Steering System: N35ZDR, N45ZR (C264) N30ZDR, N35-40ZR (D470) N30ZDRS, N35-40ZRS (A265)
Steering System: N35ZDR, N45ZR (C264) N30ZDR, N35-40ZR (D470) N30ZDRS, N35-40ZRS (A265)
Steering System: N35ZDR, N45ZR (C264) N30ZDR, N35-40ZR (D470) N30ZDRS, N35-40ZRS (A265)
• 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.
• Always use HYSTER APPROVED parts when making repairs. Replacement parts must meet
or exceed the specifications of the original equipment manufacturer.
• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force
to remove parts.
• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the
unit needs repairs.
• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are
flammable. Be sure to follow the necessary safety precautions when handling these fuels and
when working on these fuel systems.
• Batteries generate flammable gas when they are being charged. Keep fire and sparks away from
the area. Make sure the area is well ventilated.
NOTE: The following symbols and words indicate safety information in this
manual:
WARNING
Indicates a hazardous situation which, if not avoided, could result in
death or serious injury.
CAUTION
Indicates a hazardous situation which, if not avoided, could result in
minor or moderate injury and property damage.
On the lift truck, the WARNING symbol and word are on orange back-
ground. The CAUTION symbol and word are on yellow background.
Steering System Table of Contents
TABLE OF CONTENTS
General ............................................................................................................................................................... 1
Discharging the Capacitors........................................................................................................................... 1
Raising the Lift Truck ................................................................................................................................... 3
How to Raise the Drive Tire End.............................................................................................................. 3
How to Raise the Entire Lift Truck .......................................................................................................... 4
Description ......................................................................................................................................................... 4
Steering Handle Assembly ................................................................................................................................ 7
Fixed Handle.................................................................................................................................................. 7
Description................................................................................................................................................. 7
Remove....................................................................................................................................................... 7
Disassemble ............................................................................................................................................... 9
Assemble .................................................................................................................................................... 11
Install ......................................................................................................................................................... 11
Adjustable Handle ......................................................................................................................................... 11
Description................................................................................................................................................. 11
Remove....................................................................................................................................................... 12
Disassemble ............................................................................................................................................... 12
Assemble .................................................................................................................................................... 16
Install ......................................................................................................................................................... 16
Steering Controller ............................................................................................................................................ 17
Description ..................................................................................................................................................... 17
Remove ........................................................................................................................................................... 17
Disassemble ................................................................................................................................................... 18
Assemble ........................................................................................................................................................ 18
Install ............................................................................................................................................................. 18
Steering Proximity Switch ................................................................................................................................ 19
Replace ........................................................................................................................................................... 19
Steering Motor ................................................................................................................................................... 20
Description ..................................................................................................................................................... 20
Remove ........................................................................................................................................................... 20
Disassemble ................................................................................................................................................... 21
Assemble ........................................................................................................................................................ 21
Install ............................................................................................................................................................. 21
Caster Assembly - General ................................................................................................................................ 22
Caster Adjustment......................................................................................................................................... 22
Elastomer Spring Type Adjustment ......................................................................................................... 22
Belleville Spring Type Adjustment .......................................................................................................... 23
Spring Pack Replacement ......................................................................................................................... 25
Remove Spring Assembly ..................................................................................................................... 25
Replace Spring Pack ............................................................................................................................. 26
Install Spring Assembly ....................................................................................................................... 26
Caster Wheels .................................................................................................................................................... 27
Remove ........................................................................................................................................................... 27
Install ............................................................................................................................................................. 28
Caster Wheel Assembly (Nonsteered)............................................................................................................... 28
Description ..................................................................................................................................................... 28
Remove ........................................................................................................................................................... 29
Disassemble ................................................................................................................................................... 30
Upper and Lower Support Housings........................................................................................................ 30
Spring Assembly From Lower Support Assembly ................................................................................... 30
Caster Spindle From Lower Support ....................................................................................................... 31
ii
1600 SRM 1187 General
General
WARNING WARNING
The AC Reach Truck has a cooling fan installed These lift truck models may be furnished with
under the front left cover to regulate the mo- automotive or reverse steering. Before work-
tor controller temperatures. Some trucks have ing on any of these lift trucks, be sure of the
a motor door fan installed as an added option type of steering that has been installed on the
for higher temperatures or extreme duty cycle lift truck.
operations. The cooling fans of the motor con-
trollers and motor compartment (if installed) Throughout this section, forward will refer to travel
run continuously when power is on. Remove in the direction of the forks. Left and right will be
power from the truck by turning the key switch determined by an operator standing in the operator
OFF and unplugging the battery before servic- compartment facing the forks. See Figure 1.
ing the truck or removing covers.
If power-on diagnostic checks are necessary re-
quiring servicing the truck with the covers re-
moved or the motor door open, the fans should
be unplugged first or suitable guards installed
over the fans to prevent possible injury from
the rotating blades of the fans. If diagnostic
checks require the lift motor or drive motor to
be used, the motor controller fan is required to
prevent the motor controllers from overheat-
ing and the front left cover for the fan must re-
main in place during operation of the truck.
CAUTION
Electrical components on this truck are po-
larity sensitive and may be damaged if wired A. LEFT SIDE
incorrectly. Make sure each electrical wire B. RIGHT SIDE
C. FORWARD TRAVEL
connection is tagged and properly identified
before removal or installation. If the proper Figure 1. Truck Orientation
location for connection is unclear, consult the
wiring diagram for the truck. Make sure test- DISCHARGING THE CAPACITORS
ing meters have adequate voltage and current
capacities to handle the output of the electri-
WARNING
cal components they are used to check. Never
wire aftermarket components to this truck DO NOT make repairs or adjustments unless
without factory approval. you have both authorization and training. Re-
pairs and adjustments that are not correct can
This section describes the disassembly and assembly create dangerous operating conditions. DO
of the steering system. There is a description for each NOT operate a lift truck that needs repairs.
part of the steering system. The steering system is Report the need for repairs to your supervisor
primarily electronic. The steering handle assembly immediately. If repair is necessary, attach a
turns a steering sensor, which supplies a signal to DO NOT OPERATE tag on the steering wheel.
the steering controller. The steering controller sends Remove the key from the key switch.
current to the steering motor, which drives the mas-
ter drive unit (MDU) through a gear set to steer the Disconnect the battery before opening the elec-
lift truck. trical compartment covers or inspecting or re-
pairing the electrical system. If a tool causes
a short circuit, the high current flow from the
battery can cause personal injury or property
damage.
1
General 1600 SRM 1187
Some checks and adjustments are done with NOTE: Some lift trucks are equipped with a premium
the battery connected. DO NOT connect the controller, which controls the hydraulic motor as well
battery until the procedure tells you to do so. as the traction motors.
Never have any metal on your fingers, arms,
or neck. Metal items can accidentally make an 3. Discharge the capacitor in the controller by con-
electrical connection and cause injury. necting a 200-ohm, 2-watt resistor across the
controller’s B+ and B terminals for 10 seconds
Before performing any tests or adjustments, using insulated jumper wires. See Figure 2.
block the lift truck to prevent unexpected
movement.
CAUTION
To avoid controller damage, always disconnect
the battery, discharge the capacitor(s), and
never put power to the controller while any
power wires are disconnected. Never short 1. POSITIVE CONNECTION (B+)
any controller terminal or motor terminal to 2. NEGATIVE CONNECTION (B )
the battery. Make sure to use proper proce- 3. INSULATED JUMPER WIRES
dure when servicing the controller. 4. 200-OHM, 2-WATT RESISTOR
1. Turn key switch to OFF position and disconnect Figure 2. Discharging the Capacitors
the battery. Block load wheels to prevent lift
truck from moving.
2
1600 SRM 1187 General
RAISING THE LIFT TRUCK of these components and other lift points are
not designed to support the weight of the lift
WARNING truck. The truck can be damaged or it can fall
on someone causing serious injury. Attach a
The lift truck must be put on blocks or an ap-
chain or sling to a support structure of the lift
proved stand for some types of maintenance
truck frame.
and repair. The removal of the following as-
semblies will cause large changes in the center Put the lift truck on blocks only if the surface is solid,
of gravity: mast and load axle, battery, and the even, and level. Make sure that any blocks used to
counterweight. When the lift truck is put on support the lift truck are solid, one-piece units. Put
blocks, put additional blocks under the rear of blocks in front and back of the tires to prevent move-
the frame before removing the mast so the lift ment of the lift truck.
truck cannot fall backward or to the side.
3
Description 1600 SRM 1187
2. Use a special low-clearance hydraulic jack under 1. Remove the mast from the lift truck. Refer to
the rear of the frame to raise the drive/steer tire Mast, Repair 4000 SRM 1195.
and caster wheels. Another lift truck can also be
used to raise the lift truck. Make sure that the 2. Turn the key to the OFF position and disconnect
jack or other lifting device has a capacity of at the battery from the lift truck at the battery con-
least 2/3 of the total weight of the lift truck as nector.
shown on the nameplate.
WARNING
3. Raise the lift truck only enough to suspend the
The battery is heavy. Use appropriate lifting
drive/steer tire and the caster wheels. Install
equipment to avoid personal injury.
blocks under the rear of the frame to support the
lift truck. 3. Remove the battery from the lift truck.
Description
The steering system is primarily electronic. See Fig- • Adjustable
ure 4. The steering handle assembly is attached to The fixed steering handle assembly has the steering
a sensor unit that senses the direction and speed handle rotation center fixed and cannot be moved.
of rotation of the steering handle. The sensor unit The adjustable steering handle assembly has a fea-
sends a signal to the steering controller, which, in ture where the steering handle center of rotation may
turn, controls electrical power to the steering motor be moved to provide more efficient and comfortable
mounted to the MDU mounting plate. The steering operation. Both steering handle options are avail-
motor turns a gear on the end of the motor shaft that able with either stance configuration. With the fore/
meshes with a large gear attached to the MDU. As aft stance configuration, the steering handle assem-
the steering motor rotates, the MDU also rotates. bly is mounted in the horizontal position. In the
The speed of rotation is directly proportional to how sidestance configuration, the steering handle assem-
fast the steering wheel is being rotated. The speed bly is mounted at a slight angle toward the operator.
of rotation is also regulated by the speed of the lift
truck. As the speed of the lift truck increases, the Two versions of the caster assembly are also avail-
steering controller will slow the speed of the steering able on these lift trucks. The standard configuration
motor as the steering handle is turned. is a nonsteered caster assembly. An optional steered
caster with a separate caster steering controller is
The lift truck listed on the front cover of this section also available.
come in several optional configurations. All configu-
rations are covered by this section. These lift trucks During startup, the steering system will perform a
are available with two steering operating positions: self-test and center the drive wheel. The proximity
• Sidestance sensor located on the MDU plate signals the steering
• Fore/Aft Stance controller when the drive wheel is in the centered
position. The lift truck will "wiggle" during startup
The steering handle assembly used on these lift as the drive tire self-centers. The optional steered
trucks also comes in two optional configurations: caster assembly also includes a centering proximity
• Fixed switch and will self-center at truck startup.
4
1600 SRM 1187 Description
5
Description 1600 SRM 1187
The steering caster wheel assembly comprises the drive. The caster wheel centered position is moni-
other part of the steering system. The steering tored by an electronic proximity sensor mounted in
caster wheel assembly comes in two different config- the steer caster axle beside the steer caster motor.
urations. See Figure 5 and Figure 6. The caster steering motor is controlled by a separate
caster steering controller located beneath the opera-
The standard configuration is a spring-loaded, non- tor compartment. As the steering handle is rotated,
steered caster wheel assembly. See Figure 5. The the steering signal is sent to both the MDU steering
caster wheel assembly has two polyurethane wheels controller and the caster steering controller to allow
that are free to rotate about a pivot shaft as the truck the caster wheels to turn in the same direction as the
is driven. The caster is spring loaded to allow the MDU. The movement of the MDU and caster wheels
caster wheel assembly to move up and down with is coordinated to allow for optimum steering geom-
variations in the floor surface and allow the truck to etry to be obtained during steering maneuvers. As
maintain four-wheel contact at all times. with configuration one, the caster wheel assembly is
spring loaded to allow the caster assembly to move
up and down with variations in the floor surface and
allow the truck to maintain four-wheel contact at all
times.
6
1600 SRM 1187 Steering Handle Assembly
Remove
1. Turn the key to the OFF position and disconnect
the battery connector.
7
Steering Handle Assembly 1600 SRM 1187
1. CAPSCREWS 2. CAPSCREWS
8
1600 SRM 1187 Steering Handle Assembly
9
Steering Handle Assembly 1600 SRM 1187
10
1600 SRM 1187 Steering Handle Assembly
11
Steering Handle Assembly 1600 SRM 1187
Disassemble
For the following instructions, refer to Figure 13.
1. Turn the key to the OFF position and disconnect 4. Remove the steering handle from the steer sup-
the battery connector. port pad and recover the Woodruff key from the
steering unit shaft.
2. Loosen the compartment door mounting cap-
screws (2) and open the compartment door.
12
1600 SRM 1187 Steering Handle Assembly
1. CAPSCREWS 2. CAPSCREWS
13
Steering Handle Assembly 1600 SRM 1187
14
1600 SRM 1187 Steering Handle Assembly
WARNING
Be careful when removing or installing retain-
ing rings. Retaining rings can eject during
removal or installation with enough force to
cause injury. Always use the correct retaining
ring pliers and wear eye and face protection
during removal or installation. 1. CLIP
2. LOCKING ROD
3. BUSHING
7. Remove the locking pin assembly from the steer 4. SPRING
support pad: 5. BUSHING
a. Unscrew the pull knob from the shaft. Figure 14. Locking Pin Assembly
b. Remove the upper retaining ring and pull the
locking plunger assembly from the steer sup-
port pad.
15
Steering Handle Assembly 1600 SRM 1187
8. Remove the three capscrews (20), lockwashers 6. Slide the handle knob onto the steering handle
(19), and washers (18) securing the race assem- pin and install the retaining ring. Install the cap
bly to the mounting bracket. onto the handle knob.
9. Remove the four capscrews (26), lockwashers 7. Install the locking pin assembly into the steer
(25), washers (24) and nuts (14) securing the support pad:
outer race (top), mounting plate (inner race),
and outer race (bottom) to the tiller latch plate. a. Install the bushing and lower retaining ring
Unstack the races from the tiller latch plate to into the steer support pad.
complete disassembly.
b. Install the locking plunger assembly and the
top retaining ring into the top of the steer
Assemble
support pad.
For the following instruction, refer to Figure 13.
c. Screw the pull knob onto the locking plunger
1. Install the outer race (bottom) onto the tiller assembly
latch plate. Stack the mounting plate (inner
8. Align on the bottom of the steer support pad with
race) and then the outer race (top) as removed.
the holes in the top of the mounting plate (inner
2. Align the holes in the outer race (top), inner race). Install four capscrews, washers, and spac-
race, outer race (bottom), and tiller latch plate ers as removed to secure the steer support pad to
as removed. Secure together using the four cap- the mounting plate.
screws (26), lockwashers (25), washers (24) and
9. Secure the steering unit harness to the steering
nuts (14).
handle assembly using clamps as removed (not
3. Position the race assembly (tiller latch plate side) shown).
onto the top of mounting bracket. Align mount-
ing holes and secure using three capscrews (20), Install
lockwashers (19), and washers (18).
For the following instructions, refer to Figure 12.
4. Assemble the steering unit to the steer support
1. If removed, install the steering handle assembly
pad with the four capscrews (8) and washers (7).
to the drive unit compartment door with the cap-
5. Insert the Woodruff key into the steering unit screws (2) as removed.
shaft. Align the slot in the steering handle with
2. Connect the harness from the steering handle as-
the Woodruff key and install the steering handle
sembly to the connector on the main truck har-
onto the steering unit shaft. Install the washer
ness. Secure harness to the frame with clamps
(3) and nut (2) to secure. Install the cover onto
as removed.
the steering handle.
3. Close the compartment door and tighten the two
WARNING capscrews (1).
Be careful when removing or installing retain- 4. Reconnect the battery to the lift truck. Turn the
ing rings. Retaining rings can eject during key switch to the ON position and test for proper
removal or installation with enough force to operation.
cause injury. Always use the correct retaining
ring pliers and wear eye and face protection
during removal or installation.
16
1600 SRM 1187 Steering Controller
Steering Controller
DESCRIPTION 6. Disconnect the remaining wiring from the steer-
ing controller. Tag the wiring to assist when re-
The steering controller receives signals from the installing the steering controller.
steering sensor in the steering handle assembly, the
steering motor encoder, and the steering centering 7. The controller assembly sits into two clips at the
proximity switch. The steering controller translates bottom of the compartment and is retained to the
those signals into commands to the steering motor. lift truck frame by two capscrews and washers
The steering controller determines the correct di- at the top of the mounting plate. See Figure 15.
rection and speed to drive the steering motor from Remove the capscrews and washers from the top
the input received from the steering sensor. The of the mounting plate.
steering motor encoder sends signals back to the
steering controller to verify the correct direction
and speed. The steering centering proximity switch
signal is used by the steering controller to center
the steering system to the straight-ahead position
at system startup.
REMOVE
1. Turn the key to the OFF position and disconnect
the battery connector.
17
Steering Controller 1600 SRM 1187
1. Carefully maneuver the controller assembly be- 8. Reconnect the battery connector.
tween the truck frame and the lift pump inlet
hose.
18
1600 SRM 1187 Steering Proximity Switch
1. JAM NUT
2. FRAME
3. STEER GEAR
4. GAP MEASURE
5. PROXIMITY SWITCH
1. TRACTION MOTOR 6. TARGET PLATE
2. STEERING MOTOR 7. CAPSCREW
3. PROXIMITY SWITCH 8. WASHER
4. STEERING GEAR
5. FRAME Figure 17. Switch Mounting
6. DRIVE TIRE
7. BATTERY COMPARTMENT 5. Remove the switch by turning the switch shaft
Figure 16. Switch Location counterclockwise and unscrewing it from the
frame.
REPLACE NOTE: Make note of the depth of the old switch for
proper installation of the new switch.
1. Turn the key to the OFF position and disconnect
the battery connector. 6. Install the jam nut to the switch shaft in the
same position. Apply antiseize lubricant lightly
2. Loosen the compartment door mounting cap- to the threads of the new switch shaft and install
screws and open the compartment door. to the frame by turning clockwise as removed.
Adjust the proximity switch to obtain a gap of 1
3. Disconnect the switch wiring from the main ±0.5 mm (0.039 ±0.020 in.) between the end of
wiring harness. the proximity switch and the target plate. See
Figure 17. Lock the proximity switch in place
NOTE: Make note of the depth of the old switch for
with the jam nut on the switch.
proper installation of the new switch.
NOTE: Because the proximity switch gap is not easily
4. Slightly loosen the jam nut securing the switch
measurable, the distance is determined by the num-
to the frame. See Figure 17.
ber of turns of the proximity switch off the target
plate face. Adjustments of 1 to 1 1/4 turns off the
target plate face is approximately 1.016 to 1.270 mm
(0.040 to 0.050 in.) gap distance.
19
Steering Motor 1600 SRM 1187
7. Connect the switch wiring to the main wiring 9. Reconnect the battery. Turn the key switch to the
harness. ON position and test for proper operation.
Steering Motor
DESCRIPTION 4. Loosen and remove the four capscrews and wash-
ers retaining the steering motor to the lift truck
The 3-phase AC permanent magnet steering motor frame. See Figure 18.
is located in the drive unit compartment to the right
of the traction motor. The steering motor receives
signals from the steering controller that control di-
rection and speed of the steering motor. The steering
motor encoder is built into the steering motor and
sends signals back to the steering controller to verify
the steering motor is operating in the correct direc-
tion and speed.
REMOVE
1. Turn the key to the OFF position and disconnect
the battery connector.
CAUTION
Electrical components on this truck are po-
larity sensitive and may be damaged if wired
incorrectly. Make sure each electrical wire
connection is tagged and properly identified
1. CAPSCREW
before removal or installation. If the proper 2. WASHER
location for connection is unclear, consult the
wiring diagram for the truck. Figure 18. Steering Motor Mounting
3. Disconnect the two wiring connectors connecting 5. Carefully lift the steering motor vertically and
the steering motor to the lift truck wiring har- remove from the lift truck.
ness.
20
1600 SRM 1187 Steering Motor
DISASSEMBLE ASSEMBLE
1. Remove the capscrew and washers from the bot- 1. Insert the key supplied with the motor into the
tom of the motor shaft. See Figure 19. motor shaft.
INSTALL
1. Insert the drive gear into the lift truck so that it
meshes with the MDU gear. Ensure the steering
motor is fully seated in the lift truck frame.
CAUTION
Electrical components on this truck are po-
larity sensitive and may be damaged if wired
incorrectly. Make sure each electrical wire
1. CAPSCREW connection is tagged and properly identified
2. WASHER before removal or installation. If the proper
3. WASHER location for connection is unclear, consult the
4. DRIVE GEAR wiring diagram for the truck.
Figure 19. Gear Mounting 3. Reconnect the wiring connectors from the steer-
ing motor to the lift truck wiring harness.
NOTE: The capscrew has been installed with thread-
lock. 4. Close the compartment door and tighten the door
mounting capscrews.
2. Slide the drive gear from the motor shaft.
5. Reconnect the battery. Turn the key switch to the
NOTE: There are no serviceable parts within the
ON position and test for proper operation.
steering motor. A failed steering motor must be
replaced as a compete unit.
21
Caster Assembly - General 1600 SRM 1187
CASTER ADJUSTMENT
Casters must be adjusted periodically. Adjustment
procedures differ depending on the caster spring
type. Two spring types are used on caster assem-
blies: Belleville Springs and Elastomer Springs. If
the caster can no longer be adjusted within speci-
fication, check the drive tire wear and replace as
necessary. If the spring pack (Belleville or Elas-
tomer) shows any visible damage, the spring pack
should be replaced. Belleville Spring packs (includ-
1. MOUNTING CAPSCREWS
ing washers) should be replaced with Elastomer 2. SHIMS
Spring packs and corresponding washers when 3. CASTER SPRING PRELOAD
replacement becomes necessary. See Spring Pack 4. UPPER ADJUSTMENT CAPSCREW
Replacement. 5. UPPER ADJUSTMENT GAP
6. LOWER ADJUSTMENT CAPSCREW
7. LOWER ADJUSTMENT GAP
Elastomer Spring Type Adjustment
Figure 20. Caster Adjustment (Elastomer Type)
NOTE: The battery must be installed in the lift truck
with no load on the forks. 4. Spring preload measurements (dimension 3)
should be within specifications for your lift
1. Ensure the lift truck is on a flat and level floor.
truck. Refer to Table 1.
22
1600 SRM 1187 Caster Assembly - General
5. If spring preload measurements are not within 8. Set the lower adjustment capscrew (see Fig-
specification, raise the rear of the lift truck ure 20) to the proper gap (dimension 7). Refer to
approximately 50 mm (2 in.), loosen the three Table 1.
mounting capscrews, and add or subtract shims
as necessary. Belleville Spring Type Adjustment
• Greater than Specification = Add Shims
• Less than Specification = Remove Shims For the following instructions, refer to Figure 21.
6. Retighten the mounting capscrews and lower NOTE: Battery must be installed in truck with no
the rear of the lift truck. Remeasure the spring load on forks.
preload. If the spring measurement is not within
1. Ensure the lift truck is on a flat and level floor.
specification, return to Step 5. If the spring mea-
surement is within specification, continue to 2. If the upper or lower adjustment capscrews are
Step 7. touching the lower housing, loosen jam nuts then
turn bolts clockwise to clear lower support hous-
7. Set the upper adjustment capscrew (see Fig-
ing.
ure 20) to the proper gap (dimension 5). Refer to
Table 1.
23
Caster Assembly - General 1600 SRM 1187
A. FRONT B. BACK
24
1600 SRM 1187 Caster Assembly - General
25
Caster Assembly - General 1600 SRM 1187
5. On steered units, remove steer motor to access 2. Remove spring retainer and spherical bearing
the caster spring. from guide rod.
6. Remove retaining capscrew and slide pin from 5. Apply a thin coat of antiseize lubricant to guide
lower support housing. Remove spring assembly. rod shaft.
Replace Spring Pack 6. Install new bottom washer onto guide rod.
1. Remove capscrew and washer from top of spring NOTE: Different size elastomer springs are use on
assembly. See Figure 24. different models. Make sure to use the proper spring
for your model lift truck. Refer to the Parts Manual.
1. CAPSCREW
2. WASHER
3. SPRING RETAINER
4. SPHERICAL BEARING
5. GUIDE ROD
6. BUSHING
7. LOWER WASHER
8. SPRING PACK
9. UPPER WASHER
26
1600 SRM 1187 Caster Wheels
Caster Wheels
REMOVE
For the following instructions, see Figure 25.
WARNING
Cleaning solvents can be flammable and toxic
and can cause skin irritation. Wear protection
when handling solvents and always follow the
recommendations of the manufacturer.
CAUTION
Replace bearings in sets to maintain proper
wheel loading and operation.
5. Remove the caster wheel from the axle shaft. 1. BEARING CAP
2. BEARING LOCKWASHER
3. BEARING LOCK NUT
CAUTION 4. CASTER WHEEL
5. AXLE SHAFT
Use a hammer and a suitable brass or alu- 6. BEARING
minum driver when removing bearings to
avoid damage to the bearings and/or caster Figure 25. Caster Wheels
wheel.
7. Inspect the caster wheel for damage to the
The bearings are removed and replaced by bonded wheel surface and cracks in the hub
pressing on the outer race of the bearing only. or wheel material. Replace any wheel that is
Pressing on the inner race will damage the damaged, cracked, or has large cracks or large
bearing. chunks of the outside material missing. Replace
wheels in sets if damaged.
6. Remove the bearing by pressing it from the wheel
hub using a suitable brass or aluminum driver.
27
Caster Wheel Assembly (Nonsteered) 1600 SRM 1187
28
1600 SRM 1187 Caster Wheel Assembly (Nonsteered)
WARNING
When lifting the rear of the lift truck frame,
block the front of the load wheels so the lift
truck cannot roll forward while lifting.
REMOVE
1. Remove the mast from the lift truck. Refer to
Mast, Repair 4000 SRM 1195.
29
Caster Wheel Assembly (Nonsteered) 1600 SRM 1187
WARNING
The caster wheel assembly is heavy. Be sure
that all lifting devices (hoists, cables, chains,
slings, etc.) are suitable and of adequate capac-
ity to lift the caster wheel assembly.
DISASSEMBLE
Upper and Lower Support Housings
1. Remove the retaining pins from the links on
both sides of the caster wheel assembly. See
Figure 28.
1. RETAINING PIN
2. Remove the four links from the linkage pins and 2. LINK
remove the four linkage pins from the two pieces 3. LINKAGE PIN
of the caster wheel assembly. 4. UPPER SUPPORT HOUSING
5. LOWER SUPPORT HOUSING
3. Remove the upper support housing from the 6. CAPSCREW
7. PIN
lower support housing. 8. SPRING ASSEMBLY
30
1600 SRM 1187 Caster Wheel Assembly (Nonsteered)
CAUTION
Use a hammer and a suitable brass or alu-
minum driver when removing bearings to
avoid damage to the bearings and/or caster
wheel.
31
Caster Wheel Assembly (Nonsteered) 1600 SRM 1187
CAUTION
Use a hammer and a suitable brass or alu-
minum driver when removing bearings to
avoid damage to the bearings and/or lower
support housing.
1. BEARING CAP
2. BEARING LOCKWASHER
3. BEARING LOCK NUT
4. CASTER WHEEL
5. AXLE SHAFT
6. BEARING
WARNING
Be careful when removing or installing retain-
ing rings. Retaining rings can eject during 1. BUSHINGS
removal or installation with enough force to 2. BEARING
cause injury. Always use the correct retaining 3. RETAINING RING
ring pliers and wear eye and face protection
during removal or installation. Figure 31. Lower Support Housing
1. Inspect the lower support housing bearing by ro- 3. Check all bushings for wear. Bushings should
tating it. If the bearing is worn or rough, it have an inside diameter of 22.30 to 22.33 mm
should be replaced. (0.878 to 0.879 in.).
32
1600 SRM 1187 Caster Wheel Assembly (Nonsteered)
4. Press the bushings out of the lower support hous- 2. Press the spherical bearing from the upper sup-
ing using a suitable brass or aluminum driver if port housing.
replacement is needed.
3. Remove the two adjustment capscrews and jam
5. Remove any worn guide bearings from the sides nuts.
of the lower support housing. See Figure 32.
The guide bearing should be replaced if less than 4. Check all bushings for wear. Bushings should
10 mm (0.39 in.) in length. have an inside diameter of 22.30 to 22.33 mm
(0.878 to 0.879 in.).
1. GUIDE BEARING
33
Caster Wheel Assembly (Nonsteered) 1600 SRM 1187
ASSEMBLE
Upper Support Housing
For the following instructions, refer to Figure 33.
WARNING
Cleaning solvents can be flammable and toxic
and can cause skin irritation. Wear protection
when handling solvents and always follow the
recommendations of the manufacturer.
CAUTION
Use a brass or aluminum driver when in-
stalling bearings to avoid damage to bearings
and/or upper support housing.
34
1600 SRM 1187 Caster Wheel Assembly (Nonsteered)
WARNING
Cleaning solvents can be flammable and toxic
and can cause skin irritation. Wear protection
when handling solvents and always follow the
recommendations of the manufacturer.
CAUTION
Use a suitable brass or aluminum driver when
installing bearings to avoid damage to bear-
ings and/or lower support housing.
35
Caster Wheel Assembly (Nonsteered) 1600 SRM 1187
36
1600 SRM 1187 Caster Wheel Assembly (Nonsteered)
WARNING 1. CAPSCREW
The battery is heavy. Use appropriate lifting 2. WASHER
equipment to avoid personal injury. 3. TOP FRAME MOUNT
4. SHIMS
5. UPPER SUPPORT HOUSING
6. Install the battery. 6. JAM NUT
7. ADJUSTMENT CAPSCREW
7. Install the mast to the lift truck. Refer to Mast,
Repair 4000 SRM 1195. Figure 36. Caster Wheel Assembly Installation
37
Caster Assembly (Steered) 1600 SRM 1187
38
1600 SRM 1187 Caster Assembly (Steered)
REMOVE
1. Remove the mast from the lift truck. Refer to
Mast, Repair 4000 SRM 1195.
WARNING
The battery is heavy. Use appropriate lifting
equipment to avoid personal injury.
WARNING
When lifting the rear of the lift truck frame,
block the front of the load wheels so the lift
truck cannot roll forward while lifting.
39
Caster Assembly (Steered) 1600 SRM 1187
DISASSEMBLE
Upper and Lower Support
1. Remove the capscrews and washers (9) retaining
the steering motor to the caster wheel assembly.
Remove the steering motor. See Figure 39.
40
1600 SRM 1187 Caster Assembly (Steered)
Caster Wheels
For the following instructions, refer to Figure 41.
CAUTION
Replace bearings in sets to maintain proper
wheel loading and operation.
CAUTION
Use a hammer and a suitable brass or alu-
minum driver when removing bearings to
avoid damage to the bearings and/or caster
wheel.
41
Caster Assembly (Steered) 1600 SRM 1187
1. BEARING CAP
2. BEARING LOCKWASHER
3. BEARING LOCK NUT
4. CASTER WHEEL
5. AXLE SHAFT
6. BEARING
WARNING
Be careful when removing or installing retain-
ing rings. Retaining rings can eject during
removal or installation with enough force to
cause injury. Always use the correct retaining
ring pliers and wear eye and face protection
1. RETAINING RING
during removal or installation. 2. BEARING
3. CAPSCREW
4. STEERING STOP PIN
CAUTION 5. CASTER GEAR
Use a hammer and a suitable brass or alu- 6. BUSHINGS
minum driver when removing bearings to
Figure 42. Lower Support Housing
42
1600 SRM 1187 Caster Assembly (Steered)
5. Lift the caster gear slightly and slide the gear out 1. Press the spherical bearing from the upper sup-
the side of the lower support housing. port housing.
6. Check all bushings for wear. Bushings should 2. Remove the two adjustment capscrews and jam
have an inside diameter of 22.30 to 22.33 mm nuts.
(0.878 to 0.879 in.).
3. Check all bushings for wear. Bushings should
7. Press the bushings out of the lower support hous- have an inside diameter of 22.30 to 22.33 mm
ing using a suitable brass or aluminum driver if (0.878 to 0.879 in.).
replacement is needed.
4. Press the bushings out of the upper support hous-
8. Remove any worn guide bearings from the sides ing if replacement is needed.
of the lower support housing. See Figure 43.
The guide bearing should be replaced if less than
9.9 mm (0.39 in.) in length.
1. GUIDE BEARING
1. SPHERICAL BEARING
2. ADJUSTMENT CAPSCREW
Figure 43. Guide Bearings 3. JAM NUT
4. BUSHING
Upper Support Housing
Figure 44. Upper Support Housing
For the following instructions, refer to Figure 44.
Caster Steering Motor
CAUTION 1. Remove the capscrew and washers from the end
Use a hammer and a suitable brass or alu- of the caster steering motor shaft. See Figure 45.
minum driver when removing bearings to
avoid damage to the bearings and/or upper
support housing.
43
Caster Assembly (Steered) 1600 SRM 1187
ASSEMBLE
Caster Steering Motor
1. Insert the key supplied with the motor into the
motor shaft.
WARNING
Cleaning solvents can be flammable and toxic
and can cause skin irritation. Wear protection
when handling solvents and always follow the
recommendations of the manufacturer.
CAUTION
Use a suitable brass or aluminum driver when
installing bearings to avoid damage to bear-
ings and/or upper support housing.
44
1600 SRM 1187 Caster Assembly (Steered)
CAUTION
The bearing set in the lower support housing
is sealed and lubricated for the life of the bear-
ing. DO NOT attempt to lubricate or clean the
bearing set.
WARNING
Be careful when removing or installing retain-
ing rings. Retaining rings can eject during
removal or installation with enough force to
cause injury. Always use the correct retaining
ring pliers and wear eye and face protection
during removal or installation.
45
Caster Assembly (Steered) 1600 SRM 1187
46
1600 SRM 1187 Caster Assembly (Steered)
to the threads of the new switch shaft and install 1. Install the spring assembly into the lower sup-
to the caster by turning clockwise as removed. port housing.
Adjust the proximity switch to obtain a gap of 1.0
±0.5 mm (0.039 ±0.020 in.) between the end of 2. Install the pin through the lower support housing
the proximity switch and the target (gear). See and spring assembly.
Figure 48. Lock the proximity switch in place
3. Install the retaining capscrew and washer
with the jam nut on the switch.
through the pin retainer and into the lower
support housing.
47
Caster Assembly (Steered) 1600 SRM 1187
WARNING
The battery is heavy. Use appropriate lifting
equipment to avoid personal injury.
1. CAPSCREW
2. WASHER
3. TOP FRAME MOUNT
4. SHIMS
5. UPPER SUPPORT HOUSING
6. JAM NUT
7. ADJUSTMENT CAPSCREW
48
1600 SRM 1187 Troubleshooting
Troubleshooting
Most troubleshooting procedures can be accom- Use the dash display menus and the troubleshooting
plished using the on-board diagnostic menus avail- fault codes to help identify and correct the problem.
able through the dash display. The service menus
will allow you to check the status and operation of If the steering system still does not operate correctly
most steering system electrical components. after verifying the correct performance of the elec-
trical components, check the system for mechanical
When a fault occurs, a fault code is displayed on the binding.
dash display. A description of these fault codes and
troubleshooting instructions can be found in section Ensure the gear drives are meshing properly and are
AC Motor Controllers/Display Panel, Descrip- not prevented from rotating due to debris.
tion, Checks, Adjustments, and Troubleshoot-
Ensure the MDU bearing is operating smoothly and
ing 2200 SRM 1190 or AC Motor Controllers/Dis-
does not need service or repair.
play Panel, Description, Checks, Adjustments,
and Troubleshooting 2200 SRM 1308. Instruc- Ensure the caster wheel assembly can rotate freely.
tions for navigating the dash display menu system
can be found in section User Interface, Service
Technician (Standard Display) 2200 SRM 1193.
49
NOTES
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