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
Electromagnetic Shield (Power Assist 6/2009⇒) ......................................................................................... 3
Calibration.......................................................................................................................................................... 3
Power Assist Steering.................................................................................................................................... 3
Control Handle................................................................................................................................................... 4
Control Handle Head..................................................................................................................................... 4
Control Handle .............................................................................................................................................. 4
Standard Steering ..................................................................................................................................... 4
Remove .................................................................................................................................................. 4
Install..................................................................................................................................................... 6
Power Assist Steering (⇒ 5/2009) ............................................................................................................ 6
Remove .................................................................................................................................................. 6
Install..................................................................................................................................................... 8
Power Assist Steering (6/2009 ⇒) ............................................................................................................ 11
Remove .................................................................................................................................................. 11
Install..................................................................................................................................................... 12
Gas Spring .......................................................................................................................................................... 14
Discharging the Gas Spring .......................................................................................................................... 14
Remove .......................................................................................................................................................... 14
Install ............................................................................................................................................................. 15
Articulating Shaft and Pinions (Power Assist Models).................................................................................... 16
Remove ........................................................................................................................................................... 16
Pinion Repair ................................................................................................................................................. 16
Upper Pinion.............................................................................................................................................. 17
Lower Pinion.............................................................................................................................................. 18
Install ............................................................................................................................................................. 19
Steer Motor Assembly........................................................................................................................................ 19
Repair ............................................................................................................................................................. 19
Steer Motor, Replace ................................................................................................................................. 19
Steer Motor Gear, Replace ........................................................................................................................ 20
Gearbox/Complete Assembly, Replace...................................................................................................... 21
Steer Support Assembly .................................................................................................................................... 21
Standard Steering ......................................................................................................................................... 21
Remove (Complete Unit) ........................................................................................................................... 21
Disassemble ............................................................................................................................................... 22
Assemble .................................................................................................................................................... 22
Install (Complete Unit) ............................................................................................................................. 24
Power Assist Steering (Option)..................................................................................................................... 25
Remove (Complete Unit) ........................................................................................................................... 25
Disassemble ............................................................................................................................................... 25
Support Base ......................................................................................................................................... 25
Steer Swivel........................................................................................................................................... 27
Assemble .................................................................................................................................................... 27
Steer Swivel........................................................................................................................................... 27
Support Base ......................................................................................................................................... 28
Install (Complete Unit) ............................................................................................................................. 30
Coast Control Option ......................................................................................................................................... 30
Disassemble ................................................................................................................................................... 30

©2009 HYSTER COMPANY i

Table of Contents Steering Mechanism

TABLE OF CONTENTS (Continued)

Assemble ........................................................................................................................................................ 31
Checks ............................................................................................................................................................ 32
Troubleshooting.................................................................................................................................................. 33

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
several functions. The standard control handle in-
cludes the speed/direction control and buttons for the
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- 1. FLOOR MAT
2. DRIVE UNIT COMPARTMENT COVER
dle. A power assist option is available that senses 3. FRAME
when the operator begins to move the control handle 4. CASTER ADJUSTMENT ACCESS
side to side and activates a motor in the drive unit
compartment to turn the drive unit. This greatly Figure 1. Floor Mat
reduces the operator effort needed to steer the lift
truck. Power assist steer models up to and including
those trucks built in May 2009 (denoted as ⇒5/2009)
differ slightly in construction from those built from
June 2009 to the present (denoted as 6/2009⇒). Al-
though the two models operate virtually the same, it
is important to use the proper instructions for your
model lift truck when performing service or repairs.

ACCESSING THE DRIVE UNIT

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 1. DRIVE UNIT COMPARTMENT COVER
Figure 2. With both hands, pull up and away from 2. RETAINER TABS
the truck until the bottom of the cover kicks out from 3. GRIP SLOT
the retaining clips. Repeat this for the other side of 4. FRAME
the cover. Work around the edge of the cover until it Figure 2. Drive Unit Compartment Cover
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
Special Precautions 1600 SRM 1284

partially into the upper retaining clips. Do not push is aligned and started properly, press the cover com-
either edge of the cover in completely before start- pletely into the retaining clips and place the floor mat
ing all edges into the proper place. When the cover into the operator platform around the cover.

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

ELECTROMAGNETIC SHIELD (POWER
ASSIST 6/2009⇒)
WARNING
Never operate Power Assist models built
6/2009⇒ with the Electromagnetic Shield re-
moved.
A metallic shield is installed between the MDU and
brake assembly and the steering assembly on power
assist steering units built from 6/2009 to the present.
This shield deflects the electromagnetic field gener-
ated by the MDU and brake assembly which can in-
terfere with the operation of the torque sensor. Make
certain that the Electromagnetic Shield is reinstalled
before operating the lift truck after servicing to pre-
vent erratic operation of the power assist steering
function.

Calibration
POWER ASSIST STEERING WARNING
The following calibration instructions apply to all DO NOT interfere with the lift truck or tiller
power assist steering models. handle during the calibration cycle.

5. Standing clear of the steer handle, turn the key

WARNING switch to the ON position.
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 (right post) of the con-
tactor, 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.

NOTE: If lift truck is not equipped with coast control,

use a the control arm stop bolt, or wedge a deep well A. BRAKE ON
socket or 50 mm (2.00 in.) by 20 mm (0.75 in.)wood B. REGEN BRAKING
block into the control arm/swivel joint area to hold C. BRAKE OFF
the control arm in the Brake OFF position.
Figure 4. Brake Activation
4. Position the control arm in the Brake OFF posi-
tion (see Figure 4) and secure in position using
the coast control stop flipped forward.

3
Control Handle
NOTE: Communication error codes may appear dur-
ing this process. This is a normal part of the calibra-
tion process.
6. 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.
7. Wait at least 5 seconds after the calibration cycle
has ended (the tiller has stopped moving) and
remove the jumper wire.
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.
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.
4
1600 SRM 1284
8. Wait at least 5 seconds after the jumper wire is
removed and cycle the key switch to OFF and
then back to ON.
9. If no Power Steering error appears, the power
steering system was calibrated successfully.
10. Check the lift truck for proper operation. Rein-
stall the drive unit compartment cover and re-
turn to the lift truck to service.
Refer to Figure 5 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.
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 5.
NOTE: Be careful not to damage the brake switches
when removing the gas spring.
1600 SRM 1284 Control Handle

7. Remove the gas spring. See Gas Spring in this 10. Remove bushings from the control handle arm if
section. necessary.

8. Remove the pin from control handle arm and 11. If necessary, remove the control handle head. See
slide the pivot shaft out. Recover shims for later the section Electrical System 2200 SRM 1287.
installation. Remove the control handle arm Remove nut and clamp and pull wiring harness
from the swivel. through control handle arm.

9. Carefully pull the wiring harnesses through the 12. Remove two screws from the swivel and remove
center of the support. the brake switches and nutplate.

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 5. Control Handle (Standard Steering)

5
Control Handle
Install
Refer to Figure 5 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.
6
1600 SRM 1284
9. With the control handle in the upright position,
pull the harness and check for binding. Position
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.
Power Assist Steering (⇒ 5/2009)
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 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
in the drive unit compartment. Wear safety
glasses. Make certain the battery has been
disconnected.
The following instructions apply to power assist
steering lift trucks built up to and including those
produced in May of 2009 (denoted as ⇒5/2009).
Refer to Figure 8.
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.
1600 SRM 1284 Control Handle

6. Remove the gas spring. Refer to Gas Spring in

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.
this section.
NOTE: Making note of potentiometer notch position
can eliminate several steps during potentiometer in-
stallation.
7. Make note of potentiometer adjustment slot
position and potentiometer notch orientation for
proper reassembly. See Figure 7.
8. Remove the two screws and washers securing po-
tentiometer to swivel. Slide potentiometer off of
the sensor shaft. See Figure 8.
9. Disconnect the main wiring harness from the po-
tentiometer connector.

4. Tag and disconnect the control handle wiring 10. Unscrew left and right pivot pin from swivel.
harness (eight-pin connector). Disassemble pivot pins as necessary for repair.

5. Gently pry the Hyster plate from the center of the
swivel cover. Remove the two screws and wash-
ers securing the cover to the steer support and
lift the cover off. See Figure 6.
NOTE: Make sure control handle wiring is discon-
nected/removed before removing control handle from
swivel.
11. Remove control handle from swivel. Remove
bushings and grease fittings as necessary for
repair.

1. COVER
2. SCREW
3. WASHER
4. CONTROL ARM
5. SWIVEL COVER 1. SENSOR SHAFT
6. STEER SUPPORT BASE 2. POTENTIOMETER
7. DASH 3. ADJUSTMENT SLOTS
4. POTENTIOMETER NOTCH
Figure 6. Swivel Cover
Figure 7. Potentiometer Position
NOTE: Be careful not to damage the brake switch
when removing the gas spring.

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 8. Control Handle Mounting (Power Assist Steering ⇒5/2009)

Install 2. Position control handle to swivel. Apply Loc-

Refer to Figure 8 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.
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)
NOTE: If the control arm wiring harness has been
replaced with the replacement kit on these models,

8
1600 SRM 1284 Control Handle

studs in the kit should be installed into the swivel us-

ing an Allen wrench and the wiring harness bracket
positioned onto the studs. The swivel cover will be in-
stalled directly on top of the wiring harness bracket
later and will then be secured by installing two nuts
and washers onto the studs. The screws formerly
securing the cover to the swivel will no longer be
needed.

3. Reconnect control arm 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.

4. Install the gas spring. Refer to Gas Spring in this

section.
1. SENSOR SHAFT
2. POTENTIOMETER
NOTE: If the pivot pin has been removed, the poten- 3. ADJUSTMENT SLOTS
tiometer must be set manually (skip to Step 6). 4. POTENTIOMETER NOTCH
5. If the sensor shaft rests in the same orientation Figure 9. Potentiometer Adjust
after pivot pin has been reinstalled or if the pivot
pin was not removed, the potentiometer may be
installed using the following steps:

a. Turn the potentiometer notch to the same po-

sition as removed. Connect the main wiring
harness to the potentiometer connector as re-
moved.

b. With the control handle in the full upright

position, install potentiometer onto the sen-
sor shaft with the potentiometer notch in the
same position as removed. See Figure 9.

c. Turn potentiometer so adjustment slots are

oriented as when removed. Apply Loctite®
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 10.

d. Calibrate the tiller angle potentiometer. Re-

fer to the sections User Interface, Super- 1. STEER SWIVEL
visor Functions On-Board Dash Display 2. PIVOT PIN
2200 SRM 1323 or User Interface, Service 3. SCREWS AND WASHERS
Technician Functions On-Board Dash 4. POTENTIOMETER
5. SENSOR SHAFT
Display 2200 SRM 1324 for calibration pro-
cedures. If the calibration screens display Figure 10. Potentiometer Install
errors during calibration, the potentiometer
may have to be set manually (refer to Step 6). 6. If the potentiometer must be set manually, in-
If the tiller angle is calibrated successfully, stall the potentiometer using the following steps:
skip to Step 7.

9
Control Handle
a. Position the potentiometer onto the sensor
shaft with the wiring harness disconnected.
Apply Loctite® 242 and loosely install two
screws and washers through the adjustment
slots into the steer swivel. See Figure 10.
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 11.
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.
Figure 11. Potentiometer Adjust
10
1600 SRM 1284
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.
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 12.
1600 SRM 1284
NOTE: If the control arm wiring harness has been
replaced with the replacement kit on these models,
then the swivel cover will install over studs in the
swivel holding a wiring harness bracket in position.
The swivel cover will then be secured by installing
two nuts and washers onto the studs. The screws for-
merly securing the cover to the swivel will no longer
be needed.
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. Lightly
coat the edges of the Hyster plate with silicone
sealant and gently snap the plate into the center
of the swivel cover.
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.
Figure 12. Rotate Notch 180
Control Handle
Power Assist Steering (6/2009 ⇒)
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 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
in the drive unit compartment. Wear safety
glasses. Make certain the battery has been
disconnected.
Refer to Figure 8 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.
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 tag, identify, and note the rout-
ing of the wires before disconnecting any wire. The
wiring must be routed properly at assembly to pre-
vent steering problems and prevent chafing of the
harness.
4. Tag and disconnect the control handle wiring
harness from the main wiring harness.
11
Control Handle 1600 SRM 1284

5. Gently pry the Hyster plate from the center of the
swivel cover. Remove the two nuts and washers
securing the cover to the steer support studs and
lift the cover off. See Figure 13.
10. Unscrew left pivot pin from control arm. Remove
grease fitting if necessary.
NOTE: Make sure control handle wiring is discon-
nected/removed before removing control arm from
swivel.

11. Separate control arm from swivel. See Figure 14.

Install

Refer to Figure 14 for the following instructions.

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.
1. NUT
2. WASHER NOTE: Be careful not to damage the brake switches
3. STUD
4. CONTROL ARM when installing the gas spring.
5. SWIVEL COVER
6. STEER SUPPORT BASE 4. Install the gas spring. Refer to Gas Spring in this
7. DASH section.
8. PLATE
5. Calibrate the tiller angle potentiometer. Refer
Figure 13. Swivel Cover to the sections User Interface, Supervisor
Functions On-Board Dash Display 2200
6. Tag, identify, and disconnect the control handle SRM 1323 or User Interface, Service Tech-
wiring from the brake switches. Remove the two nician Functions On-Board Dash Display
screws and spacer securing brake switches to the 2200 SRM 1324 for calibration procedures.
swivel. Remove the switches.
6. Position the cover to the steer swivel and install
7. Disconnect the proximity switch from the main the two screws and washers to secure. Gently
wiring harness. Remove the jam nut from the snap the Hyster plate into the center of the
switch and unscrew switch from the MDU. swivel cover.
NOTE: Be careful not to damage the brake switches 7. Install drive unit compartment covers. See Ac-
when removing the gas spring. cessing the Drive Unit Compartment in this sec-
tion.
8. Remove the gas spring. Refer to Gas Spring in
this section. 8. Connect the battery and turn the key switch to
the ON position and test for proper operation.
9. Unscrew right pivot pin from swivel. Remove
Return the lift truck to service.
grease fitting if necessary.

12
1600 SRM 1284 Control Handle

1. SWIVEL 12. NUT

2. STUD 13. GAS SPRING
3. NUT 14. BALL STUD
4. CAPSCREW 15. BUSHING
5. GREASE FITTING 16. PIN
6. BUSHING 17. DRIVE PIN
7. PIN 18. SCREWS
8. CONTROL ARM 19. SPACER
9. CAPSCREW 20. SWITCH
10. NUT 21. SWITCH
11. BUSHING

Figure 14. Control Arm Mounting (Power Assist Steering (6/2009 ⇒))

13
Gas Spring
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.
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 re-
assembly. This is necessary because internal damage
to the spring components which are not detectable
could cause damage or injury when the spring is re-
moved.
14
1600 SRM 1284
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.
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.
3. Discharge the pressure from the gas spring. See
Discharging the Gas Spring.
CAUTION
DO NOT damage the control handle wiring har-
ness inside the control handle arm.
4. Remove the retention clip from the gas spring
ball socket. Disconnect the gas spring from the
ball stud.
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.
1600 SRM 1284 Gas Spring

and hold in position. Install the hardware se-

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 15.
INSTALL
curing the rod end of the gas spring to the steer
swivel. Tighten to 27 N•m (20 lbf ft).
6. Install the plastic plugs to the access holes on the
control handle shaft as removed.
NOTE: Apply Loctite® 242 to the capscrew threads
before installing the jam nut.
7. Install the stop bolt and jam nut to the control
handle arm as removed.

1. Install ball stud and nut into control arm if re- 8. Test for proper operation. Install covers as re-
moved. Tighten to 27 N•m (20 lbf ft). moved.

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.
1. GREASE FITTING
4. On Power Assist Steer models, align the lower 2. PIVOT PIN
3. BRAKE SWITCH
end of the gas spring with the steer swivel re- 4. RETAINING PIN
taining pin using a flat screwdriver and hold in 5. SWIVEL
position. Drive the retaining pin into the swivel 6. BUSHING
until flush. 7. ROD END
8. SUPPORT BASE
NOTE: Apply Loctite® 242 to the capscrew threads 9. GREASE FITTING
before installing the nut. 10. GAS SPRING ROD

5. On Standard Steer models, align the lower end of Figure 15. Gas Spring Lower Connection
the gas spring into position using a screwdriver

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

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.

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. 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 1. CAPSCREW
support the weight of the steering support. 2. CAPSCREW
3. CAPSCREW
7. Slightly loosen the two upper capscrews, nuts, 4. ARTICULATING SHAFT
5. CAPSCREW
and washers that hold the steering support to the 6. SUPPORT BASE
frame. 7. UPPER PINION SHAFT (NOTCH FORWARD)
8. WASHER
8. Remove the two lower capscrews, nuts, and 9. WASHER
washers that secure the steering support to the 10. WASHER
frame. 11. LOCK NUT
12. WASHER
9. Lift the steer support (control arm end) so that 13. LOCK NUT
14. LOCK NUT
it pivots on the two upper capscrews to separate 15. LOCKWASHER
the gear pin from the articulated shaft. Secure
the articulated shaft out of the way. Figure 16. Articulating Shaft
10. Remove the capscrew and lock nut from the bot- PINION REPAIR
tom of the articulated shaft.

11. Remove the articulating shaft from the lower CAUTION

pinion shaft. See Figure 16. 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.

16
1600 SRM 1284 Articulating Shaft and Pinions (Power Assist Models)

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 17.
CAUTION
Ensure that pinion shaft notch and steer swivel
(control handle) are aligned in the "straight
ahead" position before continuing.
4. Install the pinion into the support base with the
notch aligned with the steer swivel (control han-
dle) in the straight ahead position. Position the
gear cover to the support base and install two
screws and washers to secure.

1. STEER SWIVEL
2. WASHER
3. SCREW
4. STEER SUPPORT GEAR
5. PINION GEAR
6. GEAR COVER
7. SUPPORT BASE
8. TILLER SENSOR

Figure 17. Gear Cover

NOTE: Disassemble only as necessary for repair. Pin- 1. PINION GEAR

ion assembly parts are not individually repairable on 2. PINION SHAFT
models 6/2009⇒, but the assembly may be replaced 3. BEARING
4. CAPSCREW
as a whole. 5. ARTICULATING SHAFT
6. RETAINING PIN
2. Lift the upper pinion assembly from the support 7. WASHER
base. Remove bearing from shaft. Drive pin from 8. LOCK NUT
gear and remove gear from shaft as necessary.
See Figure 18. Figure 18. Upper Pinion Assembly (⇒5/2009
Model Shown)
3. Install gear to shaft as removed. Align hole in
gear with hole in shaft and install retaining pin.
Install bearing onto shaft.

17
Articulating Shaft and Pinions (Power Assist Models) 1600 SRM 1284

Lower Pinion 2. Install new bearing onto shaft and position

into mounting bracket as removed. Install the
After removing the articulating shaft, the lower pin- Woodruff key into shaft. Align pinion shaft with
ion can be removed from the mounting plate for re- the notch in the "straight ahead" position.
pair. See Figure 19.

CAUTION
Steering functions will not operate properly if
pinion is not installed with notch aligned prop-
erly with drive tire.

3. Slide gear onto shaft and key. Secure in place

with gear retaining washer, washer, lockwasher,
and capscrew as removed.

1. LOWER PINION SHAFT (NOTCH FORWARD)

2. LOWER PINION MOUNTING PLATE
3. LOWER PINION GEAR
4. STEER MOTOR GEAR
5. MOUNTING SCREWS
6. STEER GEAR
7. DRIVE UNIT HOUSING
8. TRACTION MOTOR
9. STEER MOTOR
1. LOWER PINION MOUNTING BRACKET
Figure 19. Lower Pinion Mounting (⇒5/2009 2. WASHER
Model Shown) 3. LOCKWASHER
4. CAPSCREW
1. Remove the capscrew, lockwasher, washer, and 5. RETAINING WASHER
gear retaining washer from bottom of pinion as- 6. GEAR
sembly. Remove gear from shaft and recover the 7. BEARING
8. WOODRUFF KEY
Woodruff key. Remove pinion shaft and bearing 9. PINION SHAFT
from mounting bracket. Remove bearing from
shaft. See Figure 20. Figure 20. Lower Pinion Assembly

18
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).
3. Lift the steer support (control arm end) up so that
it pivots on the two upper capscrews. Position the
articulated shaft to the pinion.
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.
Steer Motor Assembly
4. Lower the steer support (control arm end) while
guiding the articulated shaft onto the pinion
shaft.
5. 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.
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
(10 to 15 lbf ft).
7. Install the dash to the steer support as removed.
Secure using two screws. Refer to Electrical
System 2200 SRM 1287.
8. Replace the drive unit compartment covers as re-
moved. Reconnect the battery and turn the key
switch to the ON position. Test for proper opera-
tion.
2. Discharge the capacitor. See Special Precautions
in this section.
Steer Motor, Replace
Refer to Figure 21 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-
tion.
5. Install wiring and cables to steer motor as re-
moved.
6. Calibrate the power assist steering sensor. See
Calibration in this section.
19
Steer Motor Assembly 1600 SRM 1284

Steer Motor Gear, Replace

Refer to Figure 22 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.

1. LOWER PINION SHAFT

2. BEARING
3. WOODRUFF KEY
4. LOWER PINION GEAR
5. WASHER
6. CAPSCREW
7. CAPSCREW
1. STEER MOTOR 8. WASHER
2. GEARBOX 9. STEER MOTOR GEAR
3. WASHER 10. WOODRUFF KEY
4. CAPSCREW 11. SCREW
5. SHAFT 12. WASHER
6. WOODRUFF KEY 13. BRACKET
14. STEER MOTOR
Figure 21. Steer Motor
Figure 22. Steer Motor Assembly

20
1600 SRM 1284
4. Install the washer and capscrew securing gear to
shaft as removed.
Gearbox/Complete Assembly, Replace
Refer to Figure 21 and Figure 22 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
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
Steer Support Assembly
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
unit housing as removed.
CAUTION
Very small variations can prevent steering sys-
tems from operating properly.
7. Align the marks on the articulating shaft lower
pinion gear with the mark on the steer gear as
removed. Refer to Articulating Shaft and Pin-
ions (Power Assist Models) for more information
on gear alignment. Position the lower bearing
bracket to the drive unit housing as removed and
install four capscrews securing bracket and steer
motor to the drive unit housing.
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.
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.
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.
21
Steer Support Assembly
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.
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 24.
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 23.
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.
22
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
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.
1600 SRM 1284 Steer Support Assembly

8. Install control handle wiring harness through 9. Place cover on swivel and secure with screws.
support.

1. SCREWS 9. BRAKE SWITCHES 17. STEER SHAFT

2. SWIVEL COVER 10. SCREWS 18. WIRE SLEEVE
3. WIRE SLEEVE 11. UPPER BEARING CONE 19. NUT
4. BEARING NUT 12. UPPER BEARING CUP 20. WASHER
5. LOCKING WASHER 13. CENTER SUPPORT 21. WASHER
6. KEY 14. LOWER BEARING CUP 22. CAPSCREW
7. SWIVEL 15. LOWER BEARING CONE 23. STEER PLATE
8. NUT PLATE 16. SPACER

Figure 23. Steer Support (Standard Steering)

23
Steer Support Assembly
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 24.
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.
Figure 24. Steering and Dash - Complete Removal (Power Assisted Steering ⇒5/2009 Shown)
24
1600 SRM 1284
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.
1600 SRM 1284
Legend for Figure 24
1. STRAP
2. TILLER HANDLE
3. SUPPORT
4. ARTICULATING SHAFT
5. NUT
POWER ASSIST STEERING (OPTION)
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)
Refer to Figure 24 for the following instructions.
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. 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
Steer Support Assembly
6. LOCKWASHER
7. WASHER
8. WASHER
9. CAPSCREW
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
this section.
7. Lower the overhead lifting device until the steer
support rests on top of the brake. Readjust the
sling and tighten to support the steer support
evenly.
8. Remove the remaining capscrews, nuts, and
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 support base may be disassembled to access the
steer swivel bearings, the steering gear, or the torque
sensor.
1. Remove the steer support assembly as a unit if
necessary to access the support base. See Re-
move (Complete Unit) 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 25. Lift the
pinion from the support base. Repair or replace
as necessary. Refer to Articulating Shaft and
Pinions (Power Assist Models).
3. Remove two capscrews and washers from the bot-
tom of the support base. See Figure 26. Lower
the support base from the center support.
25
Steer Support Assembly 1600 SRM 1284

Legend for Figure 26

1. SUPPORT BASE
2. SNAP RING
3. CAPSCREW AND LOCKWASHER
4. CENTER SUPPORT
5. PINION SHAFT

4. Remove the snap ring and bearing from the sup-

port base using an appropriate-sized driver.

5. Remove the pin from the bottom of the steer gear

and lower the gear from the torsion shaft. See
Figure 27.

1. STEER SWIVEL
2. WASHER
3. SCREW
4. STEER GEAR
5. PINION
6. GEAR COVER
7. SUPPORT BASE
8. POTENTIOMETER (⇒5/2009 ONLY)

Figure 25. Steer Gear and Pinion (⇒5/2009

Shown) 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

Figure 27. Steer Gear and Torque Sensor

NOTE: Make note of torque sensor position and ori-

entation.

6. Recover the torque sensor from the swivel.

7. Check that sensor guard is securely mounted to

the underside of the center support and properly
engages with the sensor to prevent rotation. Re-
Figure 26. Support Base pair or replace as necessary. See Figure 28.

26
1600 SRM 1284 Steer Support Assembly

1. SWIVEL NUT
2. SWIVEL SHAFT
3. CENTER SUPPORT
4. GUARD
5. TORQUE SENSOR
6. ALIGNMENT RAIL (THIN)
7. ALIGNMENT RAIL (THICK)

Figure 28. Torque Sensor and Guard (Models 1. SWIVEL

6/2009⇒) 2. PIN
3. UPPER BEARING
Steer Swivel 4. TORSION SHAFT
5. CENTER SUPPORT
The steer swivel may be disassembled to access the 6. LOWER BEARING
steer swivel bearings. The support base must be 7. BEARING NUT
disassembled first in order to disassemble the steer
Figure 29. Swivel and Bearing Assembly
swivel. See Disassemble, Support Base.

1. Remove the bearing nut from the bottom of the Assemble

center support. See Figure 29.
2. Lift the steer swivel from the top of the center
support and place on a clean workbench.
3. Remove the lower bearing from the bottom of the
center support.
Steer Swivel
NOTE: Clean all parts of the steer swivel before re-
assembling. Make sure all old sealant is removed be-
fore reinstalling parts. Inspect each component and
repair or replace as necessary.

4. Remove the upper bearing from the steer swivel
or center support.
5. Remove the pin securing the torsion shaft to the
swivel. Remove the torsion shaft.
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 29.

27
Steer Support Assembly
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.
3. On the upper 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 swivel and bearing as-
sembly into the center support. Carefully lower
the swivel shaft through the lower bearing.
4. Apply Loctite® 242 and install the bearing nut
onto the swivel shaft against the lower bearing.
Tighten slowly, periodically turning the swivel to
prevent binding. Torque to 52 to 54 N•m (38 to
40 lbf ft).
Support Base
The steer swivel must be assembled before the sup-
port base may be assembled. See Assemble, Steer
Swivel.
CAUTION
The torque sensor must be correctly set in
alignment and installed in the proper ori-
entation. New torque sensors will have an
alignment pin or collar which should not be
removed until the sensor is installed to the
swivel shaft. Sensors being reinstalled must
be aligned by hand before installation. The
truck may operate erratically if torque sensor
is misaligned or installed improperly.
NOTE: Fit should be snug; no tools necessary to as-
semble torque sensor to the steer swivel.
NOTE: Check that sensor guard (refer to Figure 28)
is securely mounted to the underside of the center
support and properly engages with the torque sensor
to prevent rotation. Replace as necessary.
NOTE: New torque sensors should be installed with
position key or collar pointing down toward the steer
gear. Do not remove key or collar until torque sensor
is installed to truck.
1. Align the torque sensor by hand if position key or
collar has been removed:
a. Models ⇒5/2009:Locate the hole in the bot-
tom of the torque sensor. Straighten a pa-
perclip and insert into the hole. Rotate the
28
1600 SRM 1284
actuator around the inside of the sensor un-
til the paper clip drops further into the sen-
sor locking the actuator from turning. The
alignment hole is located on the bottom of the
sensor (toward the steer gear). Use tape to
secure the paperclip to the bottom of the sen-
sor and remove after the sensor has been in-
stalled to the swivel shaft.
b. Models 6/2009⇒:The sensor has two inde-
pendent actuators located inside the inner
diameter of the sensor. Each actuator has
a raised alignment rail. Turn the actua-
tors to align both alignment rails with each
other. Then turn both actuators so that
the alignment rails point toward the
sensor wiring harness. One alignment
rail is thicker than the other. The thicker
alignment rail is located on the bottom of
the sensor (toward the steer gear). The
torque sensor will not operate properly
if installed in the alignment rails in the
incorrect position or if the sensor is
installed upside down. SeeFigure 30.
1. SWIVEL NUT
2. SWIVEL SHAFT
3. CENTER SUPPORT
4. GUARD
5. TORQUE SENSOR
6. ALIGNMENT RAIL (THIN)
7. ALIGNMENT RAIL (THICK)
Figure 30. Torque Sensor and Guard (Models
6/2009⇒)
1600 SRM 1284 Steer Support Assembly

NOTE: Fit should be tight; no tools are necessary to of the support base. Apply Loctite® 641 to the in-
assemble torque sensor to swivel shaft. side of the inner race of the support bearing.

NOTE: The swivel shaft may have multiple grooves.
Make sure the sensor alignment rails are aligned
with the sensor harness and that the sensor is in-
stalled onto the shaft so that it seats directly into the
sensor guard.
2. Position the torque sensor onto the steer swivel
with position key or collar (bottom of the torque
sensor) facing down toward the steer gear. After
the torque sensor is installed to the swivel shaft,
remove position key (paperclip) or alignment col-
lar. See Figure 31.
5. Position the support base (with bearing in-
stalled) to the bottom of the center support as
removed. Make sure the steering gear hub
installs through the support bearing and the
support base properly seats against the flange of
the center support before tightening capscrews.
Install two capscrews and lockwashers to the
bottom of the support base. Torque capscrews to
40 N•m (30 lbf ft). See Figure 32.
6. Install the snap ring fully into the groove in the
steer gear hub against the support bearing.

CAUTION
Steering functions will not operate properly if
pinion is not aligned with steer swivel (control
handle).

7. Install the pinion into the support base with the

notch aligned with the steer swivel (control han-
dle) in the straight ahead position. Refer to Ar-
ticulating Shaft and Pinions (Power Assist Mod-
els) in this section. Position the gear cover to the
support base and install two screws and washers
to secure. See Figure 25.

1. SWIVEL
2. CENTER SUPPORT
3. SENSOR GUARD
4. TORQUE SENSOR
5. TORSION SHAFT
6. PIN
7. STEER GEAR
8. POSITION KEY (⇒5/2009 ONLY)
9. BEARING
10. RETAINING RING

Figure 31. Support Base Installation (⇒5/2009

Shown)

3. Align the steer gear detent with lower detent or

rail of torque sensor and assemble. Align hole in
steer gear to hole in swivel shaft. Install pin to 1. SUPPORT BASE
secure lower end of torsion bar to bottom of gear. 2. SUPPORT BEARING AND SNAP RING
3. CAPSCREW AND LOCKWASHER
4. Apply Loctite® 641 to the outside of the outer 4. CENTER SUPPORT
race of the support bearing and install into the 5. PINION SHAFT
support base shaft using the proper sized driver.
Figure 32. Support Base
Make sure the bearing fully seats into the flange

29
Coast Control Option
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.
Coast Control Option
DISASSEMBLE
1. Remove six screws and remove the cover halves
from the control handle. See Figure 33.
2. Remove four nuts, washers, and screws retaining
the guard to the control handle. See Figure 34.
3. Remove the guard from the control handle.
4. Disconnect the coast control wiring harness from
the main wiring harness.
5. Remove the retaining ring and pin retaining the
coast control unit to the control handle. See Fig-
ure 35.
30
1600 SRM 1284
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.
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.
11. 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.
6. On Power Steer trucks only, remove the insert
from the steering pivot cover and remove the two
screws retaining the cover. See Figure 36. Re-
move the cover.
7. Remove the screw, washer, and nut retaining the
coast control rod to the lower mount. See Fig-
ure 35.
8. Remove the coast control unit from the lift truck.
9. Remove clevis from end of coast control cylinder
rod. See Figure 37.
10. Remove nut from rod and remove boot.
1600 SRM 1284 Coast Control Option

1. SCREW
2. COVER
3. CONTROL HANDLE
4. GUARD
1. NUT
Figure 33. Covers 2. WASHER
3. SCREW
4. CONTROL HANDLE
NOTE: The coast control unit is non-serviceable and 5. GUARD
must be replaced as a complete unit.
Figure 34. Guard
ASSEMBLE
6. Align the clevis with the lower coast control unit
1. Install the boot over the rod. See Figure 37. mount and install the shoulder bolt, washer, and
nut.
2. Thread the nut supplied with the coast control
unit to the end of the threads on the rod. 7. On Power Steer trucks, install the steering pivot
cover and install the two screws to retain the
3. Apply Loctite 242 to the threads on the end of the
cover. See Figure 36. Install the insert.
rod.
8. Connect the coast control unit wiring harness to
4. Thread the clevis onto the rod until it touches the
the main harness connections.
nut. Tighten the nut against the clevis to lock the
clevis in place. 9. Install the coast control guard to the control han-
dle. See Figure 34.
5. Assemble the coast control unit to the control
handle using the pin and retaining ring. See Fig- 10. Install the cover halves to the guard using
ure 35. screws. See Figure 33.

NOTE: Ensure the alignment tabs on the boot align

with the slots in the cover halves.

31
Coast Control Option 1600 SRM 1284

fully up or fully down position to engage the lift

truck brake.

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.

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

Figure 35. Mounting

1. INSERT
CHECKS 2. SCREW
3. COVER
1. With the coast control engaged, the lift truck 4. CONTROL HANDLE
speed must not exceed 4.0 mph.
Figure 36. Cover
2. With the coast control engaged, the control han-
dle must be able to be manually moved to the

32
1600 SRM 1284 Troubleshooting

Legend for Figure 37

1. COAST CONTROL 3. NUT
UNIT 4. CLEVIS
2. BOOT

Figure 37. Clevis

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 (Models Check fuses/replace as necessary.

⇒5/2009 Only).

Power steering "Relaxed" due to sen- Check for error codes. (PS may re-
sor or system fault (Models 6/2009⇒ sume once truck stops if system re-
Only). covers)

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.

33
 NOTES

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34
 TECHNICAL PUBLICATIONS

1600 SRM 1284 7/09 (7/08)(12/06)(11/06) Printed in U.S.A.