STEERING MECHANISM

P2.0 [A290];W45ZHD [A419]

PART NO. 4035861 1600 SRM 1504

 SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• The Service Manuals are updated on a regular basis, but may not reflect recent design changes to the
product. Updated technical service information may be available from your local authorized Hyster®
dealer. Service Manuals provide general guidelines for maintenance and service and are intended for
use by trained and experienced technicians. Failure to properly maintain equipment or to follow
instructions contained in the Service Manual could result in damage to the products, personal injury,
property damage or death.
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and
that the load being lifted is balanced. Make sure the crane, cables, and chains have the capacity to
support the weight of the load.
• Do not lift heavy parts by hand, use a lifting mechanism.
• Wear safety glasses.
• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift
trucks. 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 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.
• Be sure to follow the WARNING and CAUTION notes in the instructions.
• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are
flammable. Be sure to follow the necessary safety precautions when handling these fuels and when
working on these fuel systems.
• Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the
area. Make sure the area is well ventilated.
NOTE: The following symbols and words indicate safety information in this
manual:

WARNING
Indicates a hazardous situation which, if not avoided, could result in death
or serious injury.

CAUTION
Indicates a hazardous situation which, if not avoided, could result in minor
or moderate injury and property damage.
On the lift truck, the WARNING symbol and word are on orange back-
ground. The CAUTION symbol and word are on yellow background.
 Table of Contents

TABLE OF CONTENTS
General .....................................................................................................................................................................1
Special Precautions ................................................................................................................................................. 1
Control Handle Head .............................................................................................................................................. 2
Control Handle ........................................................................................................................................................ 3
Remove .................................................................................................................................................................3
Install ................................................................................................................................................................... 9
Gas Spring ............................................................................................................................................................. 10
Discharging the Gas Spring ..............................................................................................................................10
Remove ...............................................................................................................................................................10
Install ................................................................................................................................................................. 11
Troubleshooting .....................................................................................................................................................11

This section is for the following models:

P2.0 [A290];
(W45ZHD) [A419]

©2018 HYSTER COMPANY i

"THE
QUALITY
KEEPERS"

HYSTER
APPROVED
PARTS
1600 SRM 1504 General

General
The control handle assembly is designed to perform left or right to turn the drive/steer tire and steer the
several functions. The standard control handle truck. Controls mounted in the handle are linked to
includes the speed/direction control and buttons for the control panel by a wiring harness that passes
the horn, traction reversing, and hydraulic through the center of the handle. The brake is
functions. The control handle is connected to the applied when the handle is in the full up or down
Master Drive Unit (MDU) and is used to steer the position.
truck as it turns the MDU. Move the control handle

Special Precautions
disconnected. Never short any controller terminal
WARNING or motor terminal to battery. Make sure to use
The capacitor in the controller can hold an proper procedures when servicing the controller.
electrical charge after the battery is disconnected.
1. Move the truck to a safe, level area. Turn the
To prevent electrical shock and personal injury,
key switch to the OFF position and disconnect
discharge the capacitor before inspecting or
the battery.
repairing any component. Wear safety glasses.
Make certain the battery has been disconnected.
2. Remove the drive unit compartment cover to
DO NOT use a screwdriver to discharge the
access the drive unit compartment.
traction motor controller.

CAUTION
WARNING DO NOT short across the motor controller
To avoid personal injury and prevent electrical terminals with a screwdriver or jumper wire.
shock, perform the following steps before
performing any troubleshooting or adjustments, 3. Discharge the capacitors in the controllers by
and connecting or disconnecting a handset or PC. connecting a 200-ohm, 2-watt resistor across
the controller's B+ and B− terminals using
insulated jumper wires. See Figure 1.
CAUTION
To avoid controller damage, always disconnect the
battery. Discharge the capacitor and never put
power to the controller with any power wire

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Control Handle Head 1600 SRM 1504

Legend for Figure 1.

1. CONTROLLER
2. POSITIVE CONNECTION
3. INSULATED JUMPER WIRES
4. 200-OHM, 2-WATT RESISTOR
5. NEGATIVE CONNECTION

4. Remove the 200-ohm, 2-watt resistor before

reconnecting the battery.

Figure 1. Discharging Controller

Control Handle Head

Refer to the section Electrical System handle. The instructions for disassembly and
2200SRM1508 for instructions on removing and assembly of the control handle head can be located
installing the control handle head from the control in the same section.

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1600 SRM 1504
Control Handle
REMOVE
WARNING
The gas springs used on the control handle are
installed under tension and can release with
enough force to cause personal injury or property
damage.
WARNING
The capacitor in the controller can hold an
electrical charge after the battery is disconnected.
To prevent electrical shock and personal injury,
discharge the capacitor before inspecting or
repairing any component in the drive unit
compartment. Wear safety glasses. Make certain
the battery has been disconnected. Refer to the
Special Precautions section of this manual.
Control Handle
1. Move the lift truck to a safe, level area and
block the wheels to prevent movement.
2. Turn the key switch to the OFF position and
disconnect the battery.
3. Remove the drive unit compartment cover.
Refer to AC Motor Repair 0620SRM1513.
4. Discharge the capacitor in the controller by
connecting a 200-ohm, 2 watt resistor between
the B+ and B- connectors on the controller. See
Figure 1.
5. Disconnect the control handle wiring harness
plug and the control handle arm prox sensor
plug located on top of the drive motor.
For the following instructions refer to Figure 2,
Figure 3, or Figure 4.
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Control Handle 1600 SRM 1504

Figure 2. Control Handle Assembly, Lift Truck Models P2.0 (A290)

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1600 SRM 1504 Control Handle

Legend for Figure 2.

1. CONTROL HANDLE HEAD 9. CAPSCREW

2. CAPSCREW 10. PIVOT SHAFT
3. LOCKNUT 11. STRAP CLAMP
4. LOCKNUT 12. BUSHING
5. HOLE PLUG 13. SENSOR
6. GAS SPRING 14. BALL STUD
7. SCREW 15. CONTROL HANDLE ARM
8. CAPSCREW 16. RETAINING NUT

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Control Handle 1600 SRM 1504

Legend for Figure 3.

1. CONTROL 7. STRAP CLAMP

HANDLE HEAD 8. BUSHING
2. CAPSCREW 9. PROX SENSOR
3. LOCKNUT 10. BALL STUD
4. HOLE PLUG 11. CONTROL HANDLE
5. GAS SPRING ARM
6. PIVOT SHAFT 12. RETAINING NUT

Figure 3. Control Handle Assembly, Lift Truck

Models W45ZHD (A419)

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1600 SRM 1504 Control Handle

Figure 4. Delivery Handle (Optional)

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Control Handle 1600 SRM 1504

Legend for Figure 4.

1. CONTROL HANDLE 6. PLUG 11. MOUNTING 16. CAPSCREW

HEAD 7. BUSHING WELDMENT 17. CAPSCREW
2. CONTROL HANDLE 8. COVER 12. GROMMET 18. STRAP CLAMP
ARM 9. CAPSCREW 13. PIVOT SHAFT 19. SHIM
3. GAS SPRING 10. WASHER 14. CAPSCREW
4. BALL STUD 15. NUT
5. NUT

6. If necessary, remove the control handle head. 14. Remove retaining nuts securing the prox sensor
See the section Electrical System to the control handle arm and remove the prox
2200SRM1508. sensor. See Figure 3

15. If bushings are worn, remove the bushings

CAUTION from the control handle arm.
Discharging the gas spring is a destructive
operation.

7. Discharge and remove the gas spring. Refer to

Gas Spring in this section.

8. Remove the capscrew securing the pivot shaft

to the support bracket and remove the pivot
shaft.

9. Remove the control handle arm from the

support bracket.

NOTE: For lift truck models P2.0 (A290) perform

Step 10 to remove prox sensor.
10. Remove retaining nuts securing the prox sensor
to control handle arm and remove the prox
sensor. See Figure 2.

NOTE: On lift truck models W45ZHD (A419) the

removal procedures for the prox sensor will depend
on which prox sensor arrangement your lift truck
has. If prox sensor is mounted with Bellville
washers and prox sensor cable is marked with
yellow heat shrink, perform Step 11 through
1. BUTTON TIE WRAP
Step 13. If prox sensor arrangement does not 2. CONTROL HANDLE ARM WIRE HARNESS
include these parts, go to Step 14 for removal 3. PROX SENSOR CABLE
procedures. 4. HEAT SHRINK
5. PROX SENSOR
11. Remove button tie wrap from side of mounting 6. CONTROL HANDLE ARM
weldment. See Figure 4.
Figure 5. Prox Sensor With Bellville Washers and
12. Remove button tie wrap from yellow heat Yellow Heat Shrink, Remove
shrink on prox sensor cable and control handle
arm wire harness. See Figure 5.

13. Remove two retaining nuts and two Bellville

washers. Remove prox sensor from control
handle arm. See Figure 5.

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1600 SRM 1504 Control Handle

INSTALL
1. If previously removed, install the bushings into
the control handle arm.

2. Install the new gas spring into the control

handle arm. Refer to Gas Spring in the section.

NOTE: For lift truck models P2.0 (A290) perform

Step 3 to install prox sensor.
3. Install the prox sensor onto the control handle
arm and secure with the retaining nuts. Leave
retaining nuts loose until the control handle
arm is installed. See Figure 2.

NOTE: On lift truck models W45ZHD (A419) the

installation procedures for the prox sensor will
depend on which prox sensor arrangement your lift
truck has. If prox sensor is mounted with Bellville
washers and prox sensor cable is marked with
yellow heat shrink, perform Step 4 through Step 9.
If prox sensor does not include these parts, go to
Step 10 for installation procedures.
NOTE: When installing Bellville washers, the side
with the larger diameter faces the bracket, and the
side with smaller diameter faces the nut.
4. Install prox sensor into control handle arm
using two Bellville washers and two retaining
nuts. See Figure 6. Hand tighten retaining nuts
for now.
5. Check to ensure the end of the prox sensor is no
more than 2.5 ±0.5 mm (0.10 ±0.02 in.) from the
support bracket. See Figure 6.
6. Take cable end of prox sensor and make a loop
of 125 mm (5.0 in.). See Figure 6.
7. Lightly pull on control handle arm wire
harness until it is taunt.
8. Install button tie wrap around control handle
arm wire harness and yellow heat shrink on
prox sensor cable. Fasten button tie wrap and
prox sensor cable and control handle arm wire
harness to side of mounting weldment. See
Figure 4 and Figure 5.
9. Tighten retaining nuts to 24 N•m (212 lbf in).
See Figure 6.
1. PROX SENSOR
2. RETAINER NUT
3. BELLVILLE WASHER
4. CABLE END
5. SUPPORT BRACKET
Figure 6. Prox Sensor With Bellville Washers and
Yellow Heat Shrink, Install
10. Install the prox sensor onto the control handle
arm and secure with the retaining nuts. Leave
retaining nuts loose until the control handle
arm is installed. See Figure 3.
11. If removed, install the control handle head. See
the section Electrical System 2200SRM1508.
12. Position the control handle arm onto the
support bracket and install the pivot shaft. See
Figure 3.
13. When installing the handle support to the
truck, replace bolts with M8 x 1.25 x 25
property class 8.8 bolts. Apply thread adhesive,
no washers required. Torque to
26 N•m (19 lbf ft).
14. Secure the lower end of the gas spring to the
support bracket with the capscrew and nut as
removed.
NOTE: Step 15 is only for lift truck models P2.0
(A290) and lift truck models W45ZHD (A419) with
prox sensor arrangement that does not include
Bellville washers and yellow heat shrink.

9
Gas Spring
15. Adjust the prox sensor so the end of the sensor
is no more than 4 mm (0.16 in.) from the
support bracket. Tighten the retaining nuts.
16. Reconnect the control handle wiring harness
and prox sensor.
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
disconnected. 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
installed 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
personal protection as metal chips and hydraulic
lubricant may be ejected from the drill operation
due to the high internal pressure.
10
1600 SRM 1504
17. Install the drive unit compartment cover.
18. Connect the battery and test the operation of
the lift truck prior to returning to service.
CAUTION
The control handle return spring is charged with
pressurized gas and contains a hydraulic oil
lubricant.
NOTE: This process is a destructive operation to
the gas spring. A new gas spring must be used
during reassembly. This is necessary because
internal damage to the spring components which
are not detectable could cause damage or injury
when the spring is removed.
1. Check that the handle return spring is
installed and properly secure the control
handle arm in the full upright position. Remove
the plastic plugs to increase visibility of the gas
spring.
WARNING
Contents are under pressure. This process may
eject metal chips and oil.
2. Locate the gas spring inside the control handle
through the access hole on the front of the
control handle and drill a 3 mm (0.125 in.) hole
into the gas spring cylinder shell to relieve
pressure.
3. Clean up any discharged oil and dispose of in
accordance with local regulations.
REMOVE
To remove the gas spring from the control handle:
1. Remove the plastic plugs to access the gas
spring.
CAUTION
DO NOT damage the control handle wiring harness
inside the control handle arm.
1600 SRM 1504 Troubleshooting

2. Discharge the pressure from the gas spring.

See Discharging the Gas Spring.
3. Remove the retention clip from the gas spring
ball socket. Disconnect the gas spring from the
ball stud.
4. Remove the ball stud from inside the control
arm as necessary.
5. Remove the capscrew and locknut securing the
rod end of the gas spring to the tiller swivel.
INSTALL
1. Install ball stud and nut into control arm if
removed. Tighten to 35 N•m (26 lbf ft).
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.
NOTE: Apply Loctite® 242 to the capscrew threads
before installing the nut.
4. Align the lower end of the gas spring into
position using a screwdriver and hold in
position. Install the capscrew and locknut
securing the rod end of the gas spring to the
steer swivel. Tighten to 35 N•m (26 lbf ft).

2. Lubricate both connection points with 5. Install the plastic plugs to the access holes on
multipurpose lithium complex grease with 2 to the control handle shaft as removed.
4% molybdenum.
6. Test for proper operation. Install covers as
removed.
CAUTION
DO NOT damage the control handle wiring harness
inside the control handle arm.

Troubleshooting

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

Steering is rough or difficult. Damaged, worn, or defective Replace bearings.

steering handle swivel bearing(s).
Steering handle swivel bearing(s)
need lubrication.
Bearing retaining nut torque
incorrect.
Drive unit housing bearing (steer)
damaged.
Lubricate or repack bearings.
Loosen retaining nut and tighten
to correct torque. See the section
Master Drive Unit
0630SRM1503.
Replace drive unit housing
bearing (steer).

Steering handle does not return to Gas spring is weak or broken. Replace gas spring.
the vertical position.
Gas spring ball stud broken or Retighten or replace gas spring
loose. ball stud.

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 NOTES

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 TECHNICAL PUBLICATIONS

1600 SRM 1504 12/18 (11/17)(7/16)(3/15)(12/13)(6/11)