Professional Documents
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STEERING MECHANISM
MSW020/025-E [A895];
MSW025/030-F [B895];
MPB040-E [B827];
MPW045-E [B802];
MPW050-E [C802]
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.
Table of Contents
TABLE OF CONTENTS
General ..................................................................................................................................................................... 1
Special Precautions .................................................................................................................................................. 1
Control Handle Head ................................................................................................................................................ 2
Control Handle ..........................................................................................................................................................2
Remove ................................................................................................................................................................ 2
Install .................................................................................................................................................................... 3
Gas Spring ................................................................................................................................................................5
Discharging the Gas Spring ..................................................................................................................................5
Troubleshooting ........................................................................................................................................................ 6
(MSW020/025-E) [A895];
(MSW025/030-F) [B895];
(MPB040-E) [B827];
(MPW045-E) [B802];
(MPW050-E) [C802]
General
The control handle assembly is designed to perform A bottom-mounted control handle assembly is used
several functions. The standard control handle on the MSW020/025-E, MSW025/030-F, MPB040-E,
includes the speed/direction control and buttons for MPW045-E, and MPW050-E. The handle is designed
the horn, traction reversing, and hydraulic functions. to be used while the operator is walking beside the lift
The control handle is connected to the Master Drive truck.
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. Controls
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.
Special Precautions
WARNING
To avoid personal injury and prevent electrical
shock, perform the following steps before trouble-
shooting or adjusting and before connecting or
disconnecting a handset or personal computer.
CAUTION
To avoid controller damage, always disconnect
the battery, discharge the capacitor, and never
put power to the controller while any power wires
are disconnected. Never short any controller ter-
minal or motor terminal to the battery. Make sure
to use the proper procedure when servicing the
controller.
1
Special Precautions 1600 YRM 1004
1. NEGATIVE CONNECTION
2. POSITIVE CONNECTION
3. 200-OHM, 2-WATT RESISTOR
4. INSULATED JUMPER WIRES
Control Handle
REMOVE repairing any component in the drive unit com-
partment. Wear safety glasses. Make certain the
battery has been disconnected. Refer to Figure 1
WARNING and Figure 2 in the Special Precautions section of
The gas springs used on the control handle are this manual.
installed under tension and can release with
enough force to cause personal injury or property 1. Move the lift truck to a safe, level area and block
damage. the wheels to prevent movement.
2
1600 YRM 1004 Control Handle
4. Discharge the capacitor in the controller by con- 2. If previously removed, install the bushings into the
necting a 200-ohm, 2 watt resistor between the B support bracket pivot pin holes.
+ and B- connectors on the controller.
NOTE: Install the switch to the bracket with wire to
5. Disconnect the control handle wiring harness plug bottom of the bracket.
and the control handle arm prox switch plug loca-
ted on top of the drive motor. 3. Install the control handle arm prox switch into the
mounting bracket and mount onto the support
For the following instructions refer to Figure 3. bracket with retaining screws. Leave retaining
screws loose until the control handle arm is instal-
6. Remove the rubber bumper retaining screw and led.
wire clamp.
4. Install the bumper and wire clamp with retaining
7. If necessary, remove the control handle head. screw and tighten to 10.5 N•m (93 lbf in).
See the section Electrical System
5. If removed, install the control handle head. See
2200YRM1007, Figure 3.
the section Electrical System 2200YRM1007,
Figure 3.
CAUTION
6. Install the control arm into the support bracket.
Discharging the gas spring is a destructive opera-
Apply Loctite® 242 to the threaded portion of the
tion.
pivot pins and install pivot pins. Torque to 190
8. Discharge and remove the gas spring. Refer to ±7 N•m (140 ±5 lbf ft).
Gas Spring.
7. Install and tighten setscrews.
9. Remove setscrews.
8. Drive the pin through lower end of gas spring to
10. Remove both threaded control arm pivot pins and secure to support bracket.
washers.
9. Adjust control handle arm prox switch. Refer to
11. Remove the control arm from the support bracket. the section Electrical System 2200YRM1007,
Control Handle Arm Prox Switch - Install.
12. Remove two screws from the support bracket and
remove the control handle arm prox switch. 10. Install the MDU covers and drive unit compart-
ment covers.
13. If bushings are worn, remove the bushings from
the support bracket pivot pin holes. 11. Connect the battery and test the operation of the
lift truck prior to returning to service.
INSTALL
1. Install the new gas spring to the control handle
arm. Refer to Gas Spring.
3
Control Handle 1600 YRM 1004
4
1600 YRM 1004 Control Handle
Gas Spring
DISCHARGING THE GAS SPRING
WARNING
Disconnect the battery by separating the battery
connector before opening the compartment cover WARNING
and before inspecting or repairing the electrical Goggles and a face shield must be worn for per-
system. DO NOT place tool on top of the battery. If sonal protection as metal chips and hydraulic lu-
a tool causes a short circuit, the high-current flow bricant may be ejected from the drill operation
from the battery can cause personal injury or due to the high internal pressure.
property damage.
CAUTION
WARNING The control handle return spring is charged with
The capacitor in the traction motor controller can pressurized gas and contains a hydraulic oil lubri-
hold an electrical charge after the battery is dis- cant.
connected. To prevent electrical shock and per-
sonal injury, discharge the capacitor before in- NOTE: This process is a destructive operation to the
specting or repairing any component. Make cer- gas spring. A new gas spring must be used during re-
tain the battery has been disconnected and al- assembly. This is necessary because internal dam-
ways wear safety glasses. See Special Precau- age to the spring components which are not detecta-
tions in this section. DO NOT attempt to discharge ble could cause damage or injury when the spring is
the capacitors by shorting the controller. removed.
5
Gas Spring 1600 YRM 1004
2. Locate and drill a 7 mm (0.25 in.) access hole 3. Locate the gas spring inside the control handle
through the center of the control handle tube, ap- through the newly drilled access hole and drill a
proximately 50 mm (2 in.) below the existing ac- 3 mm (0.125 in.) hole into the gas spring cylinder
cess hole. shell to relieve pressure.
Troubleshooting
Bearing retaining nut torque incor- Loosen retaining nut and tighten to
rect. correct torque. See the section
Master Drive Unit 0630YRM1003.
Drive unit housing bearing (steer) Replace drive unit housing bearing
damaged. (steer).
Steering handle does not return to Gas spring is weak or broken. Replace gas spring.
the vertical position.
6
1600 YRM 1004 10/15 (3/08)(10/06)(9/05)(8/05)(7/05)