10.
Remove excess slack by bundling control handle,
brake, and brake switch wiring harnesses and secure
using wire ties.
11.
Install cover to swivel using three screws.
12.
Connect the battery and test the operation of the truck
prior to returning the lift truck to service.
13.
Install the drive unit compartment cover and floor mat
as removed.
Power Assist Steering
WARNING
The gas springs used on the control handle are
installed under tension and can release with
enough force to cause personal injury or property
damage.
WARNING
The capacitor in the transistor controller can hold
an electrical charge after the battery is disconnec-
ted. To prevent electrical shock and personal in-
jury, discharge the capacitor before inspecting or
repairing any component in the drive unit com-
partment. Wear safety glasses. Make certain the
battery has been disconnected.
Refer to Figure 7 for the following instructions:
Remove
1.
Turn the key switch to the
OFF
position and discon-
nect the battery. Remove the drive unit compartment
cover. See Accessing the Drive Unit Compartment in
this section.
2.
Discharge the capacitors. See Special Precautions in
this section.
CAUTION
DO NOT cut the wiring harnesses when removing
the wire ties.
NOTE:
It is not necessary to remove the main wiring har-
ness unless harness is damaged and is being replaced.
3.
CAREFULLY
cut the wire ties securing the brake,
brake switch, and control handle wiring harnesses to-
gether at the right rear of MDU.
NOTE:
Be certain to tag, identify, and note the routing of
the wires before disconnecting any wire. The wiring must
be routed properly at assembly to prevent steering problems
and prevent chafing of the harness.
4.
Tag and disconnect the control handle wiring harness
from the main wiring harness.
5.
Remove the two capscrews holding the cover to the
steer support studs and lift the cover off. See Figure 6.
6.
Tag, identify, and disconnect the control handle wiring
from the brake switches. Remove the two screws and
spacer securing brake switches to the swivel. Remove
the switches.
7.
Disconnect the proximity switch from the main wiring
harness. Remove the jam nut from the switch and un-
screw switch from the MDU.
NOTE:
Be careful not to damage the brake switches when
removing the gas spring.
8.
Remove the gas spring. Refer to Gas Spring in this sec-
tion.
1. CAPSCREW
2. CONTROL ARM
3. SWIVEL COVER
4. STEER SUPPORT BASE
5. DASH
Figure 6. Swivel Cover
1600 SRM 1637
Control Handle
7
