SERVICE REPAIR B60Z [A230]

PART NO. 1652525 8000 SRM 1320

1600 SRM 962 Special Precautions

GeneralThe control handle assembly is designed to performseveral functions. The standard control handle in-cludes the speed/direction control and buttons for thehorn, traction reversing, and hydraulic functions.The control handle is connected to the Master DriveUnit (MDU) and is used to steer the truck as it turnsthe MDU. Move the control handle left or right toturn the drive/steer tire and steer the truck. Con-trols mounted in the handle are linked to the controlpanel by a wiring harness that passes through thecenter of the handle. The brake is applied when thehandle is in the full up or down position.

The bottom-mounted control handle assembly is usedon the W60/65/80Z, W30/40ZA, W20/30ZR, and W25/30/40ZC lift trucks. The handle is designed to beused while the operator is walking beside the lifttruck. The top-mounted control handle assembly isused on the B60/80Z lift trucks. This model is de-signed to be used while the operator is either walk-ing beside the truck or riding on a small platform tothe left or right side of the handle.

Special Precautions

WARNINGTo avoid personal injury and prevent electri-cal shock, perform the following steps beforetroubleshooting or adjusting and before con-necting or disconnecting a handset or personalcomputer.

CAUTIONTo avoid controller damage, always disconnectthe battery, discharge the capacitor, and neverput power to the controller while any powerwires are disconnected. Never short any con-troller terminal or motor terminal to the bat-tery. Make sure to use the proper procedurewhen servicing the controller.

1. Turn key switch to OFF position and disconnectthe battery.

2. Discharge the capacitors in the controllers byconnecting a 200-ohm, 2-watt resistor acrossthe controller’s B+ and B terminals. DO NOTshort across the motor controller terminals witha screwdriver or jumper wire. See Figure 1 andFigure 2.

3. Remove the 200-ohm, 2-watt resistor before re-connecting the battery.

1. POSITIVE CONNECTION2. NEGATIVE CONNECTION3. INSULATED JUMPER WIRES4. 200-OHM, 2-WATT RESISTOR

Figure 1. Discharging Controller W60/65/80Zand B60/80Z

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Control Handle (W60/65/80Z, W30/40ZA, W20/30ZR, and W25/30/40ZC) 1600 SRM 962

Figure 2. Discharging Controller - W30/40ZA,W20/30ZR, and W25/30/40ZC

Legend for Figure 2

1. NEGATIVE CONNECTION2. POSITIVE CONNECTION3. 200-OHM, 2-WATT RESISTOR4. INSULATED JUMPER WIRES

Control Handle HeadRefer to the section Electrical System 2200 SRM929 or Electrical System 2200 SRM 1026 for in-structions on removing and installing the control

handle head from the control handle. The instruc-tions for disassembly and assembly of the controlhandle head can be located in the same manual.

Control Handle (W60/65/80Z, W30/40ZA, W20/30ZR,and W25/30/40ZC)

REMOVE

Refer to Figure 3 for the following instructions.

WARNINGThe gas springs used on the control handlehave tension and can release with enoughforce to cause personal injury or propertydamage.

WARNINGThe capacitor in the transistor controller canhold an electrical charge after the battery

is disconnected. To prevent electrical shockand personal injury, discharge the capacitorbefore inspecting or repairing any componentin the drive unit compartment. Wear safetyglasses. Make certain the battery has beendisconnected.

1. Disconnect the battery and remove the drive unitcompartment cover.

2. Discharge the capacitors. See Special Precau-tions in this section.

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1600 SRM 962 Control Handle (W60/65/80Z, W30/40ZA, W20/30ZR, and W25/30/40ZC)

1. CONTROL HANDLE ARM2. SUPPORT BRACKET3. GAS SPRING4. BUSHING5. GREASE FITTING6. PIVOT PIN7. SHIM8. SUPPORT BRACKET COVER9. CAPSCREWS10. WASHERS11. LOCKING PIN12. SWITCH BRACKET

13. LOCKWASHER14. SCREW15. CONTROL HANDLE WIRING

HARNESS16. SUPPORT PLATE17. STUD18. WASHER19. LOCKWASHER20. CAPSCREW21. NUT22. PROX SWITCH23. BUSHINGS

24. SCREWS25. CAPSCREW26. LOCKSCREW27. CLAMP28. CAPSCREW29. LOCKWASHER30. WASHER31. PLUG32. SETSCREW33. CAPSCREW

Figure 3. Control Handle Mounting (W60/65/80Z, W30/40ZA, W20/30ZR, and W25/30/40ZC)

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Control Handle (W60/65/80Z, W30/40ZA, W20/30ZR, and W25/30/40ZC) 1600 SRM 962

NOTE: Study the routing of the wiring harness dur-ing disassembly for proper reassembly.

CAUTIONDO NOT cut wires when removing wire ties.

3. CAREFULLY cut wire ties that hold the brake,brake switch, and control handle wire harnessesin a bundle to the right rear of the MDU.

NOTE: It is not necessary to disconnect the four-pinconnector for the brake wiring harness when the two-pin connector has been disconnected.

4. Tag and disconnect the brake wiring harness(two-pin connector) located near the brake.

5. Tag and disconnect the brake switch wiring har-ness (two-pin connector) located in the area of thedrive motor.

6. Tag and disconnect the control handle wiringharness (six-pin connector) located in the area ofthe drive motor.

7. Remove nuts and wire clamps from both rightside studs on the MDU. Remove wire harnessfrom clamps.

8. Remove the support bracket cover.

9. If necessary, remove the control handle head. SeeElectrical System 2200 SRM 1026 or Electri-cal System 2200 SRM 929. Remove the controlhandle wiring harness by pulling the wiring har-ness through the control handle arm.

CAUTIONDischarging the gas spring is a destructive op-eration.

10. Discharge and remove the gas spring. See GasSpring.

11. Remove both threaded control handle arm pivotpins and shims. Check the bushings. If bushingsare worn, remove the bushings from the supportbracket pivot pin holes.

12. Remove the control handle arm from the supportbracket.

13. Remove two screws from the support bracket andremove the control handle arm prox switch.

INSTALL

1. Install the new gas spring to the control handlearm as removed. Refer to Gas Spring.

2. If previously removed, install bushings into thesupport bracket pivot pin holes.

3. Insert the control handle prox switch fully intothe switch bracket. Route the prox switch wireso it will not be pinched or damaged when thecontrol handle is installed.

CAUTIONDO NOT damage the plastic mounting bracketor the prox switch by overtightening thescrews.

4. Attach the control handle prox switch assemblyto the support bracket with screws. DO NOTtighten screws at this time.

5. If the control handle head has been removed, in-stall the control handle head to the control han-dle arm. See Electrical System 2200 SRM 1026or Electrical System 2200 SRM 929. Route thecontrol handle wiring harness through the con-trol handle arm and secure with clamp, screw,and lockwasher.

NOTE: Install shims onto pivot pins as needed tominimize side-to-side movement of handle.

6. Install the control handle arm into the supportbracket. Apply Loctite® 242 to the threaded por-tion of the pivot pins and install the pivot pins.Torque to 142 ±7 N•m (105 ±5 lbf ft).

7. Fully lower the control handle. Check the gapbetween the control handle prox switch and thecontrol handle. The gap should measure 3.0 to5.0 mm (0.12 to 0.20 in.). See Figure 4. If the gapdistance is different, horizontally adjust the loca-tion of the prox switch. Tighten the prox switchassembly mounting screws.

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1600 SRM 962 Control Handle (B60/80Z)

1. PROX SWITCH ASSEMBLY2. GAP 3.0 to 5.0 mm (0.12 to 0.20 in.)3. PROX SWITCH WIRE

Figure 4. Control Handle Prox Switch Assembly

8. Drive the pin through the lower end of the gasspring to secure to the support bracket.

CAUTIONThe wiring must be routed properly to preventsteering problems and prevent chafing of theharness.

Verify that the harness is not wrapped aroundthe gas spring. Check harness with handle inthe up, down, full left, and full right positions.

9. Loosely route the control handle and brakeswitch wiring harnesses up from the supportbracket to the right, front stud of the drive mo-tor. Using a wire clamp, secure wiring harnesses

to top of stud leaving enough slack [approxi-mately 400 mm (16 in.)] between clamp andsupport bracket to allow drive unit to turn fromleft stop to right stop without restriction.

10. Route the control handle and brake switch wiringharnesses from the right, front stud to the right,rear stud of the drive motor. Using a wire clamp,secure wiring harnesses to top of stud.

11. Connect the brake wiring harness (two-pin con-nector) located near the brake.

12. Connect the brake switch wiring harness (two-pin connector) located in the area of the drivemotor.

13. Connect the control handle wiring harness (six-pin connector) located in the area of the drivemotor.

14. Install the support bracket cover using screwsand lockwashers.

CAUTIONOn the W60/65/80Z models, the wiring har-nesses may pull when operating the LIFT/LOWER functions. Raise and lower the lifttruck to measure the amount of wire neededto allow proper operation BEFORE installingwire ties.

15. Bundle brake, brake switch, and control handlewiring harnesses until tight and secure with wireties.

16. Connect the battery and test for proper operationprior to returning the lift truck to service.

17. Install the drive unit compartment cover.

Control Handle (B60/80Z)The following procedures describe the removal anddisassembly of the control handle and dash assem-blies for the B60/80Z. The control handle and dashassembly may be removed as a single assembly withno further disassembly. This is useful when the con-trol handle and dash assembly must be removed toaccess other components of the lift truck. For in-struction on removing the control handle and dash

assembly as a complete unit, see Steering and DashAssembly (Complete).

REMOVE (HANDLE)

Refer to Figure 5 for the following instructions.

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Control Handle (B60/80Z) 1600 SRM 962

Figure 5. Control Handle Mounting B60/80Z

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1600 SRM 962 Control Handle (B60/80Z)

Legend for Figure 5

1. GAS SPRING2. CONTROL ARM3. PLUG4. SWIVEL5. STEER PLATE6. DASH COVER7. CAPSCREW8. SUPPORT9. CAPSCREW10. WASHER11. LOCKWASHER12. NUT13. CAPSCREW14. WASHER15. LOCKWASHER16. NUT17. STAND-OFF

18. CAPSCREW19. WASHER20. LOCKWASHER21. NUT22. COVER23. CAPSCREW24. BEARING RACE25. BEARING26. LOCKING WASHER27. WOODRUFF KEY28. SLEEVE29. SPACER30. NUT31. LOCKWASHER32. CAPSCREW33. WASHER34. FITTING

35. BALL STUD36. CLAMP37. LOCKWASHER38. SCREW39. NUT40. NUT41. PIVOT SHAFT42. PIN43. SCREWS44. NUT PLATE45. BRAKE SWITCH46. BUSHING47. SHIM(S)48. LOCKING BOLT49. CAPSCREW50. BUSHING

WARNINGThe gas springs used on the control handlehave tension and can release with enoughforce to cause personal injury or propertydamage.

WARNINGThe capacitor in the transistor controller canhold an electrical charge after the batteryis disconnected. To prevent electrical shockand personal injury, discharge the capacitorbefore inspecting or repairing any componentin the drive unit compartment. Wear safetyglasses. Make certain the battery has beendisconnected.

1. Disconnect the battery. Remove the drive unitcompartment cover to access the wiring and con-trol handle mounting.

2. Discharge the capacitors. See Special Precau-tions in this section.

CAUTIONDO NOT cut the wiring harnesses when remov-ing the wire ties.

NOTE: It is not necessary to remove the main wiringharness unless harness is damaged and is being re-placed.

3. CAREFULLY cut the wire ties securing thebrake, brake switch, and control handle wiringharnesses together at the right rear of MDU.

NOTE: Be certain to note the routing of the wiresbefore disconnecting any wire. The wiring must be

routed properly at assembly to prevent steering prob-lems 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 brake switch wiring har-ness (two-pin connector) and if equipped, the op-tional coast control switch (two-pin connector).

6. Tag and disconnect the control handle wiringharness (three-pin connector).

7. Remove the clamps that hold the wiring har-nesses to the right side motor mounting studs.

8. Remove cover from swivel by removing threeAllen head screws.

NOTE: Be careful not to damage the brake switchwhen removing the gas spring.

9. Remove gas spring. See Gas Spring.

10. Remove locking bolt from control handle arm andslide pivot shaft out. Recover shims for later in-stallation. Remove the control handle arm fromthe swivel.

11. Carefully pull the wiring harnesses through thecenter of the support.

12. Remove bushings from the control handle arm ifnecessary.

13. If necessary, remove the control handle head.See Electrical System 2200 SRM 929. Removenut (39) and clamp (36) and pull wiring harnessthrough control handle arm.

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Control Handle (B60/80Z) 1600 SRM 962

14. Remove two screws (43) from the swivel and re-move the brake switches and nutplate.

STEER BEARINGS AND SUPPORT

Disassemble

1. Remove control handle swivel:

a. Remove cover (22) by removing screws (23).

b. Remove nut (30) by bending tabs on lockingwasher (26) down using a flat screwdriverand turning nut counterclockwise.

c. Remove nut and locking washer.

2. Lift control handle swivel off dash and stand-offshaft and recover Woodruff key.

3. Remove dash cover by removing screws (7).

4. Remove stand-off (17), spacer (29), and lowerbearing (25) :

a. Remove capscrews (18), washers (19, 20),and nuts (21) securing stand-off to steerplate.

b. Lower stand-off and bearing assembly fromthe support.

c. Remove the lower bearing from stand-off us-ing a standard bearing puller then removespacer by hand.

d. Remove lower sleeve (28) from bottom ofstand-off.

5. Remove upper sleeve (28), spacer (29), and upperbearing (25).

NOTE: Be careful not to damage bearing races or sup-port when removing bearing races.

6. Clean and inspect bearing races for pits andgrooves.

7. Remove bearing races from support using a ham-mer and punch if damaged.

Repair

Clean the bearing assemblies by washing themin solvent to remove all grease and dirt. Whenclean, the bearing assemblies should ALWAYS rollsmoothly. Place the bearing inside the race. Turnthe bearing while applying pressure with your hand

to check for places where the bearing does not turnsmoothly. Inspect the bearing assembly for pits orgrooves. If any rough places are found, replace thebearing with a new bearing assembly.

Assemble

1. Install bearing races to support using a hammerand proper size bearing driver, if removed.

2. Pack bearings with Hyster® synthetic grease,P/N 2074114, using a standard bearing packingdevice. Place a liberal coating of synthetic greaseon the surface of the bearing races.

3. Install stand-off (17) and bearing assembly:

a. Install spacer and lower bearing to stand-offusing a press.

b. Install sleeve to bottom of stand-off.

c. Lift stand-off and bearing assembly into thesupport.

d. Install capscrews (18), washers (19, 20), andnuts (21) to secure stand-off to steer plate.

4. Install upper bearing (25) and spacer (29) tostand-off shaft.

5. Position the Woodruff key into groove on thestand-off shaft and lower swivel onto shaft.Turn swivel left and right alternately to aligngroove with the Woodruff key WHILE holdingthe Woodruff key in place.

6. Install the locking washer (26) and nut (30)to the end of stand-off shaft. Tighten nut to26 N•m (19 lbf ft) and bend tabs on lockingwasher against nut.

7. Install sleeve (28).

8. Install control handle wiring harness throughsupport.

9. Place cover (22) on swivel (4) and secure withscrews (23).

INSTALL (HANDLE)

1. Install brake switches and nutplate into theswivel (4) using two screws.

2. Install bushings into the control handle arm ifremoved.

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1600 SRM 962 Gas Spring

3. Install control handle head if removed. See thesection Electrical System 2200 SRM 929. Pullwiring harness though control handle arm andsecure with clamp (36) and nut (39).

4. Route the control handle and brake switchwiring harnesses down through the sleeves inthe support. Carefully pull the wiring harnessesthrough the center of the support.

NOTE: Install shims onto the pivot shaft as requiredto minimize side to side movement of handle.

5. Install the control handle arm into the swivel us-ing pivot shaft, shims, and locking bolt. Installshims between the control handle arm and swivelon the LEFT side of the swivel (side nearest thecontroller).

6. Install the gas spring to the control handle. SeeGas Spring.

CAUTIONMake certain that the wiring is properly routedto prevent steering problems and chafing of theharness.

7. Connect the control handle wiring harness to themain wiring harness.

8. Connect the brake switch connector and, ifequipped, the optional coast control.

CAUTIONVerify that the wiring harness is not wrappedaround gas spring. Check the wiring harnesswith the control handle in the up, down, fullleft, and full right positions.

9. With the control handle in the upright position,pull the harness and install the clamps that holdthe control handle harness to the motor. Securethe wiring harness with slack between the clampand the main wiring harness to allow for side toside movement when the control handle is turnedin any direction.

10. Remove excess slack by bundling the control han-dle, brake, and brake switch wiring harnessesand secure using wire ties.

11. Install the cover to the swivel using three screws.

12. Connect the battery and test the operation of thetruck prior to returning the lift truck to service.

13. Install the drive unit compartment cover.

Gas Spring

WARNINGDisconnect the battery and separate the con-nector before opening the compartment coverand before inspecting or repairing the electri-cal system. If a tool causes a short circuit, thehigh-current flow from the battery can causepersonal injury or property damage.

WARNINGThe capacitor in the traction motor controllercan hold an electrical charge after the batteryis disconnected. To prevent electrical shockand personal injury, discharge the capacitor

before inspecting or repairing any component.Wear safety glasses. Make certain the batteryhas been disconnected. Discharge the capaci-tors. See Special Precautions. DO NOT use ascrewdriver to discharge the traction motorcontroller.

WARNINGThe gas spring used on the control handle is un-der tension and can release with enough forceto cause personal injury or property damage.

Review the following procedures before removing thegas spring.

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Gas Spring 1600 SRM 962

DISCHARGING THE GAS SPRING

WARNINGGoggles and a face shield must be worn for per-sonal protection as metal chips and hydrauliclubricant may be ejected from the drill opera-tion due to the high internal pressure.

CAUTIONThe control handle return spring is chargedwith pressurized gas and contains a hydraulicoil lubricant.

NOTE: This process is a destructive operation to thegas spring. A new gas spring must be used duringreassembly.

1. Check that the handle return spring is installedand properly secure the control handle arm in thefull upright position. Remove the plastic plugs toincrease visibility of the gas spring.

CAUTIONDO NOT damage the control handle wiring har-ness inside the control handle arm.

2. Locate and drill a 7 mm (0.25 in.) access holethrough the center of the control handle tube, ap-proximately 50 mm (2 in.) below the existing ac-cess hole.

WARNINGContents are under pressure. This process mayeject metal chips and oil.

3. Locate the gas spring inside the control handlethrough the newly drilled access hole and drill a3 mm (0.125 in.) hole into the gas spring cylindershell to relieve pressure.

4. Clean up any discharged oil and dispose of in ac-cordance with local regulations.

REMOVE (W60/65/80Z, W30/40ZA,W20/30ZR, AND W25/30/40ZC)

To remove the gas spring from the control handle:

1. Discharge the pressure from the gas spring. SeeDischarging the Gas Spring.

2. Remove the rear cover and drive motor cover.

3. Raise the truck so the drive wheel is approxi-mately 77 mm (3 in.) off of the ground. for in-formation on raising the lift truck.

4. Remove the screw securing the upper end of thegas spring inside the control handle arm.

5. Use a hammer and a thin punch to drive the pinout securing the lower end of the gas spring tothe support bracket.

6. Make certain the control handle arm is securedin the full upright position and remove the gasspring from the control handle arm.

REMOVE (B60/80Z)

To remove the gas spring from the control handle:

1. Remove the stop bolt from the control handlearm.

2. Remove the plastic plugs to access the gas spring.

3. Discharge the pressure from the gas spring. SeeDischarging the Gas Spring.

CAUTIONDO NOT damage the control handle wiring har-ness inside the control handle arm.

4. Remove the retention clip from the gas springball socket. Disconnect the gas spring from theball stud.

5. Remove the ball stud from the control arm.

6. Remove the hardware securing the rod end of thegas spring to the tiller swivel.

INSTALL (W60/65/80Z, W30/40ZA,W20/30ZR, AND W25/30/40ZC)

1. Make certain the control handle arm is securedin the full upright position and position the newgas spring into the control handle arm.

2. Install the screw securing the upper end of thegas spring inside the control handle arm. Installthe plug into the control handle arm as removed.Tighten to 27 N•m (20 lbf ft).

3. Align the lower end of the gas spring into positionusing a screwdriver and hold in position. Drivethe pin securing the lower end of the gas springinto position.

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1600 SRM 962 Steering and Dash Assembly (Complete)

4. Test for proper operation. Install covers as re-moved.

INSTALL (B60/80Z)

1. Install ball stud and nut into control arm if re-moved. Tighten to 27 N•m (20 lbf ft).

2. Install ball stud and nut into steer swivel if re-moved. Tighten to 27 N•m (20 lbf ft).

3. Lubricate the connection points with whitelithium grease.

CAUTIONDO NOT damage the control handle wiring har-ness inside the control handle arm.

4. Make certain the control handle arm is securedin the full upright position and position the newgas spring into the control handle arm. Connectthe upper end of the gas spring to the ball stud

inside the control handle arm. Install the reten-tion clip to the gas spring ball socket as removed.

NOTE: Apply Loctite® 242 to the capscrew threadsbefore installing the nut.

5. Align the lower end of the gas spring into posi-tion using a screwdriver and hold in position. In-stall the hardware securing the rod end of the gasspring to the tiller swivel.

6. Install the plastic plugs to the access holes on thecontrol handle shaft as removed.

NOTE: Apply Loctite® 242 to the capscrew threadsbefore installing the jam nut.

7. Install the stop bolt and jam nut to the controlhandle arm as removed.

8. Test for proper operation. Install covers as re-moved.

Steering and Dash Assembly (Complete)REMOVE

The following procedure applies only to the B60/80Zlift trucks only.

WARNINGThe steering assembly and dash weighs ap-proximately 30 kg (66 lb), and requires the useof an overhead lifting device to hold it in placeduring removal and installation. Be sure theoverhead lifting device has an adequate ratedcapacity to lift at least 30 kg (66 lb).

WARNINGBe careful when removing or installing snaprings. The snap rings may come loose duringremoval or installation with enough force tocause personal injury. Always use the propersnap ring pliers and wear eye protection dur-ing removal and installation.

The following instructions are for removing the en-tire dash and control handle assembly without disas-sembly. This procedure is useful when the dash and

control handle must be removed for access to otherparts of the lift truck.

1. Disconnect battery and discharge capacitors. SeeSpecial Precautions.

2. Secure one end of a rope or cargo strap aroundthe steering assembly plate between the dashand the Control Handle assembly. Secure theother end to an overhead lifting device sufficientto lift at least 30 kg (66 lb). See Figure 6.

3. Remove the four capscrews, nuts, and washersthat hold the steering support to the frame. Re-move the two capscrews attaching the support tothe support bracket.

4. Remove the ignition switch by removing the key,unscrewing the nut, and removing the ignitionswitch from the rear. Disconnect all wires andcables, making sure to tag them for reassembly.

5. Using the overhead lifting device, carefully re-move the steering assembly from the truck.

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Steering and Dash Assembly (Complete) 1600 SRM 962

1. SUPPORT2. ATTACHING HARDWARE

3. DASH4. STRAPS

Figure 6. Steering and Dash Assembly

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