Beruflich Dokumente
Kultur Dokumente
B60Z AC [B230];
B80Z AC [B233]
• 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.
• 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.
• 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
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.
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.
2
1600 SRM 1284 Control Handle
Calibration
POWER ASSIST STEERING SENSOR WARNING
DO NOT interfere with the lift truck or tiller
WARNING handle during the calibration cycle.
If at any time a tiller handle slowly moves in
one direction during startup, it is likely cali- 4. Standing clear of the steer handle, turn the key
bration needs to be performed. switch to the ON position.
Power assist steering calibration should be per- 5. The lift truck will start up in calibration mode
formed if either the torque sensor or power assist and the tiller handle will begin to move on its own
steering unit is serviced or replaced or anytime the power during the calibration cycle.
drive tire is replaced.
6. Wait at least 5 seconds after the calibration cycle
1. Position the lift truck on a normal, smooth sur- has ended (the tiller has stopped moving) and
face floor away from personnel or other equip- remove the jumper wire.
ment with the drive tire centered.
7. Wait at least 5 seconds after the jumper wire is
2. Turn the key switch to the OFF position and re- removed and cycle the key switch to OFF and
move the drive unit compartment cover. then back to ON.
3. The Calibration Tab is an unconnected wire 8. Check the lift truck for proper operation. Rein-
with a female spade connector hanging near the stall the drive unit compartment cover and re-
ETACC CAN connector. Attach the Calibration turn to the lift truck to service.
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 Standard Steering
The control handle head is primarily an electronic
component and is discussed in the electrical section. WARNING
For instructions on how to remove, install, or repair The gas springs used on the control handle are
the control handle head, refer to the section Electri- installed under tension and can release with
cal System 2200 SRM 1287. enough force to cause personal injury or prop-
erty damage.
CONTROL HANDLE
The following procedures describe the removal and WARNING
disassembly of parts of the control handle and dash The capacitor in the controller can hold an
assembly for repairs. The control handle and dash electrical charge after the battery is discon-
assembly may also be removed as a single unit with nected. To prevent electrical shock and per-
no further disassembly. This is useful when the con- sonal injury, discharge the capacitor before
trol handle and dash assembly must be removed to inspecting or repairing any component in the
access other components of the lift truck. For instruc- drive unit compartment. See Special Precau-
tion on how to remove the control handle and dash tions in this section. Wear safety glasses. Make
assembly as a complete unit, see Steer Support As- certain the battery has been disconnected.
sembly in this section.
Refer to Figure 4 for the following instructions.
3
Control Handle 1600 SRM 1284
Remove 12. Remove two screws from the swivel and remove
the brake switches and nutplate.
1. Turn the key switch to the OFF position and dis-
connect the battery. Remove the drive unit com- Install
partment cover. See Accessing the Drive Unit
Compartment in this section. Refer to Figure 4 for the following instructions.
2. Discharge the capacitors. See Special Precau- 1. Install brake switches and nutplate into the
tions in this section. swivel using two screws.
NOTE: Be certain to note the routing of the wires NOTE: Install shims onto pivot shafts as required to
before disconnecting any wire. The wiring must be minimize side-to-side movement of handle.
routed properly at assembly to prevent steering prob-
lems and prevent chafing of the harness. 5. Install the control handle arm into the swivel us-
ing pivot shaft, shims, and pin. Install shims be-
4. Tag and disconnect the brake wiring harness tween the control handle arm and swivel on the
(two-pin connector) located near the brake. LEFT side of the swivel (side nearest the con-
troller).
5. Tag and disconnect the control handle wiring
harness (eight-pin connector). 6. Install the gas spring to the control handle. See
Gas Spring.
6. Remove cover from swivel by removing three
screws. See Figure 4.
CAUTION
NOTE: Be careful not to damage the brake switches Make sure that the wiring is properly routed to
when removing the gas spring. prevent steering problems and chafing of the
harness.
7. Remove the gas spring. See Gas Spring in this
section. 7. Connect the control handle wiring harness to the
main wiring harness.
8. Remove the pin from control handle arm and
slide the pivot shaft out. Recover shims for later 8. Connect the brake switch connector and, if
installation. Remove the control handle arm equipped, the optional coast control.
from the swivel.
4
1600 SRM 1284 Control Handle
the wiring harness with slack distributed evenly 11. Install cover to swivel using three screws.
to allow for movement when the control handle
is turned in any direction. 12. Connect the battery and test the operation of the
truck prior to returning the lift truck to service.
10. Remove excess slack by bundling control handle,
brake, and brake switch wiring harnesses and 13. Install the drive unit compartment cover and
secure using wire ties. floor mat as removed.
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.
Remove
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.
1. SENSOR SHAFT 4. Install the gas spring. Refer to Gas Spring in this
2. POTENTIOMETER section.
3. ADJUSTMENT SLOTS
4. POTENTIOMETER NOTCH
7
Control Handle 1600 SRM 1284
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
9
Control Handle 1600 SRM 1284
b. Turn the potentiometer to the full counter- d. If the potentiometer steadily increases be-
clockwise position. Tighten screws to 1.3 to tween 0 and 5 kOhms throughout the entire
2.0 N•m (12 to 18 lbf in). See Figure 10. range when the tiller handle is lowered, the
potentiometer is properly adjusted.
c. Connect one ohmmeter lead to the center pin
and the other lead to either outer pin. The NOTE: If calibration cannot be completed after poten-
ohmmeter will read between 0 and 5 kOhms. tiometer has been manually set, the potentiometer
Slowly lower the tiller handle and watch may be malfunctioning. Replace potentiometer only
the ohmmeter reading progress toward 5 if manual setting and calibration procedures have
kOhms. If the potentiometer reading passes been thoroughly exhausted.
5 kOhms before the tiller is completely low-
ered, the potentiometer will reach the end of e. Calibrate the properly adjusted potentiome-
its operating range and the ohmmeter will ter. Refer to the sections User Interface,
restart increasing from 0 kOhms. Supervisor Functions On-Board Dash
Display 2200 SRM 1323 or User Interface,
NOTE: If the potentiometer does not show a lineal Service Technician Functions On-Board
increase from 0 to 5 kOhms and restart increasing Dash Display 2200 SRM 1324 for calibra-
from 0 kOhms as the potentiometer notch is manu- tion procedures. If the calibration screens
ally rotated in a full circle, the potentiometer may be display errors during calibration, the poten-
malfunctioning. Make sure ohmmeter is functioning tiometer may have to be set manually (refer
properly and leads are making good contact with the to Step 6). If the tiller angle is calibrated
proper terminals. successfully, skip to Step 7.
10
1600 SRM 1284 Gas Spring
Gas Spring
DISCHARGING THE GAS SPRING
WARNING
Disconnect the battery by separating the bat-
WARNING
tery connector before opening the compart-
ment cover and before inspecting or repairing Goggles and a face shield must be worn for per-
the electrical system. DO NOT place tool on sonal protection as metal chips and hydraulic
top of the battery. If a tool causes a short lubricant may be ejected from the drill opera-
circuit, the high-current flow from the battery tion due to the high internal pressure.
can cause personal injury or property damage.
CAUTION
WARNING The control handle return spring is charged
The capacitor in the traction motor controller with pressurized gas and contains a hydraulic
can hold an electrical charge after the battery oil lubricant.
is disconnected. To prevent electrical shock
NOTE: This process is a destructive operation to the
and personal injury, discharge the capacitor
gas spring. A new gas spring must be used during
before inspecting or repairing any component.
reassembly.
Make certain the battery has been discon-
nected and always wear safety glasses. See 1. Check that the handle return spring is installed
Special Precautions in this section. DO NOT and properly secure the control handle arm in the
attempt to discharge the capacitors by short- full upright position. Remove the plastic plugs to
ing the controller. increase visibility of the gas spring.
WARNING CAUTION
The gas spring used on the control handle is DO NOT damage the control handle wiring har-
installed under tension and can release with ness inside the control handle arm.
enough force to cause personal injury or prop-
erty damage. 2. Locate and drill a 7 mm (0.25 in.) access hole
through the center of the control handle tube, ap-
Review the following procedures before removing the proximately 50 mm (2 in.) below the existing ac-
gas spring. cess hole.
11
Gas Spring 1600 SRM 1284
WARNING
Contents are under pressure. This process may
eject metal chips and oil.
REMOVE
To remove the gas spring from the control handle:
5. Remove the ball stud(s) from inside the control 2. Lubricate both connection points with multipur-
arm (and swivel, if equipped) as necessary. pose lithium complex grease with 2 to 4% molyb-
denum.
6. On Standard Steering models, remove the hard-
ware securing the rod end of the gas spring to the CAUTION
tiller swivel.
DO NOT damage the control handle wiring har-
ness inside the control handle arm.
CAUTION
Be careful not to damage the sensor when driv- 3. Make certain the control handle arm is secured
ing out the pin. in the full upright position and position the new
gas spring into the control handle arm. Connect
7. On Power Assist Models, tap the retaining pin the upper end of the gas spring to the ball stud
from the sensor side out toward the brake switch inside the control handle arm. Install the reten-
side of the steer swivel using a suitable punch tion clip to the gas spring ball socket as removed.
and hammer. Remove the gas spring. See Fig-
ure 12.
CAUTION
INSTALL Be careful not to damage the brake switch
while driving in the pin.
1. Install ball stud and nut into control arm if re-
moved. Tighten to 27 N•m (20 lbf ft). 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 7. Install the stop bolt and jam nut to the control
the gas spring into position using a screwdriver handle arm as removed.
and hold in position. Install the hardware se-
curing the rod end of the gas spring to the steer 8. Test for proper operation. Install covers as re-
swivel. Tighten to 27 N•m (20 lbf ft). moved.
2. Discharge the capacitor. See Special Precautions 11. Remove the articulating shaft from the lower
in this section. pinion shaft. See Figure 13.
13
Articulating Shaft and Pinions (Power Assist Models) 1600 SRM 1284
PINION REPAIR
CAUTION
Steering functions will not operate properly
if pinions are not aligned properly with steer
swivel (control handle) and drive tire.
Upper Pinion
After removing the articulating shaft, the upper pin-
ion can be removed from the support base for repair.
14
1600 SRM 1284 Articulating Shaft and Pinions (Power Assist Models)
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.
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
17
Steer Motor Assembly 1600 SRM 1284
Steer Motor Gear, Replace 4. Install the washer and capscrew securing gear to
shaft as removed.
Refer to Figure 19 for the following procedures.
Gearbox/Complete Assembly, Replace
1. Remove the capscrew and washer from the bot-
tom of the steer motor gear. Refer to Figure 18 and Figure 19 for the following
procedures.
2. Slide the gear from the motor shaft and recover
the Woodruff key.
CAUTION
NOTE: Make sure the groove in the gear is aligned Very small variations of gear installations can
with the Woodruff key when installing. prevent steering systems from operating prop-
3. Install the Woodruff key into the groove in the erly.
motor shaft and install the steer gear onto the 1. Mark the articulating shaft lower pinion gear
shaft and key. 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.
18
1600 SRM 1284 Steer Support Assembly
NOTE: Make sure the groove in the gear is aligned 9. Install cover and floor mat as removed. See Ac-
with the Woodruff key when installing. cessing the Drive Unit Compartment. Connect
the battery and turn the key switch to the ON
8. Install the Woodruff key into the groove in the position. Test for proper operation.
motor shaft and install the steer gear onto the
shaft and key.
19
Steer Support Assembly 1600 SRM 1284
20
1600 SRM 1284 Steer Support Assembly
c. Remove the lower bearing from stand-off us- Woodruff key WHILE holding Woodruff key in
ing a standard bearing puller then remove place.
spacer by hand.
6. Apply antiseize lubricant to threads and install
d. Remove lower sleeve from bottom of stand- locking washer and nut to end of stand-off shaft.
off. Tighten nut to 26 N•m (19 lbf ft) and bend tabs
on locking washer against nut.
5. Remove upper sleeve, spacer, and upper bearing.
7. Install sleeve.
NOTE: Use a brass punch to remove bearing races.
Be careful not to damage bearing races or support 8. Install control handle wiring harness through
when during removal. support.
6. Clean and inspect bearing races for pits and 9. Place cover on swivel and secure with screws.
grooves.
Install (Complete Unit)
7. Remove bearing races from support using a ham-
mer and brass punch if necessary. 1. Using the overhead lifting device, carefully po-
sition the steer support to the frame. Align the
Assemble holes in the steer support with mounting holes in
the frame. See Figure 21.
1. Install bearing races to support using a hammer
and proper size bearing driver, if removed. 2. Install the four capscrews, washers, and nuts se-
curing the steer support to the frame. Tighten to
2. Pack bearings with Hyster synthetic grease, P/N 88 N•m (65 lbf ft). Remove the sling and lifting
2074114, using a standard bearing packing de- device.
vice. Place a liberal coating of synthetic grease
on the surface of the bearing races. 3. Connect the control handle wiring harness, the
brake switch, and the sensor from the main
3. Install stand-off and bearing assembly: wiring harness as noted. Install a new wire tie
securing the harnesses to the main harness as
a. Install spacer and lower bearing to stand-off
removed.
using a press.
4. Reconnect wiring to the BDI display and key
b. Install sleeve to bottom of stand-off.
switch if removed. Align the slots in the dash
c. Lift stand-off and bearing assembly into the with the retaining screws and position the dash
support. to the steering support and frame. Tighten the
two screws to secure the dash assembly in place.
d. Install capscrews, washers, and nuts to se- See Electrical System 2200 SRM 1287.
cure stand-off to steer plate.
5. Position the cover onto the steer swivel. Install
4. Install upper bearing and spacer to stand-off the three screws securing the cover in place.
shaft.
6. Install the drive unit compartment covers as re-
5. Position Woodruff key into groove on stand-off moved. Connect the battery and turn the key
shaft and lower swivel onto shaft. Turn swivel switch to the ON position. Test for proper opera-
left and right alternately to align groove with 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
The following instructions are for removing the The support base may be disassembled to access the
entire steer support assembly without disassembly. lower bearing, the steering gear, or the torque sensor.
This procedure is useful when the dash and control
handle must be removed for access to other parts 1. Remove the steer support assembly as a unit if
of the lift truck such as when removing the trac- necessary to access the support base. See Stan-
tion motor. Some items may be serviced without dard Steering in this section. Move the assembly
removing the steer support assembly. Remove only onto a clean workstation and securely support in
the components necessary to safely complete the position for disassembly.
required service.
2. Remove the two screws and washers securing the
gear cover and remove. See Figure 22. Lift the
Remove (Complete Unit)
pinion from the support base. Disassemble as
1. Turn the key switch to the OFF position and dis- necessary for repair. Refer to Articulating Shaft
connect battery. Remove the drive unit compart- and Pinions (Power Assist Models).
ment covers.
23
Steer Support Assembly 1600 SRM 1284
3. Remove two capscrews and washers from the bot- 1. Remove the bearing nut from the bottom of the
tom of the support base. See Figure 23. Lower steer support. See Figure 25.
the support base from the center support.
2. Lift the swivel assembly from the top of the cen-
4. Remove the snap ring and bearing (if necessary) ter support and place on a clean workbench.
from the support base using an appropriate-sized
driver if necessary. 3. Remove the lower bearing from the bottom of the
center support.
5. Remove the pin from the bottom of the steer gear
and lower the gear and torque sensor from the 4. Remove the upper bearing from the swivel.
torsion shaft. See Figure 24. 5. Remove the pin securing the torsion shaft to the
swivel. Remove the torsion shaft.
Assemble
Steer Swivel
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.
1. SWIVEL
2. PIN
3. UPPER BEARING
4. TORSION SHAFT
5. CENTER SUPPORT
6. LOWER BEARING
7. BEARING NUT
25
Steer Support Assembly 1600 SRM 1284
3. Squeeze the position key bars together and pull Install (Complete Unit)
to remove key from the sensor.
1. Align the drive tire and the notch of the lower
4. Apply Loctite® 641 to the inside of the inner race articulated shaft pinion in the "straight ahead"
of the support bearing and install onto the lower position.
shaft of the steer gear. Install the snap ring to
the lower steer gear against the bearing. 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
CAUTION the frame.
Steering functions will not operate properly if
pinion is not aligned with steer swivel (control 3. Loosely install the two upper capscrews, wash-
handle). ers, and nuts securing the steer support to the
frame.
5. Assemble the pinion assembly as necessary for
repair. Refer to Articulating Shaft and Pinions 4. Lift the steer support (control arm end) up so that
(Power Assist Models) in this section. Install it pivots on the two upper capscrews. Position the
the pinion into the support base with the notch articulated shaft to the pinion.
aligned with the steer swivel (control handle) in
the straight ahead position. Position the gear WARNING
cover to the support base and install two screws Ensure that the drive tire, steer swivel (control
and washers to secure. See Figure 22. handle), and upper and lower pinion shafts are
6. Position the support base to the bottom of the aligned properly before installing the articu-
center support as removed. Make sure the bear- lating shaft.
ing properly seats into the flange of the support 5. Install the articulating shaft. Refer to Articulat-
base. Install two capscrews and lockwashers to ing Shaft and Pinions (Power Assist Models) in
the bottom of the support base. Torque capscrews this section.
to 40 N•m (30 lbf ft). See Figure 27.
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.
26
1600 SRM 1284 Coast Control Option
1. NUT 4. CONTROL
2. WASHER HANDLE
3. SCREW 5. GUARD
27
Coast Control Option 1600 SRM 1284
1. PIN
2. SCREW
3. NUT
4. WASHER
5. RETAINING RING
6. CONTROL HANDLE
28
1600 SRM 1284 Coast Control Option
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 3. Place the control handle in the travel position
rod. and engage the coast control. The control handle
should remain in the travel position.
4. Thread the clevis onto the rod until it touches the
nut. Tighten the nut against the clevis to lock the 4. Coast control function should not engage above
clevis in place. 4.0 mph.
29
Troubleshooting 1600 SRM 1284
Troubleshooting
Steering is rough or difficult. Power steering sensor out of calibra- Calibrate power steering sensor.
tion.
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
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