1600508, OPR, HYSTER, Hyster2, SRM

//-->.pos {position:absolute; z-index: 0; left: 0px; top: 0px;}INTRODUCTIONGENERALThis section has the description and repair proceduresfor the parts of the steering mechanism. These parts arethe control handle, the bearings and the steering towerwhich is only used with the top steer handle. The masterdrive unit (MDU) and brake assembly are a single unitattached to the king pin on the main frame weldment.The MDU and brake assembly turns when the handle ismoved. Repair of the brake and drive unit are in separatesections. A troubleshooting chart is provided at the endof this section.DescriptionThere are two different steering control handles used onthe W45XT series of lift trucks. A top mounted or a bot-tom mounted steering control handle can be installed onthe W45XT unit. The W40XT series of lift trucks areonly equipped with a bottom mounted steering controlhandle. The top mounted steering control handle is fas-tened to the steering tower with a groove pin and a pivotpin. The steering tower is fastened to the MDU and theMDU is attached to the king pin of the main frame weld-ment. The bottom mounted steering control handle isfastened to the MDU with a groove pin and a camshaft.The MDU rotates on the two roller bearings between theking pin and the MDU. The bearings allow the assemblyto turn for steering. Moving the handle in the directionof the turn rotates the MDU for steering.When the control handle is released from the operatingposition, a large spring returns the control handle to thefully raised vertical position and the brake is appliedmechanically. When the brake is applied, a switch dis-connects power to the traction circuit. The brake is ap-plied when the control handle is moved to the fullyraised or fully lowered position. The brake is releasedwhen the control handle is moved approximately 12°from the vertical or horizontal position.When the steering control handle is moved, the brakecamshaft is rotated and the brake cam lever pivots thebrake shoe which will apply or release the brake. On theW45XT units equipped with a top mounted steeringcontrol handle, the brake camshaft is attached to thecontrol handle through linkage.The control handle has mounts for the switches anddirectional/speed control for operation of the lift truck.REPAIRSRemoval and Disassembly–Top Steer Handle(See Figure 1)NOTE:The following procedure has steps for thecomplete removal and installation of the steering mech-anism. However, most repairs can be done without re-moving every part of the steering mechanism. Do onlythe steps necessary to make the necessary repair. If nec-essary, see the sectionMASTER DRIVE UNIT, 630SRM 507to replace the steering bearings on the kingpin. See the same section to remove the complete masterdrive unit (MDU) from the truck for any other reason.If necessary see the sectionBRAKES, 1800 SRM 509to remove the complete brake assembly.1. Move the key to the OFF position. Remove the key.2.DISCONNECT THE BATTERY CABLE.Tagthe battery cable. Remove the MDU cover. Installblocks at the load wheels and drive wheel as described intheOPERATING MANUALor in the sectionPERIODIC MAINTENANCE, 8000 SRM 627.WARNINGAll W45XT units are equipped with a Curtis transis-tor controller. The W40XT units can have either aCurtis transistor controller or a resistor tractioncontrol. The capacitor in the Curtis transistor con-trollers can hold an electrical charge after the bat-tery is disconnected. To prevent electrical shock andinjury, discharge the capacitor before inspecting orrepairing components in the MDU compartment.Wear safety glasses.3. Connect an insulated jumper wire between the B)and B* terminals of the transistor controller to dis-charge the capacitor.11234222120231918561797810MDU (REF.)1615141312111.2.3.4.5.6.7.8.CONTROL HANDLECOTTER PINCLEVIS PINLINKAGECONTROL TOWERSPRINGBRAKE ACTUATORBUSHING9.10.11.12.13.14.15.16.GROOVE PINCAMSHAFTSLEEVELOCKNUTSPECIAL WASHERWASHERTAPERED ROLLER BEARINGSNAP RING17.18.19.20.21.22.23.TAPERED ROLLER BEARINGBEARING COVERKING PINCONTROL HANDLE PIVOT PINBUSHINGRUBBER STOP PADGROOVE PINFIGURE 1 – STEERING MECHANISM–TOP STEER HANDLE24. Remove the cover from the control head of the con-trol handle.5. Install labels on all the wires of the wiring harnessthat fasten to the electrical components in the controlhandle. The labels are for correct connection during as-sembly and installation. See the sectionELEC-TRICAL SYSTEM, 2200 SRM 279.WARNINGBe careful when removing or installing snap rings.These snap rings are large and can come loose duringremoval or installation with enough force to cause aninjury. Always use the correct snap ring pliers andwear eye and face protection during removal orinstallation.13. Use a bearing puller to remove the bottom rollerbearing from the MDU housing. Remove the snap ring ifnecessary.Cleaning and Inspection–Top Steer HandleWARNINGThere are close clearances between the MDU and themain frame weldment that can cause serious injury.NEVER put hands, arms, head or legs between theseparts unless the parts have blocks to prevent move-ment.6. Remove the rubber stop pad. The wire clamp thatfastens the harness to the steering tower will also comeloose.7. Put the handle in a vertical position. Remove thegroove pin retaining the handle pivot pin. Remove thecotter pin and the clevis pin retaining the brake linkageto the handle.8. Hold the handle so that it will not fall. Use a drift toremove the pivot pin. Carefully lower the handle. Do notdamage the wires. Carefully remove the pivot pin bush-ings from the steering tower.9. If the control handle will be replaced, remove theelectrical parts and grips. See the sectionELEC-TRICAL SYSTEM, 2200 SRM 279for the correctprocedures. Remove the handle. Do not damage thewires.WARNINGCleaning solvents can be flammable and toxic, andcan cause skin irritation. Wear protection for eyesand skin. When using cleaning solvents, always fol-low the recommendations of the manufacturer.Clean and inspect all components for damage or wear.Replace any item that is worn or damaged.Assembly–Top Steer Handle1. Replace the bearings. See the sectionPERIODICMAINTENANCE, 8000 SRM 627.WARNINGBe careful when removing or installing snap rings.These snap rings are large and can come loose duringremoval or installation with enough force to cause aninjury. Always use the correct snap ring pliers andwear eye and face protection during removal orinstallation.2. Install the snap ring in the MDU housing. Install thelower bearing in the MDU.3. Install the upper bearing in the MDU housing.Install the bearing cover.4. To complete the assembly of the steering mecha-nism, see the sectionMASTER DRIVE UNIT, 630SRM 507.5. Install the steering tower on the MDU using the sixcapscrews. Tighten the capscrews to a torque of 49 NSm(36 lbf ft).6. Install the pivot pin bushings in the steering tower.Use a block of wood and a hammer to install the bush-ings. Make certain the bushing edges are even with thetower.3WARNINGThe spring has tension and can release with enoughforce to cause an injury.10. If the steering tower must be replaced, carefully dis-connect the brake spring. Remove the six capscrews andwashers retaining the steering tower to the drive unit.Remove the steering tower.11. The MDU must be removed if it is necessary to re-move the steering bearings. See the sectionMASTERDRIVE UNIT, 630 SRM 507to remove the MDU.12. Remove the bearing cover and the roller bearingfrom the top of the MDU.7. Align the control handle with the steering tower andinstall the pivot pin. Align the holes in the control handleand the pivot pin and install the groove pin.8. Install the rubber stop pad and wire clamp using thecapscrews.9. Install the brake linkage on the control handle usingthe clevis pin. Install a new cotter pin in the clevis pin.blocks at the load wheels and drive wheel as described intheOPERATING MANUALor in the sectionPERIODIC MAINTENANCE, 8000 SRM 627.WARNINGAll W45XT units are equipped with a Curtis transis-tor controller. The W40XT units can have either aCurtis transistor controller or a resistor tractioncontrol. The capacitor in the Curtis transistor con-trollers can hold an electrical charge after the bat-tery is disconnected. To prevent electrical shock andinjury, discharge the capacitor before inspecting orrepairing components in the MDU compartment.Wear safety glasses.3. Connect an insulated jumper wire between the B)and B* terminals of the transistor controller to dis-charge the capacitor.WARNINGThe spring has tension and can release with enoughforce to cause an injury.10. Carefully install the spring between the brake actua-tor and the MDU housing.11. Connect all wires to the switches according to thelabels installed during removal. See the sectionsELEC-TRICAL SYSTEM, 2200 SRM 279andDIA-GRAMS, 8000 SRM 467.12. Install the control head components removed dur-ing disassembly. See the sectionsELECTRICALSYSTEM, 2200 SRM 279andDIAGRAMS, 8000SRM 467.13. Install the MDU cover.14. Remove the blocks. Remove the tag and connect thebattery. Test the lift truck for operation before placingback into service.Removal and Disassembly–Bottom Steer Handle(See Figure 2)NOTE:The following procedure has steps for thecomplete removal and installation of the steering mech-anism. However, most repairs can be done without re-moving every part of the steering mechanism. Do onlythe steps necessary to make the necessary repair. If nec-essary, see the sectionMASTER DRIVE UNIT, 630SRM 507to replace the steering bearings on the kingpin. See the same section to remove the complete masterdrive unit (MDU) from the truck for any other reason.If necessary see the sectionBRAKES, 1800 SRM 509to remove the complete brake assembly.1. Move the key to the OFF position. Remove the key.2.DISCONNECT THE BATTERY CABLE.Tagthe battery cable. Remove the MDU cover. Install4WARNINGThe control handle spring has tension and can re-lease with enough force to cause an injury.4. Disconnect the control handle spring from thehandle.5. Disconnect the electrical plug at the bottom of thehandle.6. Lower the steering handle and remove the groovepin from the handle and brake camshaft.7. Remove the two screws and washers that fasten thebrake cover. Move the cover to one side without discon-necting the wires. Remove the plug.8. Remove the brake spring anchor from the MDU.9. Insert a screwdriver into the brake cover opening.Pry the brake camshaft out of both the housing and thehandle. Remove the handle.10. Check the brake camshaft bushings for excessivewear. The maximum I.D. for the bearings should be 31.8mm (1.253 in). The minimum O.D. of the bearingsshould be 38.2 mm (1.503 in). Replace the bushings ifnecessary.11. If the control handle will be replaced, remove theelectrical parts and grips. See the sectionELEC-TRICAL SYSTEM, 2200 SRM 279for the correctprocedures. Do not damage the wires.12. The MDU must be removed if it is necessary to re-move the steering bearings. See the sectionMASTERDRIVE UNIT, 630 SRM 507to remove the MDU.13. Remove the bearing cover and the roller bearingfrom the top of the MDU.2. Install the snap ring in the MDU housing. Refer toFigure 1. Install the lower bearing in the MDU.3. Install the upper bearing in the MDU housing.Install the bearing cover.4. To complete the assembly of the steering mecha-nism, see the sectionMASTER DRIVE UNIT, 630SRM 507.5. Install the brake camshaft. Align the brake camshaftand the steering handle and install the groove pin.6. Install the brake spring on the brake shoe andthrough the MDU housing. Extend the spring throughthe opening in the housing and install the hook of thespring on the anchor.WARNINGBe careful when removing or installing snap rings.These snap rings are large and can come loose duringremoval or installation with enough force to cause aninjury. Always use the correct snap ring pliers andwear eye and face protection during removal orinstallation.14. Use a bearing puller to remove the bottom rollerbearing from the MDU housing. Remove the snap ring ifnecessary.Cleaning and Inspection–Bottom Steer HandleWARNINGThe spring has tension and can release with enoughforce to cause an injury.7. Install the steering handle spring.8. Connect the electrical plug at the bottom of thesteering handle.WARNINGCleaning solvents can be flammable and toxic, andcan cause skin irritation. Wear protection for eyesand skin. When using cleaning solvents, always fol-low the recommendations of the manufacturer.Clean and inspect all components for damage or wear.Replace any item that is worn or damaged.Assembly–Bottom Steer Handle1. Replace the bearings. See the sectionPERIODICMAINTENANCE, 8000 SRM 627.CAUTIONThe brake must be correctly adjusted for correctoperation.NOTE:The brake switch must be adjusted each timethe brake switch cover is removed and installed.9. Adjust the brake and the brake switch as describedin the sectionBRAKES, 1800 SRM 509.Refer toADJUSTMENTS.10. Install the MDU cover.11. Connect the battery cable. Remove the blocks.Check the operation of the lift truck. The brakes must becapable of holding the lift truck on a 10% slope with aload of 2043 kg (4500 lbs). The truck should also be ableto operate without any brake drag when the handle is inthe operating position.WARNINGBe careful when removing or installing snap rings.These snap rings are large and can come loose duringremoval or installation with enough force to cause aninjury. Always use the correct snap ring pliers andwear eye and face protection during removal orinstallation.5

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