Hyster B257 Operating instructions

Hyster B257 (B60ZHD, B80ZHD) Forklift

STEERING MECHANISM
B60ZAC [C230];
B60ZHD [B262];
B80ZHD [B257]
PART NO. 4096087 1600 SRM 1637

SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• The Service Manuals are updated on a regular basis, but may not reflect recent design changes to the product. Upda-
ted technical service information may be available from your local authorized Hyster® dealer. Service Manuals pro-
vide general guidelines for maintenance and service and are intended for use by trained and experienced technicians.
Failure to properly maintain equipment or to follow instructions contained in the Service Manual could result in dam-
age to the products, personal injury, property damage or death.
• 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. Dis-
connect 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 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.
• 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.

©2013 HYSTER COMPANY
TABLE OF CONTENTS
General ......................................................................................................................................................................................... 1
Accessing the Drive Unit Compartment ..................................................................................................................................1
Special Precautions .......................................................................................................................................................................2
Electromagnetic Shield ............................................................................................................................................................3
Calibration .................................................................................................................................................................................... 3
Power Assist Steering .............................................................................................................................................................. 3
Control Handle ............................................................................................................................................................................. 4
Control Handle Head ............................................................................................................................................................... 4
Control Handle .........................................................................................................................................................................4
Standard Steering ................................................................................................................................................................4
Remove .......................................................................................................................................................................... 5
Install ..............................................................................................................................................................................5
Power Assist Steering ......................................................................................................................................................... 7
Remove .......................................................................................................................................................................... 7
Install ..............................................................................................................................................................................8
Gas Spring .................................................................................................................................................................................... 9
Discharging the Gas Spring ..................................................................................................................................................... 9
Remove .................................................................................................................................................................................. 10
Install ..................................................................................................................................................................................... 10
Articulating Shaft and Pinions (EPAS) ...................................................................................................................................... 11
Remove .................................................................................................................................................................................. 11
Pinion Repair ......................................................................................................................................................................... 12
Upper Pinion ..................................................................................................................................................................... 12
Lower Pinion .....................................................................................................................................................................13
Install ..................................................................................................................................................................................... 14
Steer Motor Assembly ................................................................................................................................................................14
Repair .....................................................................................................................................................................................14
Steer Motor, Replace ........................................................................................................................................................ 14
Steer Motor Gear, Replace ................................................................................................................................................14
Gearbox/Complete Assembly, Replace ............................................................................................................................ 15
Steer Support Assembly ............................................................................................................................................................. 16
Standard Steering ...................................................................................................................................................................16
Remove (Complete Unit) ..................................................................................................................................................16
Disassemble ...................................................................................................................................................................... 17
Assemble ...........................................................................................................................................................................17
Install (Complete Unit) ..................................................................................................................................................... 18
Power Assist Steering (Option) ............................................................................................................................................. 19
Remove (Complete Unit) ..................................................................................................................................................19
Disassemble ...................................................................................................................................................................... 20
Support Base ................................................................................................................................................................ 20
Steer Swivel ................................................................................................................................................................. 21
Assemble ...........................................................................................................................................................................21
Steer Swivel ................................................................................................................................................................. 21
Support Base ................................................................................................................................................................ 22
Install (Complete Unit) ..................................................................................................................................................... 24
Advance Coast Control................................................................................................................................................................24
Disassemble ........................................................................................................................................................................... 24
Assemble ................................................................................................................................................................................27
Coast Control Adjustment Procedure .................................................................................................................................... 27
Troubleshooting ..........................................................................................................................................................................28
Steering Mechanism Table of Contents
i

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This section is for the following models:
(B60ZAC) [C230];
(B60ZHD) [B262];
(B80ZHD) [B257]
Table of Contents Steering Mechanism
ii

General
The control handle assembly is designed to perform several
functions. The standard control handle includes 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. 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.
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 handle. A power
assist option is available that senses when the operator
begins to move the control handle side to side and activates
a motor in the drive unit compartment to turn the drive unit.
This greatly reduces the operator effort needed to steer the
lift truck.
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 Figure 2.
With both hands, pull up and away from the truck until the
bottom of the cover kicks out from the retaining clips.
Repeat this for the other side of the cover. Work around the
edge of the cover until it is freed from the truck.
To install the drive unit cover, make sure the floor mat is
pulled away from the drive unit and place the bottom of the
drive unit cover onto the operator platform. Position the
lower edges partially into the lower retaining clips. Push
the top of the cover partially into the upper retaining clips.
Do not push either edge of the cover in completely before
starting all edges into the proper place. When the cover is
aligned and started properly, press the cover completely
into the retaining clips and place the floor mat into the
operator platform around the cover.
1. FLOOR MAT
2. DRIVE UNIT COMPARTMENT COVER
3. FRAME
4. CASTER ADJUSTMENT ACCESS
Figure 1. Floor Mat
1600 SRM 1637 General
1

Figure 2. Drive Unit Compartment Cover
Legend for Figure 2
1. DRIVE UNIT COMPARTMENT COVER
2. RETAINER TABS
3. GRIP SLOT
4. FRAME
Special Precautions
WARNING
The capacitor in the transistor controller can hold
an electrical charge after the battery is disconnec-
ted. To prevent electrical shock and personal in-
jury, 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 trac-
tion 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 dis-
connected.
Never short any controller terminal or motor ter-
minal to battery. Make sure to use proper proce-
dures when servicing the controller.
1. Turn the key switch to the OFF position and discon-
nect the battery.
2. Remove the drive unit compartment cover to access
the controller. See Accessing the Drive Unit Compart-
ment.
3. Discharge the capacitors in the controllers by connect-
ing a 200-ohm, 2-watt resistor across the controller's B
+ and B− terminals using insulated jumper wires. See
Figure 3. DO NOT short across the motor controller
terminals with a screwdriver or jumper wire. Remove
the 200-ohm, 2-watt resistor before reconnecting the
battery.
Special Precautions 1600 SRM 1637
2

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. Make certain that
the Electromagnetic Shield is reinstalled before operating
the lift truck after servicing to prevent erratic operation of
the power assist steering function.
1. CONTROLLER
2. POSITIVE CONNECTION
3. INSULATED JUMPER WIRES
4. 200-OHM, 2-WATT RESISTOR
5. NEGATIVE CONNECTION
Figure 3. Discharging Capacitors
Calibration
POWER ASSIST STEERING
The following calibration instructions apply to all power
assist steering models.
WARNING
If at any time a tiller handle slowly moves in one
direction during startup, it is likely calibration
needs to be performed.
Power assist steering calibration should be performed if ei-
ther the torque sensor or power assist steering unit is serv-
iced or replaced or anytime the drive tire is replaced.
1. Position the lift truck on a normal, smooth surface
floor away from personnel or other equipment with the
drive tire centered.
2. Turn the key switch to the OFF position and remove
the drive unit compartment cover.
3. The Calibration Tab is an unconnected wire with a fe-
male spade connector hanging near the ETACC CAN
connector. Attach the Calibration Tab to the B+ termi-
nal (right post) of the contactor, 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 the lift truck is not equipped with coast control,
wedge a deep well socket or 50 mm (2.00 in.) by
20 mm (0.75 in.) wood block into the control arm/swivel
joint area to hold the handle in an operating position.
4. Position the control arm in the brake OFF position and
secure using the coast control. See Figure 4.
5. Standing clear of the steer handle, turn the key switch
to the ON position.
1600 SRM 1637 Calibration
3

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.
7. Wait at least 5 seconds after the calibration cycle has
ended (the tiller has stopped moving) and remove the
jumper wire.
8. Wait at least 5 seconds after the jumper wire is re-
moved 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. Reinstall the
drive unit compartment cover and return to the lift
truck to service.
A. BRAKE ON
B. REGEN BRAKING
C. BRAKE OFF
Figure 4. Brake Activation
Control Handle
CONTROL HANDLE HEAD
The control handle head is primarily an electronic compo-
nent and is discussed in the electrical section. For instruc-
tions on how to remove, install, or repair the control handle
head, refer to the section Electrical System
2200SRM1640.
CONTROL HANDLE
The following procedures describe the removal and disas-
sembly 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 control handle and dash assembly must
be removed to access other components of the lift truck.
For instruction 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 property
damage.
WARNING
The capacitor in the controller can hold an electri-
cal charge after the battery is disconnected. To
prevent electrical shock and personal injury, dis-
charge the capacitor before inspecting or repair-
ing any component in the drive unit compartment.
See Special Precautions in this section. Wear
safety glasses. Make certain the battery has been
disconnected.
Refer to Figure 5 for the following instructions.
Control Handle 1600 SRM 1637
4

Remove
1. Turn the key switch to the OFF position and discon-
nect the battery. Remove the drive unit compartment
cover. See Accessing the Drive Unit Compartment in
this section.
2. Discharge the capacitors. See Special Precautions in
this section.
CAUTION
DO NOT cut the wiring harnesses when removing
the wire ties.
NOTE: It is not necessary to remove the main wiring har-
ness unless harness is damaged and is being replaced.
3. CAREFULLY cut the wire ties securing the brake,
brake switch, and control handle wiring harnesses to-
gether 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 prop-
erly at assembly to prevent steering problems 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.
7. Remove the gas spring. See Gas Spring in this section.
8. Remove the pin from control handle arm and slide the
pivot shaft out. Recover shims for later installation.
Remove the control handle arm from the swivel.
9. Carefully pull the wiring harnesses through the center
of the support.
10. Remove bushings from the control handle arm if nec-
essary.
11. If necessary, remove the control handle head. See the
section Electrical System 2200SRM1640. Remove
nut and clamp and pull wiring harness through control
handle arm.
12. Remove two screws from the swivel and remove the
brake switches and nutplate.
Install
Refer to Figure 5 for the following instructions.
1. Install brake switches and nutplate into the swivel us-
ing two screws.
2. Install bushings into the control handle arm if re-
moved.
3. Install the control handle head if removed. See the sec-
tion Electrical System 2200SRM1640. Pull wiring
harness through control handle arm and secure with
clamp and nut.
4. Route the control handle and brake switch wiring har-
nesses down through the sleeves in the support. Care-
fully pull the wiring harnesses through the center of the
support.
NOTE: Install shims onto pivot shafts as required to mini-
mize side-to-side movement of handle.
5. Install the control handle arm into the swivel using
pivot shaft, shims, and pin. Install shims between the
control handle arm and swivel on the LEFT side of the
swivel (side nearest the controller).
6. Install the gas spring to the control handle. See Gas
Spring.
1600 SRM 1637 Control Handle
5

CAUTION
Make sure that the wiring is properly routed to
prevent steering problems and chafing of the har-
ness.
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 harness
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 restrictions.
9. With the control handle in the upright position, pull the
harness and check for binding. Position the wiring har-
ness with slack distributed evenly to allow for move-
ment when the control handle is turned in any direc-
tion.
1. SCREW
2. COVER
3. PIN
4. PIVOT SHAFT
5. SWIVEL
6. GREASE FITTING
7. NUT
8. NUT PLATE
9. BRAKE SWITCHES
10. SHIM
11. BUSHING
12. CONTROL ARM
13. PLUG
14. BALL PIVOT
15. CAPSCREW
16. WASHER
17. CLAMP
18. NUT
19. GAS SPRING
Figure 5. Control Handle (Standard Steering)
Control Handle 1600 SRM 1637
6

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
WARNING
The gas springs used on the control handle are
installed under tension and can release with
enough force to cause personal injury or property
damage.
WARNING
The capacitor in the transistor controller can hold
an electrical charge after the battery is disconnec-
ted. To prevent electrical shock and personal in-
jury, discharge the capacitor before inspecting or
repairing any component in the drive unit com-
partment. Wear safety glasses. Make certain the
battery has been disconnected.
Refer to Figure 7 for the following instructions:
Remove
1. Turn the key switch to the OFF position and discon-
nect the battery. Remove the drive unit compartment
cover. See Accessing the Drive Unit Compartment in
this section.
2. Discharge the capacitors. See Special Precautions in
this section.
CAUTION
DO NOT cut the wiring harnesses when removing
the wire ties.
NOTE: It is not necessary to remove the main wiring har-
ness unless harness is damaged and is being replaced.
3. CAREFULLY cut the wire ties securing the brake,
brake switch, and control handle wiring harnesses to-
gether at the right rear of MDU.
NOTE: Be certain to tag, identify, and note the routing of
the wires before disconnecting any wire. The wiring must
be routed properly at assembly to prevent steering problems
and prevent chafing of the harness.
4. Tag and disconnect the control handle wiring harness
from the main wiring harness.
5. Remove the two capscrews holding the cover to the
steer support studs and lift the cover off. See Figure 6.
6. Tag, identify, and disconnect the control handle wiring
from the brake switches. Remove the two screws and
spacer securing brake switches to the swivel. Remove
the switches.
7. Disconnect the proximity switch from the main wiring
harness. Remove the jam nut from the switch and un-
screw switch from the MDU.
NOTE: Be careful not to damage the brake switches when
removing the gas spring.
8. Remove the gas spring. Refer to Gas Spring in this sec-
tion.
1. CAPSCREW
2. CONTROL ARM
3. SWIVEL COVER
4. STEER SUPPORT BASE
5. DASH
Figure 6. Swivel Cover
1600 SRM 1637 Control Handle
7

9. Remove cotter pin from end of pivot pin. Remove
grease fitting if necessary. See Figure 7.
10. Using a brass drift and hammer, remove pivot pin from
swivel and control arm. See Figure 7.
NOTE: Make sure control handle wiring is disconnected/
removed before removing control arm from swivel.
11. Separate control arm from swivel. See Figure 7.
12. Inspect bushings for excessive wear, remove from con-
trol if necessary.
Install
Refer to Figure 7 for the following instructions.
1. Install bushings into control arm.
2. Position control handle to swivel. Install pivot pin into
control arm and swivel.
3. Install cotter pin into pivot pin. Install grease fitting if
removed.
4. Reconnect control handle wiring as removed. Refer to
tags for proper identification. Install wire ties as re-
moved to secure control handle wiring to main harness.
NOTE: Be careful not to damage the brake switches when
installing the gas spring.
5. Install the gas spring. Refer to Gas Spring in this sec-
tion.
1. SWIVEL
2. STUD
3. NUT
4. CAPSCREW
5. GREASE FITTING
6. BUSHING
7. PIN
8. CONTROL ARM
9. CAP
10. GAS SPRING
11. BALL STUD
12. SCREW
13. NUT PLATE
14. BRAKE SWITCHES
15. COTTER PIN
Figure 7. Control Arm Mounting (Power Assist Steering)
Control Handle 1600 SRM 1637
8

6. Calibrate the tiller angle potentiometer. Refer to the
sections User Interface 2200SRM1323 or User Inter-
face 2200SRM1324 for calibration procedures.
7. Position the cover to the steer swivel and install the
two capscrews to secure.
8. Install drive unit compartment covers. See Accessing
the Drive Unit Compartment in this section.
9. Connect the battery and turn the key switch to the ON
position and test for proper operation. Return the lift
truck to service.
Gas Spring
WARNING
Disconnect the battery by separating the battery
connector before opening the compartment 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 dis-
connected. To prevent electrical shock and per-
sonal injury, discharge the capacitor before in-
specting or repairing any component. Make cer-
tain the battery has been disconnected and al-
ways wear safety glasses. See Special Precau-
tions in this section. DO NOT attempt to discharge
the capacitors by shorting the controller.
WARNING
The gas spring used on the control handle is in-
stalled under tension and can release with
enough force to cause personal injury or property
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 lu-
bricant may be ejected from the drill operation
due to the high internal pressure.
CAUTION
The control handle return spring is charged with
pressurized gas and contains a hydraulic oil lubri-
cant.
NOTE: This process is a destructive operation to the gas
spring. A new gas spring must be used during reassembly.
This is necessary because internal damage to the spring
components which are not detectable could cause damage
or injury when the spring is removed.
1. Check that the handle return spring is installed and
properly secure the control handle arm in the full up-
right 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, approximately
50 mm (2 in.) below the existing access 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 accord-
ance with local regulations.
1600 SRM 1637 Gas Spring
9

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 Dis-
charging 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 hardware se-
curing the rod end of the gas spring to the tiller swivel.
CAUTION
Be careful not to damage the sensor when driving
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. Re-
move the gas spring. See Figure 8
INSTALL
1. Install ball stud and nut into control arm if removed.
Tighten to 27 N•m (20 lbf ft).
2. Lubricate both connection points with multipurpose
lithium complex grease with 2 to 4% molybdenum.
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 retention clip to the gas spring ball
socket as removed.
CAUTION
Be careful not to damage the brake switch while
driving in the pin.
4. On Power Assist Steer models, align the lower end of
the gas spring with the steer swivel retaining pin using
a flat screwdriver and hold in position. Drive the re-
taining pin into the swivel until flush.
1. BRAKE SWITCH
2. CAPSCREW
3. NUT
4. SWIVEL
5. ROD END
6. SUPPORT BASE
Figure 8. Gas Spring Lower Connection
Gas Spring 1600 SRM 1637
10

NOTE: Apply Loctite® 242 to the capscrew threads before
installing the nut.
5. On Standard Steer models, align the lower end of the
gas spring into position using a screwdriver and hold in
position. Install the hardware securing 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 con-
trol 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.
8. Test for proper operation. Install covers as removed.
Articulating Shaft and Pinions (EPAS)
REMOVE
1. Turn the key switch to the OFF position and discon-
nect battery. Remove the drive unit compartment cov-
ers.
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.
4. Loosen the two screws and remove the dash assembly.
Secure dash out of the way or tag, identify, and discon-
nect all wiring from the BDI display and key switch if
necessary to remove the dash. Refer to Electrical Sys-
tem 2200SRM1640.
5. Remove the capscrew and lock nut from the top of the
articulated shaft.
6. Secure a sling around the steer support plate. Attach an
overhead lifting device of sufficient capacity to the
sling. Tighten the lifting device to support the weight
of the steering support.
7. Slightly loosen the two upper capscrews, nuts, and
washers that hold the steering support to the frame.
8. Remove the two lower capscrews, nuts, and washers
that secure the steering support to the frame.
9. Lift the steer support (control arm end) so that it pivots
on the two upper capscrews to separate the gear pin
from the articulated shaft. Secure the articulated shaft
out of the way.
10. Remove the capscrew and lock nut from the bottom of
the articulated shaft.
11. Remove the articulating shaft from the lower pinion
shaft. See Figure 9.
1. CAPSCREW
2. ARTICULATING SHAFT
3. SUPPORT BASE
4. UPPER PINION SHAFT (NOTCH FORWARD)
5. WASHER
6. LOCKWASHER
7. LOCK NUT
Figure 9. Articulating Shaft
1600 SRM 1637 Articulating Shaft and Pinions (EPAS)
11

PINION REPAIR
CAUTION
Steering functions will not operate properly if pin-
ions are not aligned properly with steer swivel
(control handle) and drive tire.
Remove and repair the pinion assemblies as necessary.
Upper Pinion
After removing the articulating shaft, the upper pinion can
be removed from the support base for repair.
1. Remove two screws, two washers and gear cover plate
from the steer support. See Figure 10.
NOTE: Disassemble only as necessary for repair. Pinion
assembly parts are not individually repairable, but the as-
sembly may be replaced as a whole.
1. STEER SWIVEL
2. WASHER
3. SCREW
4. STEER SUPPORT GEAR
5. PINION GEAR
6. GEAR COVER PLATE
7. SUPPORT BASE
Figure 10. Gear Cover
2. Lift the upper pinion assembly from the support base.
Remove bearing from shaft. Drive pin from gear and
remove gear from shaft as necessary. See Figure 11.
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
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 handle) in the
straight ahead position. Position the gear cover to the
support base and install two screws and washers to se-
cure.
1. PINION GEAR
2. PINION SHAFT
3. BEARING
4. CAPSCREW
5. ARTICULATING
SHAFT
6. RETAINING PIN
7. WASHER
8. LOCK NUT
Figure 11. Upper Pinion Assembly
Articulating Shaft and Pinions (EPAS) 1600 SRM 1637
12

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 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
Figure 12. Lower Pinion Mounting
1. Remove the capscrew, lockwasher, washer, and gear
retaining washer from bottom of pinion assembly. Re-
move gear from shaft and recover the Woodruff key.
Remove pinion shaft and bearing from mounting
bracket. Remove bearing from shaft. See Figure 13.
1. LOWER PINION MOUNTING BRACKET
2. WASHER
3. LOCKWASHER
4. CAPSCREW
5. RETAINING WASHER
6. GEAR
7. BEARING
8. WOODRUFF KEY
9. PINION SHAFT
Figure 13. Lower Pinion Assembly
2. Install new bearing onto shaft and position into mount-
ing bracket as removed. Install the Woodruff key into
shaft. Align pinion shaft with the notch in the "straight
ahead" position.
CAUTION
Steering functions will not operate properly if pin-
ion is not installed with notch aligned properly
with drive tire.
3. Slide gear onto shaft and key. Secure in place with
gear retaining washer, washer, lockwasher, and cap-
screw as removed.
1600 SRM 1637 Articulating Shaft and Pinions (EPAS)
13

INSTALL
CAUTION
Ensure that the drive tire and notch of the lower
pinion shaft are aligned in the steer swivel (con-
trol handle) are aligned in the "straight ahead" po-
sition.
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 articulated shaft
pinions in the "straight ahead" position.
2. Install the articulated shaft onto the lower pinion shaft.
Install the capscrew into the lower clevis of the articu-
lated shaft next to the flat of the pinion to secure. In-
stall 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 articu-
lated shaft to the pinion.
4. Lower the steer support (control arm end) while guid-
ing 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 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).
7. Install the dash to the steer support as removed. Secure
using two screws. Refer to Electrical System
2200SRM1640.
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 operation.
Steer Motor Assembly
REPAIR
The steer motor assembly consists of three primary sec-
tions: the electric motor, the gearbox, and the steer motor
gear. Repair procedures vary greatly depending 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 assembly while installed to the drive unit.
See Steer Motor, Replace and Steer Motor Gear, Replace.
However if the gearbox or total assembly replacement is
necessary, the steer motor assembly and lower articulating
shaft bracket and gear must be removed from the drive unit.
This requires very specific alignment when reinstalling. See
Gearbox/Complete Assembly, Replace. Remove only com-
ponents necessary to safely complete repairs. In some in-
stances, total replacement may be preferred over compo-
nent repair. Discuss repair options with your supervisor.
Begin all repairs to the steer motor assembly with the fol-
lowing procedures:
1. Turn the key switch to the OFF position and discon-
nect battery. Remove the drive unit compartment cov-
ers. See GeneralGeneral.
2. Discharge the capacitor. See Special Precautions in
this section.
Steer Motor, Replace
Refer to Figure 14 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 re-
moved.
4. Install two screws and washers securing electric motor
to gearbox.
NOTE: Refer to tags on cables for proper reinstallation.
5. Install wiring and cables to steer motor as removed.
6. Calibrate the power assist steering sensor. See Calibra-
tion in this section.
Steer Motor Gear, Replace
Refer to Figure 15 for the following procedures.
Steer Motor Assembly 1600 SRM 1637
14