This document provides a table of contents and instructions for servicing various components of the steering mechanism for two models of lift trucks, MPE060-VG and MPE080-VG. The sections cover removing and installing the control handle, gas spring, articulating shaft, pinions, steer motor assembly, steer support assembly, and electronic coast control. Safety precautions are provided, and calibration is described for power assist steering models. Troubleshooting information is also included.
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YALE (A287) MPE080-VG LIFT TRUCK Service Repair Manual
1. MPE060-VG (A292) MPE080-VG (A287)
SERVICE MANUAL CONTENTS
SECTION
PART
NUMBER
YRM
NUMBER
REV
DATE
FRAME............................................................................................................................ 550025475 0100 YRM 1448 04/11
AC MOTOR REPAIR * (WITH EPAS)............................................................................. 524274699 0620 YRM 1283 10/13
MASTER DRIVE UNIT * (WITH EPAS).......................................................................... 524164715 0630 YRM 0961 10/13
STEERING SYSTEM...................................................................................................... 550025476 1600 YRM 1449 09/12
BRAKE SYSTEM............................................................................................................ 524274701 1800 YRM 1285 04/11
HYDRAULIC SYSTEM.................................................................................................... 550026124 1900 YRM 1450 04/11
TROUBLESHOOTING AND ADJUSTMENTS USING THE AC CONTROLS
PROGRAM................................................................................................................. 524183085 2200 YRM 1058 04/11
AC MOTOR CONTROLLER........................................................................................... 524274702 2200 YRM 1286 04/11
USER INTERFACE SUPERVISOR FUNCTIONS ON-BOARD DASH DISPLAY.......... 524290090 2200 YRM 1323 04/11
USER INTERFACE SERVICE TECHNICIAN FUNCTIONS ON-BOARD DASH
DISPLAY.................................................................................................................... 524290091 2200 YRM 1324 10/12
ELECTRICAL SYSTEM.................................................................................................. 550026125 2200 YRM 1451 04/11
INDUSTRIAL BATTERY................................................................................................. 524158040 2240 YRM 0001 09/14
LIFT MECHANISM.......................................................................................................... 550025477 4000 YRM 1452 12/12
METRIC AND INCH (SAE) FASTENERS....................................................................... 524150797 8000 YRM 0231 10/13
DIAGRAMS..................................................................................................................... 524274698 8000 YRM 1288 08/12
PERIODIC MAINTENANCE............................................................................................ 550025465 8000 YRM 1453 04/11
CAPACITIES AND SPECIFICATIONS........................................................................... 550025478 8000 YRM 1454 04/11
Service information for Cummins diesel engines can be ordered through the Hyster Literature Distribution Center.
PART NO. 550025474 (09/14)
2. 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 YALE 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 background.
The CAUTION symbol and word are on yellow background.
4. Table of Contents Steering Mechanism
TABLE OF CONTENTS (Continued)
Troubleshooting ................................................................................................................................................... 30
This section is for the following models:
MPE060-VG [A292];
MPE080-VG [A287]
ii
5. 1600 YRM 1449 General
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 con-
trol 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 posi-
tion.
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 Fig-
ure 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. Po-
sition 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
1. DRIVE UNIT COMPARTMENT COVER
2. RETAINER TABS
3. GRIP SLOT
4. FRAME
Figure 2. Drive Unit Compartment Cover
1
6. Special Precautions 1600 YRM 1449
Special Precautions
WARNING
The capacitor in the transistor controller can hold
an electrical charge after the battery is discon-
nected. 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 dis-
connected. 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 discon-
nect 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 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. 1. CONTROLLER
2. POSITIVE CONNECTION
3. INSULATED JUMPER WIRES
4. 200-OHM, 2-WATT RESISTOR
5. NEGATIVE CONNECTION
Figure 3. Discharging Capacitors
2
7. 1600 YRM 1449 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 steering units. This shield deflects the elec-
tromagnetic field generated 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.
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 di-
rection during startup, it is likely calibration needs
to be performed.
Power assist steering calibration should be performed
if either the torque sensor or power assist steering unit
is serviced or replaced or anytime the drive tire is re-
placed.
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
female spade connector hanging near the ETACC
CAN connector. Attach the Calibration Tab to the
B+ terminal (right post) of the contactor, using a
914 mm (36 in.) 14 Ga. jumper wire with an alli-
gator 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.
NOTE: Communication error codes may appear during
this process. This is a normal part of the calibration
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 re-
move 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.
A. BRAKE ON
B. REGEN BRAKING
C. BRAKE OFF
Figure 4. Brake Activation
3
8. Control Handle 1600 YRM 1449
9. If no power steering error appears, the power steer-
ing 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.
Control Handle
CONTROL HANDLE HEAD
The control handle head is primarily an electronic com-
ponent and is discussed in the electrical section. For
instructions on how to remove, install, or repair the con-
trol handle head, refer to the section Electrical System
2200 YRM 1451.
CONTROL HANDLE
The following procedures describe the removal and dis-
assembly of parts of the control handle and dash as-
sembly for repairs. The control handle and dash as-
sembly 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 Assembly in this
section.
Standard Steering
WARNING
The gas springs used on the control handle are in-
stalled under tension and can release with enough
force to cause personal injury or property damage.
WARNING
The capacitor in the 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 com-
ponent 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.
Remove
1. Turn the key switch to the OFF position and discon-
nect the battery. Remove the drive unit compart-
ment cover. See Accessing the Drive Unit Com-
partment 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
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 be-
fore 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 brake wiring harness (two-
pin connector) located near the brake.
5. Tag and disconnect the control handle wiring har-
ness (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 instal-
lation. Remove the control handle arm from the
swivel.
9. Carefully pull the wiring harnesses through the cen-
ter of the support.
10. Remove bushings from the control handle arm if
necessary.
4
9. 1600 YRM 1449 Control Handle
11. If necessary, remove the control handle head. See
the section Electrical System 2200 YRM 1451.
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
using two screws.
2. Install bushings into the control handle arm if re-
moved.
3. Install the control handle head if removed. See the
section Electrical System 2200 YRM 1451. Pull
wiring harness through control handle arm and se-
cure 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 cen-
ter of the support.
1. SCREW
2. COVER
3. PIN
4. PIVOT SHAFT
5. SWIVEL
6. GREASE FITTING
7. NUT
8. NUT PLATE
9. BRAKE SWITCHES
10. SCREW
11. SHIM
12. BUSHING
13. CONTROL ARM
14. PLUG
15. BALL PIVOT
16. CAPSCREW
17. BUSHING
18. SCREW
19. WASHER
20. CLAMP
21. NUT
22. SCREW
23. LOCKWASHER
24. WASHER
25. PLUG
26. NUT
27. GAS SPRING
28. CAPSCREW
29. BUSHING
Figure 5. Control Handle (Standard Steering)
5
10. Control Handle 1600 YRM 1449
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 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.
CAUTION
Make sure that the wiring is properly routed to pre-
vent 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 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 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 se-
cure 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 in-
stalled 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 discon-
nected. To prevent electrical shock and personal
injury, 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 compart-
ment cover. See Accessing the Drive Unit Com-
partment 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
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 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 har-
ness from the main wiring harness.
5. Gently pry the Yale 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 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 unscrew switch from the MDU.
6
11. 1600 YRM 1449 Control Handle
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
section.
9. Unscrew right pivot pin from swivel. Remove
grease fitting if necessary.
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 7.
Install
Refer to Figure 7 for the following instructions.
1. Install bushings and grease fittings if removed. As-
semble pivot pins if necessary.
2. Position control handle to swivel. Apply Loctite®
242 to threads and install pivot pins to secure.
Tighten pivot pins to 95 to 102 N•m (70 to 75 lbf ft).
3. Reconnect control handle wiring as removed. Refer
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 switches
when installing the gas spring.
4. Install the gas spring. Refer to Gas Spring in this
section.
5. Calibrate the tiller angle potentiometer. Refer to
the sections User Interface, Supervisor Func-
tionsOn-Board Dash Display 2200 YRM 1323 or
User Interface, Service Technician Function-
sOn-Board Dash Display 2200 YRM 1324 for
calibration procedures.
6. Position the cover to the steer swivel and install the
two screws and washers to secure. Gently snap the
Yale plate into the center of the swivel cover.
7. Install drive unit compartment covers. See Access-
ing the Drive Unit Compartment in this section.
8. Connect the battery and turn the key switch to the
ON position and test for proper operation. Return
the lift truck to service.
1. NUT
2. WASHER
3. STUD
4. CONTROL ARM
5. SWIVEL COVER
6. STEER SUPPORT BASE
7. DASH
8. PLATE
Figure 6. Swivel Cover
7
12. Control Handle 1600 YRM 1449
1. SWIVEL
2. STUD
3. NUT
4. CAPSCREW
5. GREASE FITTING
6. BUSHING
7. PIN
8. CONTROL ARM
9. CAPSCREW
10. NUT
11. BUSHING
12. NUT
13. GAS SPRING
14. BALL STUD
15. BUSHING
16. PIN
17. DRIVE PIN
18. SCREWS
19. SPACER
20. SWITCH
21. SWITCH
Figure 7. Control Arm Mounting (Power Assist Steering)
8
13. 1600 YRM 1449 Gas Spring
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 discon-
nected. To prevent electrical shock and personal
injury, discharge the capacitor before inspecting or
repairing any component. Make certain the battery
has been disconnected and always wear safety
glasses. See Special Precautions 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 lubri-
cant 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 dam-
age to the spring components which are not detectable
could cause damage or injury when the spring is re-
moved.
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 in-
crease visibility of the gas spring.
CAUTION
DO NOT damage the control handle wiring harness
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 harness
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.
9
14. Gas Spring 1600 YRM 1449
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 ham-
mer. Remove 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).
1. GREASE FITTING
2. PIVOT PIN
3. BRAKE SWITCH
4. RETAINING PIN
5. SWIVEL
6. BUSHING
7. ROD END
8. SUPPORT BASE
9. GREASE FITTING
10. GAS SPRING ROD
Figure 8. Gas Spring Lower Connection
2. Lubricate both connection points with multipurpose
lithium complex grease with 2 to 4% molybdenum.
CAUTION
DO NOT damage the control handle wiring harness
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 retaining pin into the swivel until flush.
NOTE: Apply Loctite® 242 to the capscrew threads be-
fore 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
control handle shaft as removed.
NOTE: Apply Loctite® 242 to the capscrew threads be-
fore 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 re-
moved.
10
15. 1600 YRM 1449 Articulating Shaft and Pinions (Power Assist Models)
Articulating Shaft and Pinions (Power Assist Models)
REMOVE
1. Turn the key switch to the OFF position and discon-
nect battery. Remove the drive unit compartment
covers.
2. Discharge the capacitor. See Special Precautions
in this section.
3. Gently pry the Yale cover from the center of the
steer support cover. Remove the two screws and
washers securing the cover to the steer support and
lift the cover off.
4. Loosen the two screws and remove the dash as-
sembly. Secure dash out of the way or tag, identify,
and disconnect all wiring from the BDI display and
key switch if necessary to remove the dash. Refer
to Electrical System 2200 YRM 1451.
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 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 wash-
ers 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 ar-
ticulated 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.
PINION REPAIR
CAUTION
Steering functions will not operate properly if pin-
ions are not aligned properly with steer swivel (con-
trol 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. See
Figure 10.
1. CAPSCREW
2. CAPSCREW
3. CAPSCREW
4. ARTICULATING SHAFT
5. CAPSCREW
6. SUPPORT BASE
7. UPPER PINION SHAFT (NOTCH FORWARD)
8. WASHER
9. WASHER
10. WASHER
11. LOCK NUT
12. WASHER
13. LOCK NUT
14. LOCK NUT
15. LOCKWASHER
Figure 9. Articulating Shaft
11
16. Articulating Shaft and Pinions (Power Assist Models) 1600 YRM 1449
Remove
1. Remove the two screws and washers securing the
gear cover to the steer support and remove gear
cover.
WARNING
Be careful when removing or installing snap rings.
The snap rings can come loose during removal or
installation with enough force to cause personal in-
jury. Always use the correct snap ring pliers, and
eye wear and face protection during removal or in-
stallation.
2. From the underside of the support base, remove the
snap ring from the shaft end of the pinion gear and
lift the gear from the support base.
3. Remove the snap ring securing the bearing from
the top side of the support base and remove the
bearing as necessary.
Install
1. Install the bearing into the support base followed by
the snap ring as removed.
CAUTION
Ensure that the pinion gear notch and steer swivel
(control handle) are aligned in the "straight ahead"
position before continuing.
2. Insert the pinion gear into the support base with the
notch aligned with the steer swivel (control handle)
in the straight ahead position.
1. PINION GEAR
2. SNAP RING
3. BEARING
4. HOUSING
5. SNAP RING
6. CAPSCREW
7. LOCK NUT
8. ARTICULATING SHAFT
9. GEAR COVER
10. WASHER
11. SCREW
12. SUPPORT BASE
13. STEER SWIVEL
Figure 10. Gear Cover and Upper Pinion
12
17. 1600 YRM 1449 Articulating Shaft and Pinions (Power Assist Models)
3. From the underside of the support base, install the
snap ring onto the shaft end of the pinion gear.
4. Position the gear cover onto the support base and
install the two screws and washers to secure.
Lower Pinion
After removing the articulating shaft, the lower pinion
can be removed from the mounting plate for repair. See
Figure 11.
1. Remove the capscrew, lockwasher, washer, and
gear retaining washer from bottom of pinion as-
sembly. Remove gear from shaft and recover the
Woodruff key. Remove pinion shaft and bearing
from mounting bracket. Remove bearing from
shaft. See Figure 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 11. Lower Pinion Mounting
2. Install new bearing onto shaft and position into
mounting 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
capscrew as removed.
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 12. Lower Pinion Assembly
13
18. Steer Motor Assembly 1600 YRM 1449
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 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 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.
4. Lower the steer support (control arm end) while
guiding the articulated shaft onto the pinion shaft.
5. Install the remaining two lower capscrews, wash-
ers, 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. In-
stall 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 Sys-
tem 2200 YRM 1451.
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.
Steer Motor Assembly
REPAIR
The steer motor assembly consists of three primary
sections: the electric motor, the gearbox, and the steer
motor gear. Repair procedures vary greatly depend-
ing on what components are being serviced. If only
the electric motor or the steer motor gear is to be re-
placed, they may simply be replaced on the assembly
while installed to the drive unit. See Steer Motor, Re-
place 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 components necessary 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 assem-
bly 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.
2. Discharge the capacitor. See Special Precautions
in this section.
Steer Motor, Replace
Refer to Figure 13 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 reinstallation.
5. Install wiring and cables to steer motor as removed.
6. Calibrate the power assist steering sensor. See
Calibration in this section.
14
19. 1600 YRM 1449 Steer Motor Assembly
1. STEER MOTOR
2. GEARBOX
3. WASHER
4. CAPSCREW
5. SHAFT
6. WOODRUFF KEY
Figure 13. Steer Motor
Steer Motor Gear, Replace
Refer to Figure 14 for the following procedures.
1. Remove the capscrew and washers 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.
4. Install the washers and capscrew securing gear to
shaft as removed.
1. LOWER PINION
SHAFT
2. BEARING
3. WOODRUFF KEY
4. LOWER PINION
GEAR
5. WASHER
6. CAPSCREW
7. CAPSCREW
8. WASHER
9. STEER MOTOR
GEAR
10. WOODRUFF KEY
11. SCREW
12. WASHER
13. BRACKET
14. STEER MOTOR
15. LOCK WASHER
Figure 14. Steer Motor Assembly
15
20. Steer Motor Assembly 1600 YRM 1449
Gearbox/Complete Assembly, Replace
Refer to Figure 13 and Figure 14 for the following pro-
cedures.
CAUTION
Very small variations of gear installations can pre-
vent steering systems from operating properly.
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 information.
2. Remove the steering motor gear. See Steer Motor
Gear, Replace.
NOTE: The screws that secure the steer motor also se-
cure 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 gear-
box. Remove the gearbox from the motor and in-
stall 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 systems
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 Pinions
(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.
16
21. 1600 YRM 1449 Steer Support Assembly
Steer Support Assembly
STANDARD STEERING
WARNING
The steering assembly and dash is heavy and re-
quires the use of an overhead lifting device to posi-
tion 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 pro-
cedure 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 traction motor. Some items
may be serviced without removing the steer support as-
sembly. Remove only the components necessary to
safely complete the required service.
Remove (Complete Unit)
1. Turn the key switch to the OFF position and discon-
nect battery. Remove the drive unit compartment
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.
4. Loosen the two screws and remove the dash as-
sembly. Secure dash out of the way or tag, identify,
and disconnect all wiring from the BDI display and
key switch if necessary to totally remove the dash.
See Electrical System 2200 YRM 1451.
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. Remove
the connecting plate.
7. Secure a sling around the steer support plate. At-
tach an overhead lifting device of sufficient capacity
to the sling. Tighten the lifting device to support the
weight of the steering support. See Figure 16.
8. Remove the four capscrews, washers, and nuts se-
curing the steer support assembly to the frame.
9. Using the overhead lifting device, carefully remove
the steer support from the frame.
Disassemble
For the following instructions, refer to Figure 15.
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 YRM 1451 for additional
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.
c. Remove the lower bearing from stand-off using
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.
17
23. 1600 YRM 1449 Steer Support Assembly
Assemble
1. Install bearing races to support using a hammer
and proper size bearing driver, if removed.
2. Pack bearings with Yale synthetic grease, P/N
524226586, using a standard bearing packing
device. 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 secure
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.
8. Install control handle wiring harness through sup-
port.
9. Place cover on swivel and secure with screws.
Install (Complete Unit)
1. Using the overhead lifting device, carefully position
the steer support to the frame. Align the holes in
the steer support with mounting holes in the frame.
See Figure 16.
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 de-
vice.
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.
4. Reconnect wiring to the BDI display and key switch
if removed. Align the slots in the dash with the re-
taining screws and position the dash to the steering
support and frame. Tighten the two screws to se-
cure the dash assembly in place. See Electrical
System 2200 YRM 1451.
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 operation.
19
24. Steer Support Assembly 1600 YRM 1449
POWER ASSIST STEERING (OPTION)
WARNING
The steering assembly and dash is heavy and re-
quires the use of an overhead lifting device to posi-
tion 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 pro-
cedure 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 traction motor. Some items
may be serviced without removing the steer support as-
sembly. Remove only the components necessary to
safely complete the required service.
1. STRAP
2. TILLER HANDLE
3. SUPPORT
4. ARTICULATING SHAFT
5. NUT
6. LOCKWASHER
7. WASHER
8. WASHER
9. CAPSCREW
Figure 16. Steering and Dash - Complete Removal
20
25. 1600 YRM 1449 Steer Support Assembly
Remove (Complete Unit)
Refer to Figure 16 for the following instructions.
1. Turn the key switch to the OFF position and discon-
nect battery. Remove the drive unit compartment
covers.
2. Discharge the capacitor. See Special Precautions
in this section.
3. Gently pry the Yale cover from the center of the
steer support cover. Remove the two screws and
washers securing the cover to the steer support and
lift the cover off.
4. Loosen the two screws and remove the dash as-
sembly. Secure dash out of the way or tag, identify,
and disconnect all wiring from the BDI display and
key switch if necessary to remove the dash. See
Electrical System 2200 YRM 1451.
5. Identify, tag, and disconnect the control handle
wiring harness, the brake switch, and the sensor
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 Articulating
Shaft and Pinions (Power Assist Models) in this sec-
tion.
7. Lower the overhead lifting device until the steer sup-
port rests on top of the brake. Readjust the sling
and tighten to support the steer support evenly.
8. Remove the remaining capscrews, nuts, and wash-
ers securing the steer support to the frame.
9. Using the overhead lifting device, carefully remove
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 nec-
essary to access the support base. See Remove
(Complete Unit) in this section. Move the assem-
bly 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 17. Lift the
pinion from the support base. Repair or replace as
necessary. Refer to Articulating Shaft and Pinions
(Power Assist Models).
1. STEER SWIVEL
2. WASHER
3. SCREW
4. STEER GEAR
5. PINION
6. GEAR COVER
7. SUPPORT BASE
Figure 17. Steer Gear and Pinion
21
26. Steer Support Assembly 1600 YRM 1449
3. Remove two capscrews and washers from the bot-
tom of the support base. See Figure 18. Lower the
support base from the center support.
4. Remove the snap ring and bearing from the support
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 Fig-
ure 19.
NOTE: Make note of torque sensor position and orien-
tation.
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. Repair
or replace as necessary. See Figure 20.
Steer Swivel
The steer swivel may be disassembled to access the
steer swivel bearings. The support base must be dis-
assembled first in order to disassemble the steer swivel.
See Disassemble, Support Base.
1. Remove the bearing nut from the bottom of the cen-
ter support. See Figure 21.
2. Lift the steer swivel from the top of the center sup-
port and place on a clean workbench.
3. Remove the lower bearing from the bottom of the
center support.
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.
Assemble
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 re-
pair or replace as necessary.
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 21.
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 support
flange. Install the lower bearing to the center sup-
port 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 support
flange. Install the swivel and bearing assembly 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 support
base may be assembled. See Assemble, Steer Swivel.
CAUTION
The torque sensor must be correctly set in align-
ment and installed in the proper orientation. New
torque sensors will have an alignment pin or col-
lar which should not be removed until the sensor
is installed to the swivel shaft. Sensors being rein-
stalled 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 20) 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 po-
sition key or collar pointing down toward the steer gear.
Do not remove key or collar until torque sensor is in-
stalled to truck.
22
27. 1600 YRM 1449 Steer Support Assembly
1. SUPPORT BASE
2. SNAP RING
3. CAPSCREW AND LOCKWASHER
4. CENTER SUPPORT
5. PINION SHAFT
Figure 18. Support Base
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 19. Steer Gear and Torque Sensor
1. SWIVEL NUT
2. SWIVEL SHAFT
3. CENTER SUPPORT
4. GUARD
5. TORQUE SENSOR
6. ALIGNMENT RAIL (THIN)
7. ALIGNMENT RAIL (THICK)
Figure 20. Torque Sensor and Guard
23
28. Steer Support Assembly 1600 YRM 1449
1. SWIVEL
2. PIN
3. UPPER BEARING
4. TORSION SHAFT
5. CENTER
SUPPORT
6. LOWER BEARING
7. BEARING NUT
Figure 21. Swivel and Bearing Assembly
1. Align the torque sensor by hand if position key or
collar has been removed:
a. The sensor has two independent actuators lo-
cated inside the inner diameter of the sensor.
Each actuator has a raised alignment rail. Turn
the actuators 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 lo-
cated on the bottom of the sensor (toward the
steer gear). The torque sensor will not op-
erate properly if installed in the alignment
rails in the incorrect position or if the sen-
sor is installed upside down. See Figure 22.
2. Remove the metal ring from the top side of the
torque sensor.
CAUTION
Fit should be tight but be careful not to damage sen-
sor when installing over threaded swivel shaft; no
tools are necessary to assemble torque sensor to
swivel shaft.
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 installed onto
the shaft so that it seats directly into the sensor guard.
3. 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 po-
sition key (paperclip) or alignment collar. See Fig-
ure 23.
4. 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 secure
lower end of torsion bar to bottom of gear.
5. Apply Loctite® 641 to the outside of the outer race
of the support bearing and install into the support
base shaft using the proper sized driver. Make sure
the bearing fully seats into the flange of the support
base. Apply Loctite® 641 to the inside of the inner
race of the support bearing.
6. Position the support base (with bearing installed) to
the bottom of the center support as removed. Make
sure the steering gear hub installs through the sup-
port bearing and the support base properly seats
against the flange of the center support before tight-
ening capscrews. Install two capscrews and lock-
washers to the bottom of the support base. Torque
capscrews to 40 N•m (30 lbf ft). See Figure 24.
7. 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 pin-
ion is not aligned with steer swivel (control handle).
8. Install the pinion into the support base with the
notch aligned with the steer swivel (control handle)
in the straight ahead position. Refer to Articulat-
ing Shaft and Pinions (Power Assist Models) in this
section. Position the gear cover to the support base
and install two screws and washers to secure. See
Figure 17.
24
29. 1600 YRM 1449 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 22. Torque Sensor and Guard
1. SWIVEL
2. CENTER SUPPORT
3. SENSOR GUARD
4. TORQUE SENSOR
5. TORSION SHAFT
6. PIN
7. STEER GEAR
8. POSITION KEY
9. BEARING
10. RETAINING RING
Figure 23. Support Base Installation
1. SUPPORT BASE
2. SUPPORT BEARING AND SNAP RING
3. CAPSCREW AND LOCKWASHER
4. CENTER SUPPORT
5. PINION SHAFT
Figure 24. Support Base
25
30. Steer Support Assembly 1600 YRM 1449
Install (Complete Unit)
1. Align the drive tire and the notch of the lower artic-
ulated shaft pinion in the "straight ahead" position.
2. Using the overhead lifting device, carefully position
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, washers,
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 han-
dle), and upper and lower pinion shafts are aligned
properly before installing the articulating shaft.
5. Install the articulating shaft. Refer to Articulating
Shaft and Pinions (Power Assist Models) in this sec-
tion.
6. Install the remaining two lower capscrews, wash-
ers, 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.
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 re-
taining screws and position the dash to the steering
support and frame. Tighten the two screws to se-
cure the dash assembly in place. See Electrical
System 2200 YRM 1451.
9. Position the cover onto the steer support. Install
the two screws and washers securing the cover in
place. Place the Yale 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 handle 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 operation.
26
31. 1600 YRM 1449 Electronic Coast Control (Option)
Electronic Coast Control (Option)
DISASSEMBLE
1. Remove six screws and remove the cover halves
from the control handle. See Figure 25.
2. Remove four nuts, washers, and screws retaining
the guard to the control handle. See Figure 26.
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 27.
1. SCREW
2. COVER
3. CONTROL HANDLE
4. GUARD
Figure 25. Covers
6. On Power Steer trucks only, remove the insert from
the steering pivot cover and remove the two screws
retaining the cover. See Figure 28. Remove the
cover.
7. Remove the screw, washer, and nut retaining the
coast control rod to the lower mount. See Figure 27.
8. Remove the coast control unit from the lift truck.
9. Remove clevis from end of coast control cylinder
rod. See Figure 29.
1. NUT
2. WASHER
3. SCREW
4. CONTROL
HANDLE
5. GUARD
Figure 26. Guard
27
32. Electronic Coast Control (Option) 1600 YRM 1449
1. PIN
2. SCREW
3. NUT
4. WASHER
5. RETAINING RING
6. CONTROL HANDLE
Figure 27. Mounting
1. INSERT
2. SCREW
3. COVER
4. CONTROL HANDLE
Figure 28. Cover
28
33. 1600 YRM 1449 Electronic Coast Control (Option)
1. COAST CONTROL UNIT
2. BOOT
3. NUT
4. CLEVIS
Figure 29. Clevis
10. Remove nut from rod and remove boot.
NOTE: The coast control unit is non-serviceable and
must be replaced as a complete unit.
ASSEMBLE
1. Install the boot over the rod. See Figure 29.
2. Thread the nut supplied with the coast control unit
to the end of the threads on the rod.
3. Apply Loctite 242 to the threads on the end of the
rod.
4. Thread the clevis onto the rod until it touches the
nut. Tighten the nut against the clevis to lock the
clevis in place.
5. Assemble the coast control unit to the control han-
dle using the pin and retaining ring. See Figure 27.
6. Align the clevis with the lower coast control unit
mount and install the shoulder bolt, washer, and
nut.
7. On Power Steer trucks, install the steering pivot
cover and install the two screws to retain the cover.
See Figure 28. Install the insert.
8. Connect the coast control unit wiring harness to the
main harness connections.
9. Install the coast control guard to the control handle.
See Figure 26.
10. Install the cover halves to the guard using screws.
See Figure 25.
NOTE: Ensure the alignment tabs on the boot align with
the slots in the cover halves.
CHECKS
1. With the coast control engaged, the lift truck speed
must not exceed 4.0 mph.
2. With the coast control engaged, the control handle
must be able to be manually moved to the 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.
29
34. Troubleshooting 1600 YRM 1449
Troubleshooting
PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION
Steering is rough or difficult. Power steering sensor out of calibra-
tion.
Calibrate power steering sensor.
Power steering "Relaxed" due to sen-
sor or system fault.
Check for error codes. (PS may re-
sume once truck stops if system recov-
ers)
Steering handle swivel bearing(s)
need lubrication.
Lubricate or repack bearings.
Bearing retaining nut torque incorrect. Loosen retaining nut and re-torque to
19 N•m (26 lbf ft).
Steering handle does not re-
turn to the vertical position.
Gas spring is weak or broken. Replace gas spring.
Gas spring ball stud broken or loose. Retighten or replace gas spring ball
stud.
30
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