3.00XL (J40-60XL), E2.00-3.20XM (E45-65XM, E45-65XM2), N30XMH,
N30XM2H AND E3.50-5.50XL (E70-120XL, XL3
B. A1.00-1.50XL (A20-30XL)
1. POWER STEERING MOTOR
2. CLAMP MOUNT AND BRACKET
3. POWER STEERING PUMP
4. LIFT TRUCK FRAME
5. FROM HYDRAULIC TANK
6. TO STEERING CONTROL UNIT
7. STRAP AND MOUNT BRACKET
Figure 8. Power Steering Motor and Pump
12

1600 SRM 485 Power Steering Motor and Pump
1. LIFT TRUCK FRAME
2. STEERING MOTOR
3. STEERING PUMP
4. O-RING
5. MOUNTING BRACKET
6. PRESSURE SWITCH
7. FROM HYDRAULIC TANK
8. TO STEERING CONTROL UNIT
9. PUMP MOUNTING BOLT
10. BRACKET MOUNTING BOLT
11. MOTOR MOUNTING BOLT
Figure 9. Power Steering Motor and Pump J2.00-3.20XM (J40-60XM, J40-60XM2)
13

Power Steering Motor and Pump 1600 SRM 485
1. MOTOR
2. HYDRAULIC PUMP - STEERING
3. WASHER
4. RUBBER BUSHINGS
5. CAPSCREW AND NUT
6. MOUNT BRACKET
7. FRAME BRACKET
8. MOUNT PIN
9. MOTOR BASE
Figure 10. Power Steering Pump Motor E1.50-2.00XMS (E25-40XMS, E25-40XM2S)
REMOVE AND DISASSEMBLE, MODELS
E1.25-3.00XL (E25-60XL), J2.00-3.00XL
(J40-60XL), E2.00-3.20XM (E45-65XM,
E45-65XM2), N30XMH, AND N30XM2H,
NOTE: On some units, the power steering motor
must be removed from the mounts on the frame to
replace the brushes. Other motors require removal
of the end bell to replace the brushes.
1. Disconnect the battery and attach a tag on the
truck battery connector, stating DO NOT CON-
NECT BATTERY.
2. Remove the floor plate.
3. Install identification tags on the power cables
and disconnect them from the power steering mo-
tor.
4. Attach identification tags on the electrical wires
and disconnect them from the pressure switch.
5. Put a drain pan under the pump. Install identi-
fication tags on the hydraulic hoses and discon-
nect them from the power steering pump. See
Figure 8. Quickly put plugs in the ends of the
hoses and the pump ports to keep oil from drain-
ing and dirt from entering the system.
6. Remove the two clamp capscrews and nuts, the
washers, and the two mounts. Remove the motor,
pump, and bracket as an assembly. See Figure 8.
7. Check the motor brushes. See the sections Pe-
riodic Maintenance (foryourtruckmodel)and
DC Motor Maintenance 620 SRM 294 for ad-
ditional information for inspection of the brushes
and commutator.
8. If the motor must be disassembled for cleaning
or repairs, remove the pump so that a new oil
seal can be installed. Before disassembling the
motor, make match marks for alignment on the
end plates and the motor housing. These marks
are necessary to assemble the motor correctly. To
disassemble the motor, see Figure 8, Figure 11,
and Figure 12.
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