GROUP 2 OPERATIONAL CHECKS AND TROUBLESHOOTING

1. OPERATIONAL CHECKS
Check item Checking procedure

Steering wheel  Set rear wheels facing straight forward, then turn steering wheel to left and right.
30-60mm Measure range of steering wheel movement before rear wheel starts to move.
(1.2-2.4 in)
Range should be 30~60mm at rim of steering wheel. If play is too large, adjust
at gear box.
Test steering wheel play with forklift stopped.

Knuckle  Check knuckle visually or use crack detection method. If the knuckle is bent, the
tire wear is uneven, so check tire wear.
Steering axle  Put camber gauge in contact with hub and measure camber.
If camber is not within 1Ü0.5ä; rear axle is bent.
 Ask assistant to drive machine at minimum turning radius.
 Fit bar and a piece of chalk at outside edge of counterweight to mark line of
turning radius.
 If minimum turning radius is not withinÜ100mm (Ü4in)of specified value, adjust
turning angle stopper bolt.
Min turning radius(Outside) : Refer to page 1-5(Specifications)
Hydraulic pressure of power Remove plug from outlet port of flow divider and install oil pressure gauge.
steering Turn steering wheel fully and check oil pressure.
ö Oil pressure : 100kgf/cm2 (1420psi)

2. TROUBLESHOOTING
1) STEERING SYSTEM
Problem
Steering wheel drags.
Steering wheel fails to return
smoothly.
Cause Remedy
ÂLow oil pressure. ÂCheck lockout. Repair.
ÂBearing faulty. ÂClean or replace.
ÂSpring spool faulty. ÂClean or replace.
ÂReaction plunger faulty. ÂReplace.
ÂBall-and-screw assembly faulty. ÂClean or replace.
ÂSector shaft adjusting screw excessi- ÂAdjust.
vely tight.
ÂGears poorly meshing. ÂCheck and correct meshing.
ÂFlow divider coil spring fatigued. ÂReplace.
ÂBearing faulty. ÂClean or replace.
ÂReaction plunger faulty. ÂReplace.
ÂBall-and-screw assy faulty ÂClean or replace.
ÂGears poorly meshing. ÂCheck and correct meshing.

5-10
 Problem
Steering wheel turns unstea-
dily.
Steering system makes abn-
ormal sound or vibration.
Abnormal sound heard when
steering wheel is turned fully
Piping makes abnormal
sounds.
Valve or valve unit makes
abnormal sounds.
Insufficient or variable oil flow. ÂFlow control valve orifice clogged.
Insufficient or variable dischar- Piping
ge pressure.
Steering cylinder head
leakage (Piston rod)
Steering cylinder head thread
(A little bit leak is no problem)
Welding leakage
Rod
Piston rod bushing inner
diameter excessive gap
Cause Remedy
ÂLockout loosening. ÂRetighten.
ÂMetal spring deteriorated. ÂReplace.
ÂGear backlash out of adjustment. ÂAdjust.
ÂLockout loosening. ÂRetighten.
ÂAir in oil circuit. ÂBleed air.
Valve
ÂFaulty. (Valve fails to open.) ÂAdjust valve set pressure and check
for specified oil pressure.
Piping
ÂPipe(from pump to power steering ÂRepair or replace.
cylinder) dented or clogged.
Oil pump
ÂLack of oil. ÂAdd oil.
ÂOil inlet pipe sucks air. ÂRepair.
ÂInsufficient air bleeding. ÂBleed air completely.
Oil pump
ÂOil inlet pipe sucks air. ÂRepair or replace.
Valve
ÂFaulty. (Unbalance oil pressure) ÂAdjust valve set pressure and check
specified oil pressure.
Piping
ÂPipe(from pump to power steering) ÂRepair or replace.
dented or clogged.
ÂInsufficient air bleeding. ÂBleed air completely.
ÂClean
ÂPipe(from tank to pipe) dented or ÂRepair or replace.
clogged.
ÂPacking foreign material. ÂReplace
ÂPiston rod damage. ÂGrind surface with oil stone.
ÂRod seal damage and distortion. ÂReplace
ÂChrome gilding damage. ÂGrind
ÂO-ring damage. ÂReplace
ÂCylinder tube damage. ÂTube replace.
ÂTube inside damage. ÂGrind surface with oil store.
ÂPiston seal damage and distortion ÂReplace
ÂBushing wear. ÂReplace
5-11
 2) POWER STEERING UNIT
Problem Cause
Oil leakage ÂFittings loose, worn, or damaged.
ÂDeteriorated seals by excessive heat. ÂReplace the seals.
ÂLoose screw or its deteriorated
sealing.
ÂInternal seals worn or damaged.
ÂDamaged seal grooves.
ÂHousing crack.
Noise or vibration ÂAir inclusion in the system.
ÂValve timing error when the unit is
assembled.
ÂHydraulic pipe noise interference.
ÂControl valve damage or clogging.
Heavy steering operation ÂLack of sufficient oil supply.
ÂExcessive heat.
ÂBroken pump.
ÂLeakage in the line or connections.
ÂClogged orifice.
ÂHigh back pressure.
Irregular or no response ÂBroken pump.
ÂExcessive heat.
ÂBroken centering spring.
ÂMisalignment with column.
ÂIncorrect piping to the four port.
ÂParts missing.
ÂHigh back pressure.
ÂCorrosion on the moving parts.
5-12
Remedy
ÂCheck and replace the damaged
parts.
ÂReplace the sealing and tighten
screw appropriately.
ÂReplace it.
ÂReplace the unit or related parts.
ÂReplace the unit.
ÂBleed the air.
ÂCorrect the timing.
ÂConsult the component manufacturer.
ÂReplace the valve.
ÂCheck the pump and the line.
ÂLocate the heat source and correct it.
ÂReplace it.
ÂReplace it.
ÂDisassemble, clean, and reassemble
it.
ÂAdjust the pressure.
ÂReplace it.
ÂLocate the heat source and remove it.
ÂReplace it.
ÂDisassemble and adjust it.
ÂCorrect it.
ÂInstall the parts correctly.
ÂAdjust the pressure.
ÂReplace it.