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• Keep the tools clean and in good condition. • Always use HYSTER APPROVED parts when making repairs. Replacement parts must meet or exceed the specifi- cations of the original equipment manufacturer. • Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to remove parts.
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Table of Contents Steering Mechanism This section is for the following models: (B60ZAC) [C230]; (B60ZHD) [B262]; (B80ZHD) [B257]...
1600 SRM 1637 General General The control handle assembly is designed to perform several With both hands, pull up and away from the truck until the functions. The standard control handle includes the speed/ bottom of the cover kicks out from the retaining clips. direction control and buttons for the horn, traction Repeat this for the other side of the cover.
Special Precautions 1600 SRM 1637 Legend for Figure 2 1. DRIVE UNIT COMPARTMENT COVER 2. RETAINER TABS 3. GRIP SLOT 4. FRAME Figure 2. Drive Unit Compartment Cover Special Precautions Never short any controller terminal or motor ter- WARNING minal to battery. Make sure to use proper proce- The capacitor in the transistor controller can hold dures when servicing the controller.
1600 SRM 1637 Calibration ELECTROMAGNETIC SHIELD WARNING Never operate Power Assist models with the Elec- tromagnetic Shield removed. A metallic shield is installed between the MDU and brake assembly and the steering assembly on power assist steer- ing units. This shield deflects the electromagnetic field gen- erated by the MDU and brake assembly which can interfere with the operation of the torque sensor.
Control Handle 1600 SRM 1637 NOTE: Communication error codes may appear during this process. This is a normal part of the calibration proc- ess. 6. The lift truck will start up in calibration mode and the tiller handle will begin to move on its own power dur- ing the calibration cycle.
1600 SRM 1637 Control Handle Remove 10. Remove bushings from the control handle arm if nec- essary. 1. Turn the key switch to the OFF position and discon- 11. If necessary, remove the control handle head. See the nect the battery. Remove the drive unit compartment cover.
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Control Handle 1600 SRM 1637 CAUTION CAUTION Make sure that the wiring is properly routed to Make sure the wiring harness is not wrapped prevent steering problems and chafing of the har- around the gas spring. Check the wiring harness ness.
1600 SRM 1637 Control Handle 10. Remove excess slack by bundling control handle, NOTE: Be certain to tag, identify, and note the routing of brake, and brake switch wiring harnesses and secure the wires before disconnecting any wire. The wiring must using wire ties.
Control Handle 1600 SRM 1637 9. Remove cotter pin from end of pivot pin. Remove 1. Install bushings into control arm. grease fitting if necessary. See Figure 7. 2. Position control handle to swivel. Install pivot pin into 10. Using a brass drift and hammer, remove pivot pin from control arm and swivel.
1600 SRM 1637 Gas Spring 6. Calibrate the tiller angle potentiometer. Refer to the 8. Install drive unit compartment covers. See Accessing sections User Interface 2200SRM1323 or User Inter- the Drive Unit Compartment in this section. face 2200SRM1324 for calibration procedures. 9.
Gas Spring 1600 SRM 1637 REMOVE the gas spring to the ball stud inside the control handle arm. Install the retention clip to the gas spring ball To remove the gas spring from the control handle: socket as removed. 1. Remove the stop bolt from the control handle arm. CAUTION 2.
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 wash- ers securing the cover to the steer support and lift the cover off.
Articulating Shaft and Pinions (EPAS) 1600 SRM 1637 PINION REPAIR 3. Install gear to shaft as removed. Align hole in gear with hole in shaft and install retaining pin. Install bear- ing onto shaft. CAUTION Steering functions will not operate properly if pin- CAUTION ions are not aligned properly with steer swivel (control handle) and drive tire.
1600 SRM 1637 Articulating Shaft and Pinions (EPAS) Lower Pinion After removing the articulating shaft, the lower pinion can be removed from the mounting plate for repair. See Fig- ure 12. 1. LOWER PINION MOUNTING BRACKET 2. WASHER 3. LOCKWASHER 4.
Steer Motor Assembly 1600 SRM 1637 INSTALL 4. Lower the steer support (control arm end) while guid- ing the articulated shaft onto the pinion shaft. CAUTION 5. Install the remaining two lower capscrews, washers, and nuts securing the steer support to the frame. Ensure that the drive tire and notch of the lower Tighten all four capscrews to 41 to 47 N•m (30 to pinion shaft are aligned in the steer swivel (con-...
1600 SRM 1637 Steer Motor Assembly 1. Remove the capscrew and washers from the bottom 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.
Steer Support Assembly 1600 SRM 1637 14. STEER MOTOR 15. LOCK WASHER Figure 15. Steer Motor Assembly 5. If replacing the gearbox, remove the two screws and washer securing the electric motor to the gearbox. Re- move the gearbox from the motor and install the new gearbox.
Tighten the lifting device to support the weight proper size bearing driver, if removed. of the steering support. See Figure 17. 2. Pack bearings with Hyster synthetic grease, P/N 8. Remove the four capscrews, washers, and nuts secur- 2074114, using a standard bearing packing device.
Steer Support Assembly 1600 SRM 1637 Install (Complete Unit) 6. Install the drive unit compartment covers as removed. Connect the battery and turn the key switch to the ON 1. Using the overhead lifting device, carefully position position. Test for proper operation. the steer support to the frame.
1600 SRM 1637 Steer Support Assembly for access to other parts of the lift truck such as when re- moving the traction motor. Some items may be serviced without removing the steer support assembly. Remove only the components necessary to safely complete the required service.
Steer Support Assembly 1600 SRM 1637 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 neces- sary to access the support base. See Remove (Com- plete Unit) in this section.
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