STEERING MECHANISM

B60Z AC [B230];
B80Z AC [B233]

PART NO. 1640803 1600 SRM 1284

 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 Maintenance 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 hazardous situation which, if not avoided, could result in
death or serious injury.

CAUTION
Indicates a hazardous situation which, if not avoided, could result in
minor or moderate injury and property damage.

On the lift truck, the WARNING symbol and word are on orange back-
ground. The CAUTION symbol and word are on yellow background.
Steering Mechanism Table of Contents

TABLE OF CONTENTS

General ............................................................................................................................................................... 1
Accessing the Drive Unit Compartment ...................................................................................................... 1
Special Precautions............................................................................................................................................ 2
Discharging the Capacitors........................................................................................................................... 2
Calibration.......................................................................................................................................................... 3
Power Assist Steering Sensor ....................................................................................................................... 3
Control Handle................................................................................................................................................... 3
Control Handle Head..................................................................................................................................... 3
Control Handle .............................................................................................................................................. 3
Standard Steering ..................................................................................................................................... 3
Remove .................................................................................................................................................. 4
Install..................................................................................................................................................... 4
Power Assist Steering ............................................................................................................................... 6
Remove .................................................................................................................................................. 6
Install..................................................................................................................................................... 7
Gas Spring .......................................................................................................................................................... 11
Discharging the Gas Spring .......................................................................................................................... 11
Remove .......................................................................................................................................................... 12
Install ............................................................................................................................................................ 12
Articulating Shaft and Pinions (Power Assist Models).................................................................................... 13
Remove ........................................................................................................................................................... 13
Pinion Repair ................................................................................................................................................. 14
Upper Pinion.............................................................................................................................................. 14
Lower Pinion.............................................................................................................................................. 15
Install ............................................................................................................................................................. 16
Steer Motor Assembly........................................................................................................................................ 17
Repair ............................................................................................................................................................. 17
Steer Motor, Replace ................................................................................................................................. 17
Steer Motor Gear, Replace ........................................................................................................................ 18
Gearbox/Complete Assembly, Replace...................................................................................................... 18
Steer Support Assembly .................................................................................................................................... 19
Standard Steering ......................................................................................................................................... 19
Remove (Complete Unit) ........................................................................................................................... 19
Disassemble ............................................................................................................................................... 19
Assemble .................................................................................................................................................... 21
Install (Complete Unit) ............................................................................................................................. 21
Power Assist Steering.................................................................................................................................... 23
Remove (Complete Unit) ........................................................................................................................... 23
Disassemble ............................................................................................................................................... 23
Support Base ......................................................................................................................................... 23
Steer Swivel........................................................................................................................................... 24
Assemble .................................................................................................................................................... 24
Steer Swivel........................................................................................................................................... 24
Support Base ......................................................................................................................................... 25
Install (Complete Unit) ............................................................................................................................. 26
Coast Control Option ......................................................................................................................................... 27
Disassemble ................................................................................................................................................... 27
Assemble ........................................................................................................................................................ 29
Checks ............................................................................................................................................................ 29
Troubleshooting.................................................................................................................................................. 30

©2008 HYSTER COMPANY i

Table of Contents Steering Mechanism

TABLE OF CONTENTS (Continued)

This section is for the following models:

B60Z AC [B230];
B80Z AC [B233]

ii
1600 SRM 1284 General

General
The control handle assembly is designed to perform is aligned and started properly, press the cover com-
several functions. The standard control handle in- pletely into the retaining clips and place the floor mat
cludes the speed/direction control and buttons for the into the operator platform around the cover.
horn, traction reversing, and hydraulic functions.
The control handle is connected to the Master Drive
Unit (MDU) and is used to steer the truck as it turns
the MDU. Move the control handle left or right to
turn the drive/steer tire and steer the truck. Con-
trols mounted in the handle are linked to the control
panel by a wiring harness that passes through the
center of the handle. The brake is applied when the
handle is in the full up or down position.

A top-mounted control handle assembly is used on

these lift trucks and is designed to be used while the
operator is either walking beside the truck or riding
on a small platform to the left or right side of the han-
dle. A power assist option is available that senses
when the operator begins to move the control handle
side to side and activates a motor in the drive unit
compartment to turn the drive unit. This greatly 1. FLOOR MAT
2. DRIVE UNIT COMPARTMENT COVER
reduces the operator effort needed to steer the lift 3. FRAME
truck. 4. CASTER ADJUSTMENT ACCESS

ACCESSING THE DRIVE UNIT Figure 1. Floor Mat

COMPARTMENT
The drive unit compartment is concealed behind a
molded cover which fits securely around the steer
support assembly and into the frame. The floor mat
fits snugly in the operator platform after the drive
unit cover has been installed.

To remove the drive unit cover, first lift the corners of

the floor mat and pull it out away from the drive unit.
See Figure 1. Next, reach under the side of the drive
unit cover near the bottom and find the grip slot. See
Figure 2. With both hands, pull up and away from
the truck until the bottom of the cover kicks out from
the retaining clips. Repeat this for the other side of
the cover. Work around the edge of the cover until it
is freed from the truck.

To install the drive unit cover, make sure the floor

mat is pulled away from the drive unit and place
the bottom of the drive unit cover onto the opera-
tor platform. Position the lower edges partially into
the lower retaining clips. Push the top of the cover 1. DRIVE UNIT COMPARTMENT COVER
2. RETAINER TABS
partially into the upper retaining clips. Do not push 3. GRIP SLOT
either edge of the cover in completely before start- 4. FRAME
ing all edges into the proper place. When the cover
Figure 2. Drive Unit Compartment Cover

1
Special Precautions 1600 SRM 1284

Special Precautions
DISCHARGING THE CAPACITORS

WARNING
The capacitor in the transistor controller can
hold an electrical charge after the battery is
disconnected. To prevent electrical shock and
personal injury, discharge the capacitor before
inspecting or repairing any component. Wear
safety glasses. Make certain the battery has
been disconnected. DO NOT use a screwdriver
to discharge the traction motor controller.

WARNING
To avoid personal injury and prevent electrical
shock, perform the following steps before per-
forming any troubleshooting or adjustments,
and connecting or disconnecting a handset or
PC.

CAUTION
To avoid controller damage, always disconnect
the battery. Discharge the capacitor and never
put power to the controller with any power
wire disconnected. Never short any controller
terminal or motor terminal to battery. Make
sure to use proper procedures when servicing
the controller.

1. Turn the key switch to the OFF position and dis-

connect the battery.

2. Remove the drive unit compartment cover to ac-

cess the controller. See Accessing the Drive Unit
Compartment.

3. Discharge the capacitors in the controllers by

connecting a 200-ohm, 2-watt resistor across
the controller’s B+ and B terminals using 1. CONTROLLER
2. POSITIVE CONNECTION
insulated jumper wires. See Figure 3. DO 3. INSULATED JUMPER WIRES
NOT short across the motor controller terminals 4. 200-OHM, 2-WATT RESISTOR
with a screwdriver or jumper wire. Remove the 5. NEGATIVE CONNECTION
200-ohm, 2-watt resistor before reconnecting the
battery. Figure 3. Discharging Controller - B60Z AC and
B80Z AC

2
1600 SRM 1284
Calibration
POWER ASSIST STEERING SENSOR
WARNING
If at any time a tiller handle slowly moves in
one direction during startup, it is likely cali-
bration needs to be performed.
Power assist steering calibration should be per-
formed if either the torque sensor or power assist
steering unit is serviced or replaced or anytime the
drive tire is replaced.
1. Position the lift truck on a normal, smooth sur-
face floor away from personnel or other equip-
ment with the drive tire centered.
2. Turn the key switch to the OFF position and re-
move the drive unit compartment cover.
3. The Calibration Tab is an unconnected wire
with a female spade connector hanging near the
ETACC CAN connector. Attach the Calibration
Tab to the B+ terminal of the controller, using
a 914 mm (36 in.) 14 Ga. jumper wire with
an alligator clip on one end and a male spade
connector on the other.
Control Handle
CONTROL HANDLE HEAD
The control handle head is primarily an electronic
component and is discussed in the electrical section.
For instructions on how to remove, install, or repair
the control handle head, refer to the section Electri-
cal System 2200 SRM 1287.
CONTROL HANDLE
The following procedures describe the removal and
disassembly of parts of the control handle and dash
assembly for repairs. The control handle and dash
assembly may also be removed as a single unit with
no further disassembly. This is useful when the con-
trol handle and dash assembly must be removed to
access other components of the lift truck. For instruc-
tion on how to remove the control handle and dash
assembly as a complete unit, see Steer Support As-
sembly in this section.
Control Handle
WARNING
DO NOT interfere with the lift truck or tiller
handle during the calibration cycle.
4. Standing clear of the steer handle, turn the key
switch to the ON position.
5. The lift truck will start up in calibration mode
and the tiller handle will begin to move on its own
power during the calibration cycle.
6. Wait at least 5 seconds after the calibration cycle
has ended (the tiller has stopped moving) and
remove the jumper wire.
7. Wait at least 5 seconds after the jumper wire is
removed and cycle the key switch to OFF and
then back to ON.
8. Check the lift truck for proper operation. Rein-
stall the drive unit compartment cover and re-
turn to the lift truck to service.
Standard Steering
WARNING
The gas springs used on the control handle are
installed under tension and can release with
enough force to cause personal injury or prop-
erty damage.
WARNING
The capacitor in the controller can hold an
electrical charge after the battery is discon-
nected. To prevent electrical shock and per-
sonal injury, discharge the capacitor before
inspecting or repairing any component in the
drive unit compartment. See Special Precau-
tions in this section. Wear safety glasses. Make
certain the battery has been disconnected.
Refer to Figure 4 for the following instructions.
3
Control Handle
Remove
1. Turn the key switch to the OFF position and dis-
connect the battery. Remove the drive unit com-
partment cover. See Accessing the Drive Unit
Compartment in this section.
2. Discharge the capacitors. See Special Precau-
tions in this section.
CAUTION
DO NOT cut the wiring harnesses when remov-
ing the wire ties.
NOTE: It is not necessary to remove the main wiring
harness unless harness is damaged and is being re-
placed.
3. CAREFULLY cut the wire ties securing the
brake, brake switch, and control handle wiring
harnesses together at the right rear of MDU.
NOTE: Be certain to note the routing of the wires
before disconnecting any wire. The wiring must be
routed properly at assembly to prevent steering prob-
lems and prevent chafing of the harness.
4. Tag and disconnect the brake wiring harness
(two-pin connector) located near the brake.
5. Tag and disconnect the control handle wiring
harness (eight-pin connector).
6. Remove cover from swivel by removing three
screws. See Figure 4.
NOTE: Be careful not to damage the brake switches
when removing the gas spring.
7. Remove the gas spring. See Gas Spring in this
section.
8. Remove the pin from control handle arm and
slide the pivot shaft out. Recover shims for later
installation. Remove the control handle arm
from the swivel.
9. Carefully pull the wiring harnesses through the
center of the support.
10. Remove bushings from the control handle arm if
necessary.
11. If necessary, remove the control handle head. See
the section Electrical System 2200 SRM 1287.
Remove nut and clamp and pull wiring harness
through control handle arm.
4
1600 SRM 1284
12. Remove two screws from the swivel and remove
the brake switches and nutplate.
Install
Refer to Figure 4 for the following instructions.
1. Install brake switches and nutplate into the
swivel using two screws.
2. Install bushings into the control handle arm if
removed.
3. Install the control handle head if removed. See
the section Electrical System 2200 SRM 1287.
Pull wiring harness through control handle arm
and secure with clamp and nut.
4. Route the control handle and brake switch
wiring harnesses down through the sleeves in
the support. Carefully pull the wiring harnesses
through the center of the support.
NOTE: Install shims onto pivot shafts as required to
minimize side-to-side movement of handle.
5. Install the control handle arm into the swivel us-
ing pivot shaft, shims, and pin. Install shims be-
tween the control handle arm and swivel on the
LEFT side of the swivel (side nearest the con-
troller).
6. Install the gas spring to the control handle. See
Gas Spring.
CAUTION
Make sure that the wiring is properly routed to
prevent steering problems and chafing of the
harness.
7. Connect the control handle wiring harness to the
main wiring harness.
8. Connect the brake switch connector and, if
equipped, the optional coast control.
CAUTION
Make sure the wiring harness is not wrapped
around the gas spring. Check the wiring har-
ness with the control handle in the full up and
full down positions. Turn the control handle
fully to the left and right to check for restric-
tions.
9. With the control handle in the upright position,
pull the harness and check for binding. Position
1600 SRM 1284 Control Handle

the wiring harness with slack distributed evenly
to allow for movement when the control handle
is turned in any direction.
10. Remove excess slack by bundling control handle,
brake, and brake switch wiring harnesses and
secure using wire ties.
11. Install cover to swivel using three screws.
12. Connect the battery and test the operation of the
truck prior to returning the lift truck to service.
13. Install the drive unit compartment cover and
floor mat as removed.

1. SCREW 16. CAPSCREW

2. COVER 17. BUSHING
3. PIN 18. SCREW
4. PIVOT SHAFT 19. WASHER
5. SWIVEL 20. CLAMP
6. GREASE FITTING 21. NUT
7. NUT 22. SCREW
8. NUT PLATE 23. LOCKWASHER
9. BRAKE SWITCHES 24. WASHER
10. SCREW 25. PLUG
11. SHIM 26. NUT
12. BUSHING 27. GAS SPRING
13. CONTROL ARM 28. CAPSCREW
14. PLUG 29. BUSHING
15. BALL PIVOT

Figure 4. Control Handle (Standard Steering)

5
Control Handle 1600 SRM 1284

Power Assist Steering NOTE: Be certain to note the routing of the wires
before disconnecting any wire. The wiring must be
routed properly at assembly to prevent steering prob-
WARNING
lems and prevent chafing of the harness.
The gas springs used on the control handle
have tension and can release with enough 4. Tag and disconnect the control handle wiring
force to cause personal injury or property harness (eight-pin connector).
damage.
5. Gently pry the Hyster plate from the center of the
swivel cover. Remove the two screws and wash-
WARNING ers securing the cover to the steer support and
The capacitor in the transistor controller can lift the cover off. See Figure 5.
hold an electrical charge after the battery
is disconnected. To prevent electrical shock
and personal injury, discharge the capacitor
before inspecting or repairing any component
in the drive unit compartment. Wear safety
glasses. Make certain the battery has been
disconnected.

Refer to Figure 7 for the following instructions:

Remove

1. Turn the key switch to the OFF position and dis-

connect the battery. Remove the drive unit com-
partment cover. See Accessing the Drive Unit
Compartment in this section.

2. Discharge the capacitors. See Special Precau-

tions in this section.
1. COVER
2. SCREW
CAUTION 3. WASHER
DO NOT cut the wiring harnesses when remov- 4. CONTROL ARM
5. SWIVEL COVER
ing the wire ties. 6. STEER SUPPORT BASE
7. DASH
NOTE: It is not necessary to remove the main wiring
harness unless harness is damaged and is being re- Figure 5. Swivel Cover
placed.

3. CAREFULLY cut the wire ties securing the

brake, brake switch, and control handle wiring
harnesses together at the right rear of MDU.

6
1600 SRM 1284 Control Handle

NOTE: Be careful not to damage the brake switch 9. Disconnect the main wiring harness from the po-
when removing the gas spring. tentiometer connector.

6. Remove the gas spring. Refer to Gas Spring in 10. Unscrew left and right pivot pin from swivel.
this section. Disassemble pivot pins as necessary for repair.

NOTE: Making note of potentiometer notch position NOTE: Make sure control handle wiring is discon-
can eliminate several steps during potentiometer in- nected/removed before removing control handle from
stallation. swivel.

7. Make note of potentiometer adjustment slot 11. Remove control handle from swivel. Remove
position and potentiometer notch orientation for bushings and grease fittings as necessary for
proper reassembly. See Figure 6. repair.

8. Remove the two screws and washers securing po- Install

tentiometer to swivel. Slide potentiometer off of
the sensor shaft. See Figure 7. Refer to Figure 7 for the following instructions.

NOTE: Install potentiometer side bushing with hole

aligned with grease port.

1. Install bushings and grease fittings if removed.

Assemble pivot pins if necessary.

2. Position control handle to swivel. Apply Loc-

tite® 242 to threads and install pivot pins to se-
cure. Tighten pivot pins to 95 to 102 N•m (70 to
75 lbf ft)

3. Reconnect control handle wiring as removed. Re-

fer to tags for proper identification. Install wire
ties as removed to secure control handle wiring
to main harness.

NOTE: Be careful not to damage the brake switch

when installing the gas spring.

1. SENSOR SHAFT 4. Install the gas spring. Refer to Gas Spring in this
2. POTENTIOMETER section.
3. ADJUSTMENT SLOTS
4. POTENTIOMETER NOTCH

Figure 6. Potentiometer Position

7
Control Handle 1600 SRM 1284

1. BUSHING 6. WASHER 11. STEER SWIVEL

2. PIN 7. POTENTIOMETER 12. GREASE FITTING
3. PIVOT PIN 8. GEAR COVER 13. DRIVE-IN PIN
4. SENSOR SHAFT 9. SUPPORT BASE 14. GREASE FITTING
5. CAPSCREW 10. BUSHING 15. PIVOT PIN

Figure 7. Control Handle Mounting (Power Assist Steering)

8
1600 SRM 1284 Control Handle

NOTE: If the pivot pin has been removed, the poten- d. Calibrate the tiller angle potentiometer. Re-
tiometer must be set manually (skip to Step 6). fer to the sections User Interface, Super-
visor Functions On-Board Dash Display
5. If the sensor shaft rests in the same orientation 2200 SRM 1323 or User Interface, Service
after pivot pin has been reinstalled or if the pivot Technician Functions On-Board Dash
pin was not removed, the potentiometer may be Display 2200 SRM 1324 for calibration pro-
installed using the following steps: cedures. If the calibration screens display
errors during calibration, the potentiometer
a. Turn the potentiometer notch to the same po-
may have to be set manually (refer to Step 6).
sition as removed. Connect the main wiring
If the tiller angle is calibrated successfully,
harness to the potentiometer connector as re-
skip to Step 7.
moved.
6. If the potentiometer must be set manually, in-
b. With the control handle in the full upright
stall the potentiometer using the following steps:
position, install potentiometer onto the sen-
sor shaft with the potentiometer notch in the a. Position the potentiometer onto the sensor
same position as removed. See Figure 8. shaft with the wiring harness disconnected.
Apply Loctite® 242 and loosely install two
c. Turn potentiometer so adjustment slots are
screws and washers through the adjustment
oriented as when removed. Apply Loctite®
slots into the steer swivel. See Figure 9.
242 and install two screws and washers
through the adjustment slots into the steer
swivel. Torque to 1.3 to 2.0 N•m (12 to
18 lbf in). See Figure 9.

1. STEER SWIVEL
1. SENSOR SHAFT 2. PIVOT PIN
2. POTENTIOMETER 3. SCREWS AND WASHERS
3. ADJUSTMENT SLOTS 4. POTENTIOMETER
4. POTENTIOMETER NOTCH 5. SENSOR SHAFT

Figure 8. Potentiometer Adjust Figure 9. Potentiometer Install

9
Control Handle
b. Turn the potentiometer to the full counter-
clockwise position. Tighten screws to 1.3 to
2.0 N•m (12 to 18 lbf in). See Figure 10.
c. Connect one ohmmeter lead to the center pin
and the other lead to either outer pin. The
ohmmeter will read between 0 and 5 kOhms.
Slowly lower the tiller handle and watch
the ohmmeter reading progress toward 5
kOhms. If the potentiometer reading passes
5 kOhms before the tiller is completely low-
ered, the potentiometer will reach the end of
its operating range and the ohmmeter will
restart increasing from 0 kOhms.
NOTE: If the potentiometer does not show a lineal
increase from 0 to 5 kOhms and restart increasing
from 0 kOhms as the potentiometer notch is manu-
ally rotated in a full circle, the potentiometer may be
malfunctioning. Make sure ohmmeter is functioning
properly and leads are making good contact with the
proper terminals.
Figure 10. Potentiometer Adjust
10
1600 SRM 1284
d. If the potentiometer steadily increases be-
tween 0 and 5 kOhms throughout the entire
range when the tiller handle is lowered, the
potentiometer is properly adjusted.
NOTE: If calibration cannot be completed after poten-
tiometer has been manually set, the potentiometer
may be malfunctioning. Replace potentiometer only
if manual setting and calibration procedures have
been thoroughly exhausted.
e. Calibrate the properly adjusted potentiome-
ter. Refer to the sections User Interface,
Supervisor Functions On-Board Dash
Display 2200 SRM 1323 or User Interface,
Service Technician Functions On-Board
Dash Display 2200 SRM 1324 for calibra-
tion procedures. If the calibration screens
display errors during calibration, the poten-
tiometer may have to be set manually (refer
to Step 6). If the tiller angle is calibrated
successfully, skip to Step 7.
f. If the potentiometer reaches the end of its
operating range before the tiller is fully low-
ered (if the ohmmeter passes 5 kOhms and
restarts increasing from 0 kOhms), loosen
the screws and turn the potentiometer to the
full clockwise position. Retighten the screws
at the opposite end of the adjustment slots.
Lower the tiller again and check the ohmme-
ter. If the potentiometer stays within its op-
erating range, the potentiometer is properly
adjusted. Return to Step e for calibration.
g. If the potentiometer cannot be adjusted to
stay between 0 and 5 kOhms throughout the
entire range when the tiller handle is low-
ered, the potentiometer notch must be ro-
tated 180 . Turn the key switch to the OFF
position. Remove the capscrews and wash-
ers and slide the potentiometer off the sensor
shaft. Rotate the potentiometer notch 180
using a small screwdriver then reinstall. Re-
turn to Step 6 to check for proper adjustment
again. See Figure 11.
7. Turn the key switch to the OFF position and dis-
connect the battery to continue installation. Po-
sition the cover to the steer swivel and install the
two screws and washers to secure. Gently snap
the Hyster plate into the center of the swivel
cover.
1600 SRM 1284
8. Install drive unit compartment covers. See Ac-
cessing the Drive Unit Compartment in this sec-
tion.
9. Connect the battery and turn the key switch to
the ON position and test for proper operation.
Return the lift truck to service.
Gas Spring
WARNING
Disconnect the battery by separating the bat-
tery connector before opening the compart-
ment cover and before inspecting or repairing
the electrical system. DO NOT place tool on
top of the battery. If a tool causes a short
circuit, the high-current flow from the battery
can cause personal injury or property damage.
WARNING
The capacitor in the traction motor controller
can hold an electrical charge after the battery
is disconnected. To prevent electrical shock
and personal injury, discharge the capacitor
before inspecting or repairing any component.
Make certain the battery has been discon-
nected and always wear safety glasses. See
Special Precautions in this section. DO NOT
attempt to discharge the capacitors by short-
ing the controller.
WARNING
The gas spring used on the control handle is
installed under tension and can release with
enough force to cause personal injury or prop-
erty damage.
Review the following procedures before removing the
gas spring.
Gas Spring
Figure 11. Rotate Notch 180
DISCHARGING THE GAS SPRING
WARNING
Goggles and a face shield must be worn for per-
sonal protection as metal chips and hydraulic
lubricant may be ejected from the drill opera-
tion due to the high internal pressure.
CAUTION
The control handle return spring is charged
with pressurized gas and contains a hydraulic
oil lubricant.
NOTE: This process is a destructive operation to the
gas spring. A new gas spring must be used during
reassembly.
1. Check that the handle return spring is installed
and properly secure the control handle arm in the
full upright position. Remove the plastic plugs to
increase visibility of the gas spring.
CAUTION
DO NOT damage the control handle wiring har-
ness inside the control handle arm.
2. Locate and drill a 7 mm (0.25 in.) access hole
through the center of the control handle tube, ap-
proximately 50 mm (2 in.) below the existing ac-
cess hole.
11
Gas Spring 1600 SRM 1284

WARNING
Contents are under pressure. This process may
eject metal chips and oil.

3. Locate the gas spring inside the control handle

through the newly drilled access hole and drill a
3 mm (0.125 in.) hole into the gas spring cylinder
shell to relieve pressure.

4. Clean up any discharged oil and dispose of in ac-

cordance with local regulations.

REMOVE
To remove the gas spring from the control handle:

1. Remove the stop bolt from the control handle

arm.

2. Remove the plastic plugs to access the gas spring.

1. GREASE FITTING
3. Discharge the pressure from the gas spring. See 2. PIVOT PIN
3. BRAKE SWITCH
Discharging the Gas Spring. 4. RETAINING PIN
5. SWIVEL
6. BUSHING
CAUTION 7. ROD END
DO NOT damage the control handle wiring har- 8. SUPPORT BASE
ness inside the control handle arm. 9. GREASE FITTING
10. GAS SPRING ROD
4. Remove the retention clip from the gas spring
ball socket. Disconnect the gas spring from the Figure 12. Gas Spring Lower Connection
ball stud. (Power Assist Shown)

5. Remove the ball stud(s) from inside the control
arm (and swivel, if equipped) as necessary.
6. On Standard Steering models, remove the hard-
ware securing the rod end of the gas spring to the
tiller swivel.
CAUTION
Be careful not to damage the sensor when driv-
ing out the pin.
7. On Power Assist Models, tap the retaining pin
from the sensor side out toward the brake switch
side of the steer swivel using a suitable punch
and hammer. Remove the gas spring. See Fig-
ure 12.
INSTALL
1. Install ball stud and nut into control arm if re-
moved. Tighten to 27 N•m (20 lbf ft).
2. Lubricate both connection points with multipur-
pose lithium complex grease with 2 to 4% molyb-
denum.
CAUTION
DO NOT damage the control handle wiring har-
ness inside the control handle arm.
3. Make certain the control handle arm is secured
in the full upright position and position the new
gas spring into the control handle arm. Connect
the upper end of the gas spring to the ball stud
inside the control handle arm. Install the reten-
tion clip to the gas spring ball socket as removed.
CAUTION
Be careful not to damage the brake switch
while driving in the pin.
4. On Power Assist Steer models, align the lower
end of the gas spring with the steer swivel re-
taining pin using a flat screwdriver and hold in

12
1600 SRM 1284 Articulating Shaft and Pinions (Power Assist Models)

position. Drive the retaining pin into the swivel 6. Install the plastic plugs to the access holes on the
until flush. control handle shaft as removed.

NOTE: Apply Loctite® 242 to the capscrew threads NOTE: Apply Loctite® 242 to the capscrew threads
before installing the nut. before installing the jam nut.

5. On Standard Steer models, align the lower end of
the gas spring into position using a screwdriver
and hold in position. Install the hardware se-
curing the rod end of the gas spring to the steer
swivel. Tighten to 27 N•m (20 lbf ft).
7. Install the stop bolt and jam nut to the control
handle arm as removed.
8. Test for proper operation. Install covers as re-
moved.

Articulating Shaft and Pinions (Power Assist Models)

REMOVE
1. Turn the key switch to the OFF position and dis-
connect battery. Remove the drive unit compart-
ment covers.
the gear pin from the articulated shaft. Secure
the articulated shaft out of the way.
10. Remove the capscrew and lock nut from the bot-
tom of the articulated shaft.

2. Discharge the capacitor. See Special Precautions 11. Remove the articulating shaft from the lower
in this section. pinion shaft. See Figure 13.

3. Gently pry the Hyster cover from the center of

the steer support cover. Remove the two screws
and washers securing the cover to the steer sup-
port and lift the cover off.

4. Loosen the two screws and remove the dash as-

sembly. Secure dash out of the way or tag, iden-
tify, and disconnect all wiring from the BDI dis-
play and key switch if necessary to remove the
dash. Refer to Electrical System 2200 SRM
1287.

5. Remove the capscrew and lock nut from the top

of the articulated shaft.

6. Secure a sling around the steer support plate. At-

tach an overhead lifting device of sufficient ca-
pacity to the sling. Tighten the lifting device to
support the weight of the steering support.

7. Slightly loosen the two upper capscrews, nuts,

and washers that hold the steering support to the
frame.

8. Remove the two lower capscrews, nuts, and

washers that secure the steering support to the
frame. Figure 13. Articulating Shaft
9. Lift the steer support (control arm end) so that
it pivots on the two upper capscrews to separate

13
Articulating Shaft and Pinions (Power Assist Models) 1600 SRM 1284

Legend for Figure 13

CAUTION
1. CAPSCREW Ensure that pinion shaft notch and steer swivel
2. CAPSCREW
3. CAPSCREW (control handle) are aligned in the "straight
4. ARTICULATING SHAFT ahead" position before continuing.
5. CAPSCREW
6. SUPPORT BASE 4. Install the pinion into the support base with the
7. UPPER PINION SHAFT (NOTCH FORWARD) notch aligned with the steer swivel (control han-
8. WASHER dle) in the straight ahead position. Position the
9. WASHER
gear cover to the support base and install two
10. WASHER
11. LOCK NUT screws and washers to secure.
12. WASHER
13. LOCK NUT
14. LOCK NUT
15. LOCKWASHER

PINION REPAIR

CAUTION
Steering functions will not operate properly
if pinions are not aligned properly with steer
swivel (control handle) and drive tire.

Remove and repair the pinion assemblies as neces-

sary.

Upper Pinion
After removing the articulating shaft, the upper pin-
ion can be removed from the support base for repair.

1. Remove the cover plate from the steer support.

See Figure 14.
1. STEER SWIVEL
NOTE: Disassemble only as necessary for repair. 2. WASHER
3. SCREW
2. Lift the pinion assembly from the support base. 4. STEER SUPPORT GEAR
Remove bearing from shaft. Drive pin from gear 5. PINION GEAR
and remove gear from shaft as necessary. See 6. GEAR COVER
Figure 15. 7. SUPPORT BASE
8. TILLER SENSOR
3. Install gear to shaft as removed. Align hole in
gear with hole in shaft and install retaining pin. Figure 14. Gear Cover
Install bearing onto shaft.

14
1600 SRM 1284 Articulating Shaft and Pinions (Power Assist Models)

1. LOWER PINION SHAFT (NOTCH FORWARD)

2. LOWER PINION MOUNTING PLATE
3. LOWER PINION GEAR
4. STEER MOTOR GEAR
5. MOUNTING SCREWS
1. PINION GEAR 6. STEER GEAR
2. PINION SHAFT 7. DRIVE UNIT HOUSING
3. BEARING 8. TRACTION MOTOR
4. CAPSCREW 9. STEER MOTOR
5. ARTICULATING SHAFT
6. RETAINING PIN
7. WASHER Figure 16. Lower Pinion Mounting
8. LOCK NUT
1. Remove the capscrew, lockwasher, washer, and
Figure 15. Upper Pinion Assembly gear retaining washer from bottom of pinion as-
sembly. Remove gear from shaft and recover the
Lower Pinion Woodruff key. Remove pinion shaft and bearing
from mounting bracket. Remove bearing from
After removing the articulating shaft, the lower pin- shaft. See Figure 17.
ion can be removed from the mounting plate for re-
pair. See Figure 16.

15
Articulating Shaft and Pinions (Power Assist Models) 1600 SRM 1284

INSTALL

CAUTION
Ensure that the drive tire and notch of the
lower pinion shaft are aligned in the steer
swivel (control handle) are aligned in the
"straight ahead" position.

Ensure that the steer swivel (control handle)

and notch of the upper pinion shaft are aligned
in the "straight ahead" position.

1. Align the notch of the upper and lower articu-

lated shaft pinions in the "straight ahead" posi-
tion.

2. Install the articulated shaft onto the lower pinion

shaft. Install the capscrew into the lower clevis of
the articulated shaft next to the flat of the pinion
to secure. Install the lock nut and torque to 14 to
20 N•m (10 to 15 lbf ft).

1. LOWER PINION MOUNTING BRACKET 3. Lift the steer support (control arm end) up so that
2. WASHER it pivots on the two upper capscrews. Position the
3. LOCKWASHER articulated shaft to the pinion.
4. CAPSCREW
5. RETAINING WASHER 4. Lower the steer support (control arm end) while
6. GEAR
7. BEARING guiding the articulated shaft onto the pinion
8. WOODRUFF KEY shaft.
9. PINION SHAFT
5. Install the remaining two lower capscrews,
Figure 17. Lower Pinion Assembly washers, and nuts securing the steer support to
the frame. Tighten all four capscrews to 41 to
2. Install new bearing onto shaft and position 47 N•m (30 to 35 lbf ft). Remove the sling and
into mounting bracket as removed. Install the lifting device.
Woodruff key into shaft. Align pinion shaft with
the notch in the "straight ahead" position. 6. Install the capscrew into the clevis of the articu-
lated shaft next to the flat of the pinion to secure.
Install the lock nut and torque to 14 to 20 N•m
CAUTION
(10 to 15 lbf ft).
Steering functions will not operate properly if
pinion is not installed with notch aligned prop- 7. Install the dash to the steer support as removed.
erly with drive tire. Secure using two screws. Refer to Electrical
System 2200 SRM 1287.
3. Slide gear onto shaft and key. Secure in place
with gear retaining washer, washer, lockwasher, 8. Replace the drive unit compartment covers as re-
and capscrew as removed. moved. Reconnect the battery and turn the key
switch to the ON position. Test for proper opera-
tion.

16
1600 SRM 1284 Steer Motor Assembly

Steer Motor Assembly

REPAIR
The steer motor assembly consists of three primary
sections: the electric motor, the gearbox, and the
steer motor gear. Repair procedure vary greatly de-
pending on what components are being serviced. If
only the electric motor or the steer motor gear is to
be replaced, they may simply be replaced on the as-
sembly while installed to the drive unit. See Steer
Motor, Replace and Steer Motor Gear, Replace. How-
ever if the gearbox or total assembly replacement is
necessary, the steer motor assembly and lower ar-
ticulating shaft bracket and gear must be removed
from the drive unit. This requires very specific align-
ment when reinstalling. See Gearbox/Complete As-
sembly, Replace. Remove only components neces-
sary to safely complete repairs. In some instances,
total replacement may be preferred over component
repair. Discuss repair options with your supervisor.
Begin all repairs to the steer motor assembly with
the following procedures:

1. Turn the key switch to the OFF position and dis-

connect battery. Remove the drive unit compart-
ment covers. See Accessing the Drive Unit Com-
partment.

2. Discharge the capacitor. See Special Precautions

in this section.

Steer Motor, Replace

Refer to Figure 18 for the following procedures.

1. Tag and disconnect all power cables and wiring

from the steer motor.

2. Remove the two capscrews and washers securing

the motor to the gearbox. Lift the motor from the
gearbox and remove from the lift truck.

3. Position the new steer motor on to the gearbox as

removed.

4. Install two screws and washers securing electric

motor to gearbox.

NOTE: Refer to tags on cables for proper reinstalla- 1. STEER MOTOR

tion. 2. GEARBOX
3. WASHER
5. Install wiring and cables to steer motor as re- 4. CAPSCREW
5. SHAFT
moved. 6. WOODRUFF KEY
6. Calibrate the power assist steering sensor. See Figure 18. Steer Motor
Calibration in this section.

17
Steer Motor Assembly 1600 SRM 1284

Steer Motor Gear, Replace
Refer to Figure 19 for the following procedures.
1. Remove the capscrew and washer from the bot-
tom of the steer motor gear.
2. Slide the gear from the motor shaft and recover
the Woodruff key.
NOTE: Make sure the groove in the gear is aligned
with the Woodruff key when installing.
3. Install the Woodruff key into the groove in the
motor shaft and install the steer gear onto the
shaft and key.
4. Install the washer and capscrew securing gear to
shaft as removed.
Gearbox/Complete Assembly, Replace
Refer to Figure 18 and Figure 19 for the following
procedures.
CAUTION
Very small variations of gear installations can
prevent steering systems from operating prop-
erly.
1. Mark the articulating shaft lower pinion gear
and the steer gear so it can be reassembled in
the exact same place. Refer to Articulating Shaft
and Pinions (Power Assist Models) for more in-
formation.

2. Remove the steering motor gear. See Steer Motor

Gear, Replace.

NOTE: The screws that secure the steer motor also

secure the articulating shaft lower bearing bracket
to the drive unit housing.

3. Remove the four screws securing the steer motor

to the drive unit housing. Secure the articulating
shaft and bearing bracket out of the way.

4. Remove the steer motor assembly from the lift

truck. Repair or replace as necessary.

5. If replacing the gearbox, remove the two screws

and washer securing the electric motor to the
gearbox. Remove the gearbox from the motor and
install the new gearbox. Secure in place with two
screws and washers as removed.

6. Position the steer motor assembly to the drive

1. LOWER PINION SHAFT unit housing as removed.
2. BEARING
3. WOODRUFF KEY
4. LOWER PINION GEAR CAUTION
5. WASHER Very small variations can prevent steering sys-
6. CAPSCREW tems from operating properly.
7. CAPSCREW
8. WASHER
9. STEER MOTOR GEAR 7. Align the marks on the articulating shaft lower
10. WOODRUFF KEY pinion gear with the mark on the steer gear as
11. SCREW removed. Refer to Articulating Shaft and Pin-
12. WASHER ions (Power Assist Models) for more information
13. BRACKET on gear alignment. Position the lower bearing
14. STEER MOTOR
bracket to the drive unit housing as removed and
Figure 19. Steer Motor Assembly install four capscrews securing bracket and steer
motor to the drive unit housing.

18
1600 SRM 1284
NOTE: Make sure the groove in the gear is aligned
with the Woodruff key when installing.
8. Install the Woodruff key into the groove in the
motor shaft and install the steer gear onto the
shaft and key.
Steer Support Assembly
STANDARD STEERING
WARNING
The steering assembly and dash is heavy and
requires the use of an overhead lifting device
to position it during removal and installation.
Be sure the overhead lifting device is adequate
to lift the steer support assembly.
The following instructions are for removing the
entire steer support assembly without disassembly.
This procedure is useful when the dash and control
handle must be removed for access to other parts
of the lift truck such as when removing the trac-
tion motor. Some items may be serviced without
removing the steer support assembly. Remove only
the components necessary to safely complete the
required service.
Remove (Complete Unit)
1. Turn the key switch to the OFF position and dis-
connect battery. Remove the drive unit compart-
ment covers.
2. Discharge the capacitor. See Special Precautions
in this section.
3. Remove the three screws securing the cover to
the steer support and lift the cover off.
4. Loosen the two screws and remove the dash as-
sembly. Secure dash out of the way or tag, iden-
tify, and disconnect all wiring from the BDI dis-
play and key switch if necessary to totally remove
the dash. See Electrical System 2200 SRM
1287.
5. Identify, tag, and disconnect the control handle
wiring harness, the brake switches, and coast
control harness (if equipped) from the main
wiring harness. Clip the wire tie securing the
harnesses to the main harness for removal.
Steer Support Assembly
9. Install cover and floor mat as removed. See Ac-
cessing the Drive Unit Compartment. Connect
the battery and turn the key switch to the ON
position. Test for proper operation.
6. Remove the hardware securing the connecting
plate to the steer support and to the MDU. Re-
move the connecting plate.
7. Secure a sling around the steer support plate. At-
tach an overhead lifting device of sufficient ca-
pacity to the sling. Tighten the lifting device to
support the weight of the steering support. See
Figure 21.
8. Remove the four capscrews, washers, and nuts
securing the steer support assembly to the frame.
9. Using the overhead lifting device, carefully re-
move the steer support from the frame.
Disassemble
For the following instructions, refer to Figure 20.
1. Remove control handle swivel:
a. Remove cover by removing three screws.
b. Remove nut by bending tabs on locking
washer down using a flat screwdriver and
turning nut counterclockwise.
c. Remove nut and locking washer.
2. Lift control handle swivel off dash and stand-off
shaft and recover Woodruff key.
3. Remove dash cover by removing screws. Refer
to Electrical System 2200 SRM 1287 for addi-
tional information.
4. Remove stand-off, spacer, and lower bearing:
a. Remove capscrews, washers, and nuts secur-
ing stand-off to steer plate.
b. Lower stand-off and bearing assembly from
the support.
19
Steer Support Assembly 1600 SRM 1284

1. SCREWS 13. CENTER SUPPORT

2. SWIVEL COVER 14. LOWER BEARING CUP
3. WIRE SLEEVE 15. LOWER BEARING CONE
4. BEARING NUT 16. SPACER
5. LOCKING WASHER 17. STEER SHAFT
6. KEY 18. WIRE SLEEVE
7. SWIVEL 19. NUT
8. NUT PLATE 20. WASHER
9. BRAKE SWITCHES 21. WASHER
10. SCREWS 22. CAPSCREW
11. UPPER BEARING CONE 23. STEER PLATE
12. UPPER BEARING CUP

Figure 20. Steer Support (Standard Steering)

20
1600 SRM 1284
c. Remove the lower bearing from stand-off us-
ing a standard bearing puller then remove
spacer by hand.
d. Remove lower sleeve from bottom of stand-
off.
5. Remove upper sleeve, spacer, and upper bearing.
NOTE: Use a brass punch to remove bearing races.
Be careful not to damage bearing races or support
when during removal.
6. Clean and inspect bearing races for pits and
grooves.
7. Remove bearing races from support using a ham-
mer and brass punch if necessary.
Assemble
1. Install bearing races to support using a hammer
and proper size bearing driver, if removed.
2. Pack bearings with Hyster synthetic grease, P/N
2074114, using a standard bearing packing de-
vice. Place a liberal coating of synthetic grease
on the surface of the bearing races.
3. Install stand-off and bearing assembly:
a. Install spacer and lower bearing to stand-off
using a press.
b. Install sleeve to bottom of stand-off.
c. Lift stand-off and bearing assembly into the
support.
d. Install capscrews, washers, and nuts to se-
cure stand-off to steer plate.
4. Install upper bearing and spacer to stand-off
shaft.
5. Position Woodruff key into groove on stand-off
shaft and lower swivel onto shaft. Turn swivel
left and right alternately to align groove with
Steer Support Assembly
Woodruff key WHILE holding Woodruff key in
place.
6. Apply antiseize lubricant to threads and install
locking washer and nut to end of stand-off shaft.
Tighten nut to 26 N•m (19 lbf ft) and bend tabs
on locking washer against nut.
7. Install sleeve.
8. Install control handle wiring harness through
support.
9. Place cover on swivel and secure with screws.
Install (Complete Unit)
1. Using the overhead lifting device, carefully po-
sition the steer support to the frame. Align the
holes in the steer support with mounting holes in
the frame. See Figure 21.
2. Install the four capscrews, washers, and nuts se-
curing the steer support to the frame. Tighten to
88 N•m (65 lbf ft). Remove the sling and lifting
device.
3. Connect the control handle wiring harness, the
brake switch, and the sensor from the main
wiring harness as noted. Install a new wire tie
securing the harnesses to the main harness as
removed.
4. Reconnect wiring to the BDI display and key
switch if removed. Align the slots in the dash
with the retaining screws and position the dash
to the steering support and frame. Tighten the
two screws to secure the dash assembly in place.
See Electrical System 2200 SRM 1287.
5. Position the cover onto the steer swivel. Install
the three screws securing the cover in place.
6. Install the drive unit compartment covers as re-
moved. Connect the battery and turn the key
switch to the ON position. Test for proper opera-
tion.
21
Steer Support Assembly 1600 SRM 1284

1. STRAP 6. LOCKWASHER
2. TILLER HANDLE 7. WASHER
3. SUPPORT 8. WASHER
4. ARTICULATING SHAFT 9. CAPSCREW
5. NUT

Figure 21. Steering and Dash Removal (Power Assisted Steering Shown)

22
1600 SRM 1284 Steer Support Assembly

POWER ASSIST STEERING 8. Remove the remaining capscrews, nuts, and

WARNING
The steering assembly and dash is heavy and
requires the use of an overhead lifting device
to position it during removal and installation.
Be sure the overhead lifting device is adequate
to lift the steer support assembly.
washers securing the steer support to the frame.
9. Using the overhead lifting device, carefully re-
move the steer support from the frame.
Disassemble
Support Base

The following instructions are for removing the
entire steer support assembly without disassembly.
This procedure is useful when the dash and control
handle must be removed for access to other parts
of the lift truck such as when removing the trac-
tion motor. Some items may be serviced without
removing the steer support assembly. Remove only
the components necessary to safely complete the
required service.
Remove (Complete Unit)
1. Turn the key switch to the OFF position and dis-
connect battery. Remove the drive unit compart-
ment covers.
The support base may be disassembled to access the
lower bearing, the steering gear, or the torque sensor.
1. Remove the steer support assembly as a unit if
necessary to access the support base. See Stan-
dard Steering in this section. Move the assembly
onto a clean workstation and securely support in
position for disassembly.
2. Remove the two screws and washers securing the
gear cover and remove. See Figure 22. Lift the
pinion from the support base. Disassemble as
necessary for repair. Refer to Articulating Shaft
and Pinions (Power Assist Models).

2. Discharge the capacitor. See Special Precautions

in this section.

3. Gently pry the Hyster cover from the center of

the steer support cover. Remove the two screws
and washers securing the cover to the steer sup-
port and lift the cover off.

4. Loosen the two screws and remove the dash as-

sembly. Secure dash out of the way or tag, iden-
tify, and disconnect all wiring from the BDI dis-
play and key switch if necessary to remove the
dash. See Electrical System 2200 SRM 1287.

5. Identify, tag, and disconnect the control handle

wiring harness, the brake switch, and the sensor
from the main wiring harness. Clip the wire tie
securing the harnesses to the main harness for
removal.

6. Remove the articulated shaft. Refer to Articulat-

ing Shaft and Pinions (Power Assist Models) in 1. STEER SWIVEL
2. WASHER
this section. 3. SCREW
4. STEER GEAR
7. Lower the overhead lifting device until the steer 5. PINION
support rests on top of the brake. Readjust the 6. GEAR COVER
sling and tighten to support the steer support 7. SUPPORT BASE
evenly. 8. POTENTIOMETER

Figure 22. Steer Gear and Pinion

23
Steer Support Assembly 1600 SRM 1284

Legend for Figure 24

1. SWIVEL
2. CENTER SUPPORT
3. ALIGNMENT PIN
4. TORQUE SENSOR
5. TORSION SHAFT
6. PIN
7. STEER GEAR
8. POSITION KEY
9. BEARING
10. RETAINING RING

6. Separate the torque sensor from the steer gear.

7. Check that sensor guard (not illustrated) is se-

curely mounted to the underside of the center
support and properly engages with the sensor to
prevent rotation. Replace as necessary.
1. SUPPORT BASE Steer Swivel
2. SNAP RING
3. CAPSCREW AND LOCKWASHER The steer swivel may be disassembled to access the
4. CENTER SUPPORT
5. PINION SHAFT steer swivel bearings. The support base must be
disassembled first in order to disassemble the steer
Figure 23. Support Base swivel. See Remove (Complete Unit).

3. Remove two capscrews and washers from the bot-
tom of the support base. See Figure 23. Lower
the support base from the center support.
4. Remove the snap ring and bearing (if necessary)
from the support base using an appropriate-sized
driver if necessary.
5. Remove the pin from the bottom of the steer gear
and lower the gear and torque sensor from the
torsion shaft. See Figure 24.
1. Remove the bearing nut from the bottom of the
steer support. See Figure 25.
2. Lift the swivel assembly from the top of the cen-
ter support and place on a clean workbench.
3. Remove the lower bearing from the bottom of the
center support.
4. Remove the upper bearing from the swivel.
5. Remove the pin securing the torsion shaft to the
swivel. Remove the torsion shaft.

Assemble
Steer Swivel

1. Position the torsion shaft into the swivel and

align the pin holes. Apply Loctite® 641 and
install the pin securing the torsion shaft to the
swivel. Refer to Figure 25.

2. On the lower swivel bearing, apply Loctite® 641

to where the inner race seats to the swivel shaft
and where the outer race seats to the center sup-
port flange. Install the lower bearing to the cen-
ter support using a proper size driver.

Figure 24. Steer Gear and Torque Sensor

24
1600 SRM 1284 Steer Support Assembly

CAUTION
The position key must remain installed in the
torque sensor until items are assembled per in-
structions. Truck will not operate correctly if
position key is removed early.

NOTE: Fit should be tight; no tools necessary to as-

semble torque sensor to steer gear.

NOTE: Check that sensor guard (not illustrated) is

securely mounted to the underside of the center sup-
port and properly engages with the sensor to prevent
rotation. Replace as necessary.

1. Position the sensor to the top of the gear oriented

with the position key facing the gear. Align the
detent of gear with detent of sensor and assem-
ble. See Figure 26.

1. SWIVEL
2. PIN
3. UPPER BEARING
4. TORSION SHAFT
5. CENTER SUPPORT
6. LOWER BEARING
7. BEARING NUT

Figure 25. Swivel and Bearing Assembly

3. On the upper swivel bearing, apply Loctite® 641

to where the inner race seats to the swivel shaft 1. SWIVEL
2. CENTER SUPPORT
and where the outer race seats to the center sup- 3. ALIGNMENT PIN
port flange. Install the swivel and bearing as- 4. TORQUE SENSOR
sembly into the center support. Carefully lower 5. TORSION SHAFT
the swivel shaft through the lower bearing. 6. PIN
7. STEER GEAR
4. Apply Loctite® 242 and install the bearing nut 8. POSITION KEY
9. BEARING
onto the swivel shaft against the lower bearing. 10. RETAINING RING
Tighten slowly, periodically turning the swivel to
prevent binding. Torque to 20 to 27 N•m (15 to Figure 26. Support Base Installation
20 lbf ft).
NOTE: Fit should be tight; no tools are necessary to
Support Base assemble sensor to gear.
The steer swivel must be assembled before the sup- 2. Install sensor and gear onto torsion bar. Align
port base may be assembled. See Install (Complete upper detent of sensor with detent in swivel
Unit). shaft. Assemble sensor and gear assembly to
swivel shaft and hold in place. Install pin to
secure lower end of torsion bar to bottom of gear.

25
Steer Support Assembly
3. Squeeze the position key bars together and pull
to remove key from the sensor.
4. Apply Loctite® 641 to the inside of the inner race
of the support bearing and install onto the lower
shaft of the steer gear. Install the snap ring to
the lower steer gear against the bearing.
CAUTION
Steering functions will not operate properly if
pinion is not aligned with steer swivel (control
handle).
5. Assemble the pinion assembly as necessary for
repair. Refer to Articulating Shaft and Pinions
(Power Assist Models) in this section. Install
the pinion into the support base with the notch
aligned with the steer swivel (control handle) in
the straight ahead position. Position the gear
cover to the support base and install two screws
and washers to secure. See Figure 22.
6. Position the support base to the bottom of the
center support as removed. Make sure the bear-
ing properly seats into the flange of the support
base. Install two capscrews and lockwashers to
the bottom of the support base. Torque capscrews
to 40 N•m (30 lbf ft). See Figure 27.
1. SUPPORT BASE
2. SUPPORT BEARING AND SNAP RING
3. CAPSCREW AND LOCKWASHER
4. CENTER SUPPORT
5. PINION SHAFT
Figure 27. Support Base
26
1600 SRM 1284
Install (Complete Unit)
1. Align the drive tire and the notch of the lower
articulated shaft pinion in the "straight ahead"
position.
2. Using the overhead lifting device, carefully po-
sition the steer support to the frame. Align the
holes in the steer support with mounting holes in
the frame.
3. Loosely install the two upper capscrews, wash-
ers, and nuts securing the steer support to the
frame.
4. Lift the steer support (control arm end) up so that
it pivots on the two upper capscrews. Position the
articulated shaft to the pinion.
WARNING
Ensure that the drive tire, steer swivel (control
handle), and upper and lower pinion shafts are
aligned properly before installing the articu-
lating shaft.
5. Install the articulating shaft. Refer to Articulat-
ing Shaft and Pinions (Power Assist Models) in
this section.
6. Install the remaining two lower capscrews,
washers, and nuts securing the steer support to
the frame. Tighten all four capscrews to 41 to
47 N•m (30 to 35 lbf ft). Remove the sling and
lifting device.
7. Connect the control handle wiring harness, the
brake switch, and the torque sensor to the main
wiring harness as noted. Install a new wire tie
securing the harnesses to the main harness as
removed.
8. Reconnect wiring to the BDI display and key
switch if removed. Align the slots in the dash
with the retaining screws and position the dash
to the steering support and frame. Tighten the
two screws to secure the dash assembly in place.
See Electrical System 2200 SRM 1287.
9. Position the cover onto the steer support. Install
the two screws and washers securing the cover
in place. Place the Hyster plate into the center
of the steer support cover and press to secure in
place.
10. Calibrate the power assist steering sensor. See
Calibration in this section.
1600 SRM 1284 Coast Control Option

11. Install the drive unit compartment covers as re-

CAUTION
Before putting on cover, raise and lower the
control handle to make certain the control han-
dle wiring and coast control (optional) wiring
does not bind.
moved. Connect the battery and turn the key
switch to the ON position. Test for proper opera-
tion.

Coast Control Option

DISASSEMBLE
1. Remove six screws and remove the cover halves
from the control handle. See Figure 28.

2. Remove four nuts, washers, and screws retaining

the guard to the control handle. See Figure 29.

3. Remove the guard from the control handle.

1. NUT 4. CONTROL
2. WASHER HANDLE
3. SCREW 5. GUARD

Figure 29. Guard

4. Disconnect the coast control wiring harness from

1. SCREW the main wiring harness.
2. COVER
3. CONTROL HANDLE 5. Remove the retaining ring and pin retaining the
4. GUARD coast control unit to the control handle. See Fig-
ure 30.
Figure 28. Covers

27
Coast Control Option 1600 SRM 1284

8. Remove the coast control unit from the lift truck.

9. Remove clevis from end of coast control cylinder

rod. See Figure 32.

10. Remove nut from rod and remove boot.

NOTE: The coast control unit is non-serviceable and

must be replaced as a complete unit.

1. PIN
2. SCREW
3. NUT
4. WASHER
5. RETAINING RING
6. CONTROL HANDLE

Figure 30. Mounting

1. INSERT
6. On Power Steer trucks only, remove the insert 2. SCREW
from the steering pivot cover and remove the two 3. COVER
screws retaining the cover. See Figure 31. Re- 4. CONTROL HANDLE
move the cover.
Figure 31. Cover
7. Remove the screw, washer, and nut retaining the
coast control rod to the lower mount. See Fig-
ure 30.

28
1600 SRM 1284 Coast Control Option

5. Assemble the coast control unit to the control

handle using the pin and retaining ring. See Fig-
ure 30.

6. Align the clevis with the lower coast control unit

mount and install the shoulder bolt, washer, and
nut.

7. On Power Steer trucks, install the steering pivot

cover and install the two screws to retain the
cover. See Figure 31. Install the insert.

8. Connect the coast control unit wiring harness to

the main harness connections.

9. Install the coast control guard to the control han-

dle. See Figure 29.

10. Install the cover halves to the guard using

screws. See Figure 28.
1. COAST CONTROL UNIT NOTE: Ensure the alignment tabs on the boot align
2. BOOT with the slots in the cover halves.
3. NUT
4. CLEVIS
CHECKS
Figure 32. Clevis
1. With the coast control engaged, the lift truck
ASSEMBLE speed must not exceed 4.0 mph.

1. Install the boot over the rod. See Figure 32. 2. With the coast control engaged, the control han-
dle must be able to be manually moved to the
2. Thread the nut supplied with the coast control fully up or fully down position to engage the lift
unit to the end of the threads on the rod. truck brake.

3. Apply Loctite 242 to the threads on the end of the
rod.
4. Thread the clevis onto the rod until it touches the
nut. Tighten the nut against the clevis to lock the
clevis in place.
3. Place the control handle in the travel position
and engage the coast control. The control handle
should remain in the travel position.
4. Coast control function should not engage above
4.0 mph.

29
Troubleshooting 1600 SRM 1284

Troubleshooting

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

Steering is rough or difficult. Power steering sensor out of calibra- Calibrate power steering sensor.
tion.

Power steering fuse blown. Check fuses/replace as necessary.

Steering handle swivel bearing(s) Lubricate or repack bearings.

need lubrication.

Bearing retaining nut torque incor- Loosen retaining nut and re-torque to
rect. 19 N•m (26 lbf ft).

Steering handle does not re- Gas spring is weak or broken. Replace gas spring.
turn to the vertical position.

Gas spring ball stud broken or loose. Retighten or replace gas spring ball
stud.

30
 TECHNICAL PUBLICATIONS

1600 SRM 1284 7/08 (12/06)(11/06) Printed in U.S.A.